Centralized negative pressure system energy-saving control method based on load prediction
By constructing a target equipment processing set and analyzing negative pressure sensor data, the problems of low energy efficiency and slow response of centralized negative pressure systems were solved, achieving efficient and precise control of the negative pressure system and improving production stability and energy efficiency.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- FENGYANG CONCH PHOTOVOLTAIC TECHNOLOGY CO LTD
- Filing Date
- 2025-12-24
- Publication Date
- 2026-04-17
AI Technical Summary
Existing centralized negative pressure systems lack load forecasting, resulting in low energy efficiency, slow response, and inability to accurately control, leading to energy waste and production instability.
By constructing a target equipment processing set, combining negative pressure sensor data, mapping the negative pressure demand and output power curves, and calculating the reference negative pressure conversion coefficient, the system can achieve forward-looking control of the centralized negative pressure system.
It achieves efficient and precise control of the centralized negative pressure system, reduces energy waste, improves production stability and energy efficiency, and enables rapid response to changes in production orders.
Smart Images
Figure CN121886353A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of negative pressure management technology, specifically, it relates to an energy-saving control method for centralized negative pressure systems based on load prediction. Background Technology
[0002] With the booming development of the photovoltaic industry and the continuous expansion of photovoltaic product production scale, the energy consumption of centralized negative pressure systems, as key equipment, has received increasing attention during the production process.
[0003] Energy-saving control of centralized negative pressure systems mainly relies on real-time monitoring and manual adjustment, lacking forward-looking prediction of production load. This often leads to a mismatch between system output power and actual demand, resulting in low energy efficiency. Specifically, existing technologies are often based on simple feedback mechanisms, adjusting power after sensors detect the current negative pressure. However, they cannot anticipate changes in production orders. When switching products on the production line or starting / stopping equipment, power adjustment lags, causing negative pressure fluctuations or excess, which affects production stability and wastes energy. For example, when production orders change, existing technologies must wait for sensors to detect changes in negative pressure before responding, during which time the system continues to operate at high power. Despite reduced demand, this highlights the drawbacks of sluggish response. Furthermore, existing technologies lack standardized processes for calculating the total negative pressure demand of target equipment processing sets, relying on rough estimates rather than precise calculations for control. This leads to insufficient or excessive negative pressure supply during production, impairing product quality or increasing energy consumption. Simultaneously, the lack of systematic analysis of historical data makes it impossible to determine the optimal power range for efficient operation, resulting in the system frequently operating in inefficient regions and declining energy conversion efficiency. These drawbacks collectively contribute to the low energy efficiency, high operating costs, and insufficient stability of existing centralized negative pressure systems, making it difficult to meet the energy-saving and precise control requirements of modern intelligent manufacturing.
[0004] To address the aforementioned problems, this invention proposes an energy-saving control method for centralized negative pressure systems based on load prediction. Summary of the Invention
[0005] To address the shortcomings of existing technologies, this invention provides an energy-saving control method for centralized negative pressure systems based on load forecasting, solving the problems of low energy efficiency, slow response, and lack of load forecasting in centralized negative pressure systems.
[0006] The objective of this invention can be achieved through the following technical solutions: An energy-saving control method for a centralized negative pressure system based on load forecasting, the method comprising: Step 1: Obtain all target equipment involved in the production process of any photovoltaic product in the production order from the cloud database, construct the target equipment processing set, and calculate the total negative pressure demand of the corresponding photovoltaic product and the total output power of the centralized negative pressure system in the stable production process based on the negative pressure demand of each target equipment. Step 2: Plot the total negative pressure demand standard line and total output power fluctuation curve corresponding to the time sequence in the same two-dimensional coordinate system; By using the negative pressure sensors equipped at each negative pressure node to measure the actual negative pressure of the corresponding photovoltaic product during stable production, the total actual negative pressure is calculated, and the total actual negative pressure fluctuation curve is plotted in a two-dimensional coordinate system. The optimal total output power range associated with the total negative pressure demand standard line is determined based on the ratio between the total actual negative pressure fluctuation curve and the total negative pressure demand standard line at the same moment. Step 3: Calculate the reference negative pressure conversion coefficient between the centralized negative pressure system and the negative pressure node by combining the optimized total output power range and the total negative pressure demand standard line with the unit negative pressure demand, and evaluate the system's reference negative pressure conversion coefficient. Step 4: Obtain the orders to be produced, determine the target equipment processing set associated with any photovoltaic product, determine the predicted baseline total output power associated with the orders to be produced by combining the negative pressure requirements of each target equipment and the baseline negative pressure conversion coefficient, and adjust the total output power of the centralized negative pressure system.
[0007] As a further aspect of the present invention, the specific method for constructing the target equipment processing set in step one is as follows: Extract the OD (Original Design Object) of any production order based on a pre-built cloud database; Take any photovoltaic product P from the production order OD and include all target equipment involved in the production process, and record the total number as j; Arrange the j target devices in the order of the production process to obtain the target device processing set E={e1,e2,...,ej}.
