Energy-saving evaluation closed-loop control system for project comprehensive energy consumption and carbon emission analysis

Abstract

The present application relates to the technical field of energy-saving control, in particular to an energy-saving evaluation closed-loop control system for project comprehensive energy consumption and carbon emission analysis, which comprises a data acquisition and mapping unit for acquiring equipment account, power load table, energy consumption type table and project comprehensive energy consumption entry data, and associating the equipment to the process and the process to the project; a time sequence alignment unit for unifying the time window; a three-level verification unit for performing two-level energy consumption consistency verification and carbon emission intensity verification of equipment-process and process-project, judging whether the threshold is exceeded, and if so, tracing back to output the root cause equipment list and the over-standard contribution rate; an abnormal locking and report generation unit for generating a verification report; and a closed-loop control unit for generating a control instruction and issuing it to the executing agency, and triggering feedback iteration until the standard is reached. The present application realizes three-level closed-loop verification, abnormal quantitative tracing and automatic control of energy consumption and carbon emission, and improves the accuracy of energy-saving evaluation.

Description

Technical Field

[0001] This invention relates to the field of energy-saving control technology, and more specifically, to an energy-saving evaluation closed-loop control system for analyzing the comprehensive energy consumption and carbon emissions of a project. Background Technology

[0002] In industrial production processes, energy conservation, emission reduction, and carbon reduction are core objectives of project operation and management. Existing energy conservation assessment methods typically employ offline spreadsheet tools or conventional energy management systems (EMS) to independently evaluate equipment energy efficiency, process energy consumption, and overall project energy consumption by collecting data from equipment ledgers, electricity load meters, energy consumption type tables, and project comprehensive energy consumption input data.

[0003] However, existing technologies generally suffer from the following problems: First, there is a lack of automated hierarchical verification mechanisms among equipment energy consumption, process energy consumption, and total project energy consumption. Inconsistencies frequently occur between the sum of energy consumption of each process and the data from independent metering points within each process, and between the sum of energy consumption of each process and the total project energy consumption. This leads to contradictory evaluation results, and the root cause of the anomaly cannot be automatically located. Second, when evaluation indicators (such as unit product energy consumption or carbon emission intensity) exceed the limits, existing tools can only output a conclusion of total excess, unable to trace down the hierarchical path of "project → process → equipment," and cannot quantify which specific equipment or energy source caused the excess. The investigation work relies entirely on manual experience, resulting in low efficiency. Third, existing systems stop at "discovering problems" and generating reports, lacking the ability to transform evaluation results into control instructions and issue them to on-site execution agencies. This prevents the formation of a closed-loop control system of "evaluation → decision → execution → re-evaluation," and energy consumption exceeding the limits cannot be corrected in a timely manner. Fourth, fixed thresholds lack adaptive adjustment capabilities, easily leading to false alarms or infinite iterations under conditions of equipment aging or process fluctuations.

[0004] Therefore, an energy-saving evaluation closed-loop control system oriented towards the comprehensive energy consumption and carbon emission analysis of the project is designed. Summary of the Invention

[0005] The purpose of this invention is to provide an energy-saving evaluation closed-loop control system for comprehensive energy consumption and carbon emission analysis of projects, so as to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention aims to provide an energy-saving evaluation closed-loop control system for comprehensive energy consumption and carbon emission analysis of projects, comprising: The data acquisition and mapping unit is used to acquire equipment ledgers, power load meters, energy type tables and project comprehensive energy consumption entry data, extract equipment energy consumption data from the power load meters and energy type tables, and associate each piece of equipment with its corresponding process and each process with the project as a whole. A timing alignment unit is used to unify the time granularity of equipment energy consumption data with the time granularity of independent metering points of processes into the same time window. The three-level verification unit is used to perform equipment-process energy consumption consistency verification to calculate the first deviation rate, process-project energy consumption consistency verification to calculate the second deviation rate, and carbon emission intensity index verification to calculate the carbon emission intensity value. It also determines whether the first deviation rate exceeds a first preset threshold, whether the second deviation rate exceeds a second preset threshold, and whether the carbon emission intensity value exceeds a preset carbon emission benchmark value. When any index exceeds the corresponding preset threshold, it traces down the hierarchical path from the project through the process to the equipment and outputs a list of root cause equipment and the contribution rate of exceeding the standard. An anomaly locking and report generation unit is used to receive judgment results and traceability results, and automatically generate a verification report containing the anomaly level, deviation rate or carbon emission intensity value and the location object when any indicator exceeds the corresponding preset threshold. The closed-loop control unit is used to generate control commands based on the root cause device list and the contribution rate of exceeding the standard, send the control commands to the field actuators, and re-trigger the data acquisition and mapping unit and the three-level verification unit after the command is sent to obtain new judgment results and traceability results. If there are still cases that exceed the corresponding preset threshold in the new judgment results, new control commands are generated iteratively until all indicators meet the standard or the upper limit of the number of iterations is reached.