[0008] As a further aspect of the present invention, the specific method for calculating the total negative pressure demand of the corresponding photovoltaic product in stable production process and the total output power of the centralized negative pressure system in step one is as follows: Obtain the predefined negative pressure requirements G1, G2, ..., Gj for all target equipment in the processing set E associated with photovoltaic product P, where G1 to Gj correspond to e1 to ej, and the unit of negative pressure requirement is kPa. Calculate the total negative pressure demand of photovoltaic product P during stable production as related to time, G_all = G1 + G2 + ... + Gj, where G_all is determined based on the target equipment processing set and is a constant value, that is, the total negative pressure demand at each time is always equal to G_all; The stable production process means that all target equipment within the target equipment processing set E is in a working state; During stable production, the total output power of the processing set E of the target equipment corresponding to the centralized negative pressure system is collected in time sequence and denoted as the total output power sequence tp1, tp2, ..., tpm, where m represents the total number of time moments in the stable production process. The total output power is obtained by the centralized negative pressure system in combination with the current load and self-regulation.
[0009] As a further aspect of the present invention, the specific method for plotting the total negative pressure demand standard line and the total output power fluctuation curve corresponding to the time sequence in step two is as follows: Construct a two-dimensional coordinate system with the timeline as the horizontal axis, the output power value as the positive half-axis of the vertical axis, and the negative pressure demand value as the negative half-axis of the vertical axis. Set the value of the negative half-axis of the vertical axis of the two-dimensional coordinate system to be positive. The horizontal axis spans m time points. Determine the value on the negative half of the vertical axis as the scale of the total negative pressure demand G_all. Construct a line segment perpendicular to the vertical axis and parallel to the horizontal axis from this scale in the positive direction of the horizontal axis. This line segment is denoted as the standard line L of the total negative pressure demand. The span of the standard line L of the total negative pressure demand is m time intervals. The m total output power values in the total output power sequence tp1, tp2, ..., tpm are plotted as data points in a two-dimensional coordinate system according to the time sequence, resulting in m data points. A curve is then fitted to these data points, which is denoted as the total output power fluctuation curve W1.
[0010] As a further aspect of the present invention, the specific method for plotting the total actual negative pressure fluctuation curve in a two-dimensional coordinate system in step two is as follows: At any given moment during the stable production process, j actual negative pressure values are collected based on the negative pressure sensors equipped on the negative pressure nodes connected to each target device in the target equipment processing set E, and summed to form the total actual negative pressure. Construct the total actual negative pressure sequence TG1,TG2,...,TGm corresponding to the stable production process; Using the total output power fluctuation curve W1, and combined with the total actual negative pressure sequence TG1, TG2, ..., TGm, the total actual negative pressure fluctuation curve W2 is plotted in a two-dimensional coordinate system.
[0011] As a further aspect of the present invention, in step two, the specific method for determining the preferred total output power range associated with the total negative pressure demand standard line based on the ratio relationship between the simultaneous actual negative pressure fluctuation curve and the total negative pressure demand standard line is as follows: Calculate the ratio of the total actual negative pressure to the total negative pressure demand at m time points, and arrange them into a ratio sequence R1, R2, ..., Rm; Obtain the ratio range [R_min, R_max] preset by the operator; Filter out all times corresponding to ratios within the ratio interval [R_min, R_max] and combine them into a qualified time set T_vad; From the total output power sequence tp1, tp2, ..., tpm, extract the total output power values corresponding to the times belonging to the qualified time set T_vad. The minimum value is denoted as tp_min and the maximum value is denoted as tp_max, which constitute the preferred total output power interval [tp_min, tp_max] associated with the photovoltaic product P. Similarly, the optimal total output power range associated with each type of photovoltaic product is determined.
[0012] As a further aspect of the present invention, the specific method for evaluating the system's baseline negative pressure conversion coefficient in step three is as follows: Take the median value of the preferred total output power range [tp_min, tp_max] associated with photovoltaic product P, and denote it as the base output power tp_base=(tp_min+tp_max) / 2; The ratio of the base output power tp_base to the total negative pressure demand G_all is calculated to obtain the base negative pressure conversion coefficient β_x of the centralized negative pressure system for photovoltaic product P under stable production conditions. β_x = G_all / P_base, where the unit of the base negative pressure conversion coefficient β_x is kpa / kW. Similarly, determine the reference negative voltage conversion coefficients β_1,β_2,...,β_N for each photovoltaic product, where N represents the total number of photovoltaic products, and β_x∈β_1,β_2,...,β_N; The arithmetic mean of the N reference negative pressure conversion coefficients is denoted as the system reference negative pressure conversion coefficient β.
[0013] As a further aspect of the present invention, the specific method for determining the predicted total output power associated with the production order in step four, by combining the negative pressure requirements calibrated by each target device and the reference negative pressure conversion coefficient, is as follows: Retrieve the production order OD_new to be executed; Extract any photovoltaic product P_new to be produced from OD_new; From the cloud database, obtain the target equipment processing set E_new={e1',e2',...,ej'} for producing photovoltaic products P_new, and obtain the calibration negative pressure requirements of each target equipment in E_new, arranged as: G1',G2',...,Gj'; Calculate the total rated negative pressure requirement of photovoltaic product P_new during stable production process: G_all_new = G1' + G2' + ... + Gj'; Based on the system's baseline negative pressure conversion coefficient β, calculate the predicted baseline total output power P_base_new required for the total calibrated negative pressure demand G_all_new: P_base_new = G_all_new / β; Repeat the above steps to complete the calibration of the predicted reference total output power for various photovoltaic products.
[0014] As a further aspect of the present invention, the specific method for adjusting the total output power of the centralized negative pressure system in step four is as follows: When the photovoltaic product P_new is in a stable production process, the total output power of the centralized negative pressure system is the predicted baseline total output power P_base_new.
[0015] The beneficial effects of this invention are: This invention achieves forward-looking regulation of the output power of a centralized negative pressure system by constructing a target equipment processing set and predicting the total negative pressure demand. Its core advantage lies in dynamically determining the optimal output power range by combining historical production data and actual operation feedback, and deriving the system's baseline negative pressure conversion coefficient. This allows for rapid and accurate prediction and setting of the optimal total output power when facing different production orders. This achieves the technical effect of improving system response speed and energy efficiency matching accuracy. At the same time, it effectively avoids energy waste caused by load fluctuations in traditional control, and achieves the beneficial effect of overall system energy saving and consumption reduction while ensuring production negative pressure demand. This invention lays the foundation for accurately calculating the total negative pressure demand in the stable production of photovoltaic products by constructing a set of target equipment and organizing the production process in an orderly manner, thereby realizing quantitative management of energy consumption. Secondly, by mapping the standard line and fluctuation curve of the total negative pressure demand, the production status is visualized, which facilitates real-time monitoring and adjustment and improves process controllability. Furthermore, based on the ratio of actual negative pressure to demand, the optimal total output power range is determined, guiding the centralized negative pressure system to operate in the high-efficiency range, effectively optimizing energy distribution, reducing energy consumption and operating costs, while enhancing production stability and product consistency, and improving the energy efficiency and reliability of photovoltaic product production. This invention achieves precise and efficient control of the output power of a centralized negative pressure system by applying a system benchmark negative pressure conversion coefficient to power prediction for new orders. Its advantages lie in extracting a universally applicable conversion coefficient through statistical analysis of historical production data, thereby summarizing complex equipment-level negative pressure requirements into a unified and predictable total power benchmark. It enhances the intelligence level of energy allocation, enabling rapid and automatic calculation of the matching total negative pressure power based on the production processes of different products, avoiding energy waste or insufficient supply caused by experience-based estimations. Furthermore, it improves the energy efficiency and stability of the entire production system, achieving on-demand energy supply and energy conservation while ensuring the negative pressure requirements of each target device, and simplifying the system configuration process during production switchovers. Attached Figure Description
[0016] The invention will now be further described with reference to the accompanying drawings.
[0017] Figure 1 This is a flowchart illustrating the method described in this invention. Detailed Implementation
[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0019] like Figure 1 As shown, this application provides an intelligent traffic management system based on the Internet of Things; As an embodiment 1 of this application, it specifically includes: Step 1: Obtain all target equipment involved in the production process of any photovoltaic product in the production order from the cloud database, construct the target equipment processing set, and calculate the total negative pressure demand of the corresponding photovoltaic product and the total output power of the centralized negative pressure system in the stable production process based on the negative pressure demand of each target equipment. Step 2: Plot the total negative pressure demand standard line and total output power fluctuation curve corresponding to the time sequence in the same two-dimensional coordinate system; By using the negative pressure sensors equipped at each negative pressure node to measure the actual negative pressure of the corresponding photovoltaic product during stable production, the total actual negative pressure is calculated, and the total actual negative pressure fluctuation curve is plotted in a two-dimensional coordinate system. The optimal total output power range associated with the total negative pressure demand standard line is determined based on the ratio between the total actual negative pressure fluctuation curve and the total negative pressure demand standard line at the same moment. Step 3: Calculate the reference negative pressure conversion coefficient between the centralized negative pressure system and the negative pressure node by combining the optimized total output power range and the total negative pressure demand standard line with the unit negative pressure demand, and evaluate the system's reference negative pressure conversion coefficient. Step 4: Obtain the orders to be produced, determine the target equipment processing set associated with any photovoltaic product, determine the predicted baseline total output power associated with the orders to be produced by combining the negative pressure requirements of each target equipment and the baseline negative pressure conversion coefficient, and adjust the total output power of the centralized negative pressure system.
[0020] Example 2 An energy-saving control method for centralized negative pressure systems based on load forecasting, such as Figure 1 As shown, this system includes the following: Traditional centralized negative pressure systems may always operate at high power, resulting in energy waste. This method, through a "prediction-modeling-application" process, allows the system power to be dynamically adjusted to closely match actual production needs, achieving "supply only what is needed." This invention discloses an energy-saving control method for centralized negative pressure systems based on load forecasting. Through a process of forecasting, modeling, and application, the system power can be dynamically adjusted to closely match actual production needs, achieving supply only what is required. Ultimately, this solves the technical problem of inaccurate negative pressure regulation in existing centralized negative pressure systems used in the photovoltaic production field, which makes it difficult to achieve both forward-looking and energy-saving control.
[0021] This method analyzes historical production data to establish a precise model between production orders and negative pressure demand, thereby enabling accurate prediction and on-demand control of negative pressure power for future production tasks, ultimately achieving energy conservation. The details are as follows: First, retrieve all target equipment involved in the production process of any photovoltaic product from the cloud database, construct a target equipment processing set, and calculate the total negative pressure demand of the corresponding photovoltaic product during stable production and the total output power of the centralized negative pressure system based on the negative pressure requirements specified for each target equipment. Specifically: This step provides a standard profile for establishing a theoretical negative pressure demand and output power consumption for a stable production process of a specific photovoltaic product. Based on this, by performing the same operation on other photovoltaic products, standard profiles associated with each type of photovoltaic product can be constructed, namely, the total negative pressure demand associated with time and the total output power of the centralized negative pressure system.
[0022] Among them, a stable production process refers to the process in which all target equipment of a certain photovoltaic product is in a non-idle state during the production process. In other words, during a stable production process, each target equipment with a negative pressure node (providing negative pressure) needs to provide negative pressure to maintain the normal operation of the production process.
[0023] Next, the total negative pressure demand standard line and the total output power fluctuation curve corresponding to the time sequence are plotted in the same two-dimensional coordinate system. The total actual negative pressure is calculated by using the negative pressure sensor equipped at each negative pressure node to measure the actual negative pressure of the corresponding photovoltaic product during stable production and time. The total actual negative pressure fluctuation curve is plotted in the two-dimensional coordinate system. Finally, the optimal total output power range associated with the total negative pressure demand standard line is determined based on the ratio between the total actual negative pressure fluctuation curve and the total negative pressure demand standard line at the same moment. It should be noted that the total negative pressure demand standard line is a line segment, and all total negative pressure demand values on the total negative pressure demand standard line are the same. The total output power fluctuation curve is based on the total output power. The output power of the centralized negative pressure system is directly measured in time sequence by relevant modules (such as energy management system or smart meter). At the same time, the ratio of the total actual negative pressure fluctuation curve to the total negative pressure demand standard line reflects the deviation between the actual operating efficiency and the theoretical value of the centralized negative pressure system. The centralized negative pressure system is calibrated by combining the actual situation.
[0024] Finally, by analyzing the ratio between the total actual negative pressure fluctuation curve and the total negative pressure demand standard line at different times, we can find the fluctuation range of the total output power of the system when the actual negative pressure meets the theoretical demand, that is, when the ratio is within an acceptable range. This fluctuation range is the optimal total output power range, that is, the power band that can both guarantee the production negative pressure demand and the system can operate relatively efficiently, thereby achieving the technical effect of energy-saving control.
[0025] Next, by combining the optimized total output power range and the total negative pressure demand standard with the unit negative pressure demand, the reference negative pressure conversion coefficient between the centralized negative pressure system and the negative pressure node is calculated, and the system's reference negative pressure conversion coefficient is evaluated. Specifically: The optimal total output power range (power for efficient system operation) and the total negative pressure demand standard (pressure required for production) obtained from the above steps are combined with the unit negative pressure demand to calculate a reference negative pressure conversion coefficient corresponding to the unit negative pressure demand. The reference negative pressure conversion coefficient establishes a quantitative relationship between the negative pressure required for production and the output power that the system should provide, and includes losses and efficiency factors in actual operation. Finally, by performing the same process on several photovoltaic devices and evaluating several reference negative pressure conversion coefficients, a final and unique stable system reference negative pressure conversion coefficient is determined. This coefficient represents the quantitative relationship between the output power associated with the centralized negative pressure system and the production negative pressure. For example, if the output power is 1kW and the final actual negative pressure value that can be provided is 500kPa, then the system reference negative pressure conversion coefficient is 500kPa / 1kW = 500(kPa / kW). KPa / kW is the unit of the system reference negative pressure conversion coefficient, which is convenient for subsequent calculation and conversion operations. It should be noted that the system reference negative pressure conversion coefficient needs to be updated regularly to adapt to changes in the production environment.
[0026] Finally, obtain the orders to be produced, determine the target equipment processing set associated with any photovoltaic product, combine the negative pressure requirements of each target equipment with the benchmark negative pressure conversion coefficient to determine the predicted benchmark total output power associated with the orders to be produced, and adjust the total output power of the centralized negative pressure system. The controller of the centralized negative pressure system adjusts the total output power in advance or in real time (the specific adjustment is determined by the operator based on actual needs) according to the predicted baseline total output power, so that the output power of the centralized negative pressure system matches the predicted demand and avoids ineffective high-load operation.
[0027] Example 3 This embodiment, based on embodiment 2, further discloses a method for determining the total negative pressure demand of a corresponding photovoltaic product in a stable production process and the total output power of a centralized negative pressure system, specifically including the following: This embodiment describes and analyzes in detail the method for determining the total negative pressure requirement of photovoltaic products and the total output power of centralized negative pressure systems as described in Embodiment 2 through the following steps.
[0028] First, obtain the cloud database pre-built by the operators, which stores all parameters involved in the centralized negative pressure system and the target equipment during the actual production process.
[0029] Next, extract any production order from the cloud database and denote it as OD, and perform sample processing based on the production order OD; Extract any photovoltaic product P from the production order OD, and sort out the production process of photovoltaic product P. Identify all the equipment that needs to use the centralized negative pressure system. These equipment are the target equipment. Arrange the target equipment according to the production process sequence to obtain the target equipment processing set E={e1,e2,...,ej}, where j is the total number of all target equipment involved in the production process of photovoltaic product P.
[0030] For example, suppose the production order OD is "1000 monocrystalline PERC photovoltaic modules", where the photovoltaic product P is "monocrystalline PERC solar cells". The production process involves: texturing and cleaning machine (e1), diffusion furnace (e2), etching machine (e3), PECVD (plasma-enhanced chemical vapor deposition) equipment (e4), screen printing machine (e5), and testing and sorting machine (e6). Then j=6, and the target equipment processing set E is arranged in this order as {e1,e2,e3,e4,e5,e6}.
[0031] Next, obtain the predefined negative pressure requirements of all target equipment in the target equipment processing set E associated with photovoltaic product P by the operator, and sort them according to the arrangement order of the target equipment processing set E, denoted as G1, G2, ..., Gj, where G1 corresponds to e1, G2 corresponds to e2, and so on until e1 corresponds to ej, and the unit of negative pressure requirement is kPa.
[0032] By using G_all = G1 + G2 + ... + Gj, the total negative pressure demand G_all associated with time during the stable production process of photovoltaic product P is calculated. Here, G_all is a constant value based on the set of equipment. During the stable production process, all equipment runs continuously and the demand remains unchanged. The theoretical total negative pressure demand at each time is always equal to G_all.
[0033] During the stable production process, the total output power of the processing set E of the target equipment corresponding to the centralized negative pressure system (the sum of the output power of all target equipment at the same time) is collected in time sequence and denoted as the total output power sequence tp1, tp2, ..., tpm, where m represents the total number of time moments in the stable production process. The total output power is obtained by the centralized negative pressure system in combination with the current production load.
[0034] Example 4 This embodiment, based on embodiment 3, further discloses a method for determining the preferred total output power range associated with each type of photovoltaic product, specifically including the following: This embodiment uses a two-dimensional coordinate system to visually compare theoretical requirements and actual system power, thereby determining the power range for efficient operation of the centralized negative pressure system.
[0035] First, we construct a special two-dimensional coordinate system. The horizontal axis of this two-dimensional coordinate system represents time, and the span corresponds to m moments in a stable production process. The vertical axis of the two-dimensional coordinate system is given a dual meaning, realizing the comparison of pressure and power in the same time dimension. The positive half of the vertical axis represents the total output power of the centralized negative pressure system, and the negative half of the vertical axis represents the negative pressure demand. Although it is a negative half axis, through processing, all the scales on the negative half axis are given a positive sign.
[0036] Next, find the position with the scale value G_all on the negative half of the vertical axis, which represents the theoretical total negative pressure demand. Draw a line segment parallel to the horizontal axis from this point to the right, spanning the entire time axis, including m moments, and denot it as the total negative pressure demand standard line L. The total negative pressure demand standard line L represents the constant ideal demand of the negative pressure system for the corresponding photovoltaic product P during stable production, and serves as a benchmark for evaluating whether the performance of the centralized negative pressure system meets the standard.
[0037] The total output power data tp1, tp2, ..., tpm collected at m time points are plotted on the upper half of the coordinate system, i.e., the positive half-axis, with time and power values as coordinates. Then, a smooth curve is used to fit these data points to obtain a curve, which is denoted as the total output power fluctuation curve W1.
[0038] Thus, in the same two-dimensional coordinate system, the correspondence between the constant negative pressure demand and the energy consumption with fluctuating output power is clearly shown.
[0039] Next, the third key curve is plotted—the total actual negative pressure fluctuation curve W2; At every moment during the stable production process, the actual negative pressure values of j target devices are collected in real time and continuously by the negative pressure sensors installed on the negative pressure nodes of each target device, and the summation is used to obtain the total actual negative pressure TG at that moment. The total actual negative pressure TG is different from the total negative pressure demand G_all. G_all is the theoretical and expected demand value; TG is the actual pressure value measured on-site and achieved.
[0040] The data is repeatedly collected and summed over the entire m time intervals to obtain the total actual negative pressure sequence TG1,TG2,...,TGm; Using time and TG value as coordinates, in the lower half of the coordinate system, i.e. the negative half of the vertical axis, the data points of the temple fair are fitted with curves to obtain the total actual negative pressure fluctuation curve W2, which represents the total actual negative pressure of each negative pressure node in the production site.
[0041] This completes the analytical triangle, which consists of: the total negative pressure demand standard line L: the ideal state to be achieved; the total output power fluctuation curve W1: the actual effort; and the total actual negative pressure fluctuation curve W2: the actual result.
[0042] For each moment on the horizontal axis in the two-dimensional coordinate system, calculate the ratio of the total actual negative pressure to the total negative pressure demand, and arrange the m ratios corresponding to the m moments in chronological order of the timeline to finally obtain the ratio sequence R1, R2, ..., Rm; The ratios R1 to Rm represent the proportion of the actual negative pressure obtained to the theoretically required negative pressure. Ri≈1: indicates that the demand is well met and the centralized negative pressure system is operating effectively. Ri<1: indicates that the actual negative pressure is insufficient, affecting production quality. Ri>1: indicates that the actual negative pressure exceeds the demand, resulting in energy waste.
[0043] Next, the ratio range [R_min, R_max] preset by the operator based on the actual situation is obtained. The ratio range [R_min, R_max] defines the quantitative standard for the effective satisfaction of the demand, for example: ratio range [0.95, 1.05].
[0044] All moments that satisfy the condition of being greater than or equal to R_min and less than or equal to R_max are selected and formed into a qualified moment set T_vad. These moments represent moments where the system meets production needs without significant pressure shortages or oversupply.
[0045] From the total output power sequence tp1, tp2, ..., tpm, find the total output power values corresponding to all times belonging to the T_vad set. From these total output power values, find the minimum value tp_min and the maximum value tp_max. The interval [tp_min, tp_max] formed by these values is the preferred total output power interval. This range indicates that when the output power of the centralized negative pressure system falls within this range, the negative pressure demand for production can be effectively met. This is a power operating range that is statistically derived from historical successful data and takes into account both supply assurance and energy saving.
[0046] Finally, by repeating the above analysis for each photovoltaic product in the cloud database, the optimal total output power range for each photovoltaic product is obtained.
[0047] Example 5 This embodiment, based on Embodiment 3, further discloses a method for evaluating the system's reference negative pressure conversion coefficient and regulating the output power of a centralized negative pressure system, specifically including the following: Taking photovoltaic product P as an example, we obtain the preferred total output power range [tp_min, tp_max] associated with photovoltaic product P, and extract the median from the preferred total output power range [tp_min, tp_max], which is denoted as the reference output power tp_base=(tp_min+tp_max) / 2. Here, the reference output power tp_base represents a typical, stable, and intermediate power operating point of the centralized negative pressure system under the premise of ensuring stable production of photovoltaic product P.
[0048] Next, the total negative pressure demand G_all associated with photovoltaic product P is extracted. The reference negative pressure conversion coefficient β_x of the centralized negative pressure system relative to photovoltaic product P under stable production conditions is calculated by using β_x=G_all / P_base. The unit of the reference negative pressure conversion coefficient β_x is kpa / kW. The benchmark negative pressure conversion coefficient β_x represents how many kilopascals of negative pressure a centralized negative pressure system can provide for the production of photovoltaic product P when it generates 1 kilowatt of power output. It is a special energy efficiency ratio used to reflect the network efficiency, equipment performance, and characteristics of photovoltaic product P of the centralized negative pressure system. The higher the value of the benchmark negative pressure conversion coefficient β_x, the higher the pressure output efficiency of the centralized negative pressure system.
[0049] Similarly, the above processing is performed on all known photovoltaic products to determine the reference negative voltage conversion coefficient of each photovoltaic product, which is arranged as: β_1,β_2,...,β_N, where N represents the total number of photovoltaic products, and β_x∈β_1,β_2,...,β_N.
[0050] The arithmetic mean of N benchmark negative pressure conversion coefficients is taken to obtain the final system benchmark negative pressure conversion coefficient β. The system benchmark negative pressure conversion coefficient β is no longer for a single photovoltaic product, but represents an average and comprehensive production pressure energy efficiency level of the entire centralized negative pressure system when serving the production of various typical products in the photovoltaic factory. It is a core parameter that eliminates the specific product characteristics and better reflects the inherent performance of the system itself.
[0051] Retrieve the new production order OD_new to be executed and the specific product P_new to be produced within it; Retrieve the production process data of product P_new from the cloud database to determine the target equipment processing set E_new={e1',e2',...,ej'} for photovoltaic product P_new; Next, obtain the calibration negative pressure requirements of each target device in the target device processing set E_new, and arrange them as: G1', G2', ..., Gj'.
[0052] The total rated negative pressure requirement G_all_new of photovoltaic product P_new during stable production is calculated by using the formula: G_all_new=G1'+G2'+...+Gj'. Divide the total calibrated negative pressure demand G_all_new by the system reference negative pressure conversion coefficient β to calculate the predicted reference total output power P_base_new required for the total calibrated negative pressure demand G_all_new = G_all_new / β; The predicted baseline total output power P_base_new is the predicted baseline total output power. The logic is as follows: it is known that the system can generate a negative pressure of βkPa per kW of power on average. Now, the new photovoltaic products require a negative pressure of G_all_newkPa. Therefore, the centralized negative pressure system needs to output a power of P_base_newkW.
[0053] Repeat the above steps to complete the calibration of the predicted reference total output power for various photovoltaic products; When any photovoltaic product P_new is in a stable production process, the total output power of the centralized negative pressure system is adjusted to the predicted baseline total output power P_base_new. This is achieved by adjusting the frequency of the inverter of the main fan of the centralized negative pressure system, thereby precisely controlling its speed and output power to match the set value.
[0054] Before production begins, or even during the production scheduling stage, the power requirements of the production order for the negative pressure system can be estimated in advance, realizing the transformation from passive response to proactive prediction. Furthermore, this solution has a fast calculation speed and is suitable for embedding into the Production Management System (MES) or Energy Management System (EMS) for automatic execution.
[0055] All data in the formulas described above have been calculated with dimensions removed. Furthermore, any content not described in detail in this specification is existing technology known to those skilled in the art.
[0056] The above description is merely an example and illustration of the present invention. Those skilled in the art can make various modifications or additions to the specific embodiments described, or use similar methods to replace them, as long as they do not deviate from the invention or exceed the scope defined in the claims, they should all fall within the protection scope of the present invention.
[0057] It should be stated that all user data collected in this application was collected with the user's consent and authorization. Furthermore, the uses of user data are legal and compliant, and the use and processing of user data comply with the relevant laws, regulations, and standards of the relevant regions.
Claims
1. An energy-saving control method for a centralized negative pressure system based on load forecasting, characterized in that, The method includes: Step 1: Obtain all target equipment involved in the production process of any photovoltaic product in the production order from the cloud database, construct the target equipment processing set, and calculate the total negative pressure demand of the corresponding photovoltaic product and the total output power of the centralized negative pressure system in the stable production process based on the negative pressure demand specified by each target equipment. Step 2: Plot the total negative pressure demand standard line and total output power fluctuation curve corresponding to the time sequence in the same two-dimensional coordinate system; By using the negative pressure sensors equipped at each negative pressure node to measure the actual negative pressure of the corresponding photovoltaic product during stable production, the total actual negative pressure is calculated, and the total actual negative pressure fluctuation curve is plotted in a two-dimensional coordinate system. The optimal total output power range associated with the total negative pressure demand standard line is determined based on the ratio between the total actual negative pressure fluctuation curve and the total negative pressure demand standard line at the same moment. Step 3: Calculate the reference negative pressure conversion coefficient between the centralized negative pressure system and the negative pressure node by combining the optimized total output power range and the total negative pressure demand standard line with the unit negative pressure demand, and evaluate the system's reference negative pressure conversion coefficient. Step 4: Obtain the orders to be produced, determine the target equipment processing set associated with any photovoltaic product, determine the predicted baseline total output power associated with the orders to be produced by combining the negative pressure requirements of each target equipment and the baseline negative pressure conversion coefficient, and adjust the total output power of the centralized negative pressure system.
2. The method according to claim 1, characterized in that, In step one, the specific method for constructing the target equipment processing set is as follows: Extract the OD (Original Design Object) of any production order based on a pre-built cloud database; Take any photovoltaic product P from the production order OD and include all target equipment involved in the production process, and record the total number as j; Arrange the j target devices in the order of the production process to obtain the target device processing set E={e1,e2,...,ej}.
3. The method according to claim 2, characterized in that, In step one, the specific method for calculating the total negative pressure demand of the corresponding photovoltaic product in stable production and the total output power of the centralized negative pressure system is as follows: Obtain the predefined negative pressure requirements G1, G2, ..., Gj for all target equipment in the processing set E associated with photovoltaic product P, where G1 to Gj correspond to e1 to ej, and the unit of negative pressure requirement is kPa. Calculate the total negative pressure demand of photovoltaic product P during stable production as related to time, G_all = G1 + G2 + ... + Gj, where G_all is determined based on the target equipment processing set and is a constant value, that is, the total negative pressure demand at each time is always equal to G_all; The stable production process means that all target equipment within the target equipment processing set E is in a working state; During stable production, the total output power of the processing set E of the target equipment corresponding to the centralized negative pressure system is collected in time sequence and denoted as the total output power sequence tp1, tp2, ..., tpm, where m represents the total number of time moments in the stable production process. The total output power is obtained by the centralized negative pressure system in combination with the current load and self-regulation.
4. The method according to claim 3, characterized in that, In step two, the specific method for plotting the total negative pressure demand standard line and the total output power fluctuation curve corresponding to the time series in the same two-dimensional coordinate system is as follows: Construct a two-dimensional coordinate system with the timeline as the horizontal axis, the output power value as the positive half-axis, and the negative pressure demand value as the negative half-axis, and set the value of the negative half-axis of the two-dimensional coordinate system to be positive, where the horizontal axis spans m time points; Determine the value on the negative half of the vertical axis as the scale of the total negative pressure demand G_all. Construct a line segment perpendicular to the vertical axis and parallel to the horizontal axis from this scale in the positive direction of the horizontal axis. This line segment is denoted as the standard line L of the total negative pressure demand. The span of the standard line L of the total negative pressure demand is m time intervals. The m total output power values in the total output power sequence tp1, tp2, ..., tpm are plotted as data points in a two-dimensional coordinate system according to the time sequence, resulting in m data points. A curve is obtained by fitting the data points to the curve, which is denoted as the total output power fluctuation curve W1.
5. The method according to claim 4, characterized in that, In step two, the specific method for plotting the total actual negative pressure fluctuation curve in a two-dimensional coordinate system is as follows: At any given moment during the stable production process, j actual negative pressure values are collected based on the negative pressure sensors equipped on the negative pressure nodes connected to each target device in the target equipment processing set E, and summed to form the total actual negative pressure. Construct the total actual negative pressure sequence TG1,TG2,...,TGm corresponding to the stable production process; Using the total output power fluctuation curve W1, and combined with the total actual negative pressure sequence TG1, TG2, ..., TGm, the total actual negative pressure fluctuation curve W2 is plotted in a two-dimensional coordinate system.
6. The method according to claim 5, characterized in that, In step two, the specific method for determining the preferred total output power range associated with the total negative pressure demand standard line based on the ratio between the simultaneous actual negative pressure fluctuation curve and the total negative pressure demand standard line is as follows: Calculate the ratio of the total actual negative pressure to the total negative pressure demand at m time points, and arrange them into a ratio sequence R1, R2, ..., Rm; Obtain the ratio range [R_min, R_max] preset by the operator; Filter out all times corresponding to ratios within the ratio interval [R_min, R_max] and combine them into a qualified time set T_vad; From the total output power sequence tp1, tp2, ..., tpm, extract the total output power values corresponding to the times belonging to the qualified time set T_vad. The minimum value is denoted as tp_min and the maximum value is denoted as tp_max, which constitute the preferred total output power interval [tp_min, tp_max] associated with the photovoltaic product P. Similarly, the optimal total output power range associated with each type of photovoltaic product is determined.
7. The method according to claim 6, characterized in that, In step three, the specific method for evaluating the system's baseline negative pressure conversion coefficient is as follows: Take the median value of the preferred total output power range [tp_min, tp_max] associated with photovoltaic product P, and denote it as the base output power tp_base=(tp_min+tp_max) / 2; The ratio of the base output power tp_base to the total negative pressure demand G_all is calculated to obtain the base negative pressure conversion coefficient β_x of the centralized negative pressure system for photovoltaic product P under stable production conditions. β_x = G_all / P_base, where the unit of the base negative pressure conversion coefficient β_x is kpa / kW. Similarly, determine the reference negative voltage conversion coefficients β_1,β_2,...,β_N for each photovoltaic product, where N represents the total number of photovoltaic products, and β_x∈β_1,β_2,...,β_N; The arithmetic mean of the N reference negative pressure conversion coefficients is denoted as the system reference negative pressure conversion coefficient β.
8. The method according to claim 7, characterized in that, In step four, the specific method for determining the predicted total output power associated with the production order by combining the negative pressure requirements of each target device and the reference negative pressure conversion coefficient is as follows: Get the production order OD_new to be executed; Extract any photovoltaic product P_new to be produced from OD_new; From the cloud database, obtain the target equipment processing set E_new={e1',e2',...,ej'} for producing photovoltaic products P_new, and obtain the calibration negative pressure requirements of each target equipment in E_new, arranged as: G1',G2',...,Gj'; Calculate the total rated negative pressure requirement of photovoltaic product P_new during stable production process: G_all_new = G1' + G2' + ... + Gj'; Based on the system's baseline negative pressure conversion coefficient β, calculate the predicted baseline total output power P_base_new required for the total calibrated negative pressure demand G_all_new: P_base_new = G_all_new / β; Repeat the above steps to complete the calibration of the predicted reference total output power for various photovoltaic products.
9. The method according to claim 8, characterized in that, In step four, the specific method for adjusting the total output power of the centralized negative pressure system is as follows: When the photovoltaic product P_new is in a stable production process, the total output power of the centralized negative pressure system is the predicted baseline total output power P_base_new.