[0007] As a further improvement to this technical solution, the data acquisition and mapping unit includes an equipment ledger acquisition module, an energy data acquisition module, a project energy consumption entry acquisition module, and a mapping configuration module; Among them, the equipment ledger acquisition module is used to obtain equipment identification, type, rated parameters and process to which it belongs from the equipment ledger management system; The energy data acquisition module is used to obtain the electricity, natural gas, heat and water consumption of each device from the power load meter and energy type table; The project energy consumption inlet acquisition module is used to obtain the project's comprehensive energy consumption inlet data from all primary and secondary energy inlet metering points within the project boundary; The mapping configuration module is used to configure the affiliation between equipment and processes, and supports energy consumption splitting rules for equipment shared by multiple processes.

[0008] As a further improvement to this technical solution, the timing alignment unit includes an upward aggregation module, a downward interpolation module, and a sliding window matching module; The upward aggregation module is used to aggregate high-frequency equipment energy consumption data into the same time granularity as the independent metering points of the process. The down-interpolation module is used to match low-frequency equipment energy consumption data with higher-frequency process-independent metering data through linear interpolation; The sliding window matching module is used to fill in the gaps when independent measurement point data of a process is temporarily missing by averaging the values ​​of the preceding and following time windows.

[0009] As a further improvement to this technical solution, the three-level verification unit includes an equipment-process consistency verification module, a process-item consistency verification module, and a cross-layer traceability module; Among them, the equipment-process consistency verification module is used to calculate the sum of the equipment energy consumption data of all related equipment under the same process, and obtain the independent metering point data of the process, calculate the first deviation rate, and output the equipment-level abnormal signal and locate the equipment with the largest deviation contribution when the first deviation rate exceeds the first preset threshold. The process-project consistency verification module is used to calculate the sum of independent metering point data of all processes, obtain the comprehensive energy consumption input data of the project, calculate the second deviation rate, and output process-level abnormal signal when the second deviation rate exceeds the second preset threshold and locate the process with the largest deviation contribution. The cross-layer traceability module is used to respond to events such as the first deviation rate exceeding the first preset threshold, the second deviation rate exceeding the second preset threshold, or the carbon emission intensity value exceeding the preset carbon emission benchmark value. It calculates the contribution rate of each root cause device to the energy consumption of its respective process and outputs the data in descending order of contribution rate.

[0010] As a further improvement to this technical solution, both the first preset threshold and the second preset threshold are configurable parameters, with initial default values ​​of 3% and 2% respectively, and can be set individually for different processes.

[0011] As a further improvement to this technical solution, the formula for calculating the contribution rate of exceeding the standard in the cross-layer tracing module is as follows: For the root cause device d, its contribution rate to the energy consumption exceeding the standard in its respective process. Specifically: , In the formula, This represents the actual energy consumption of the equipment. This is the equipment's baseline energy consumption; This represents the actual energy consumption of the process. This is the baseline energy consumption for the process.

[0012] As a further improvement to this technical solution, the verification report generated by the anomaly locking and report generation unit also includes at least one of the following additional contents: historical deviation rate trend chart, snapshot of the operating parameters of the abnormal equipment, priority ranking of processing suggestions, and estimated energy-saving potential; and the report also records the control command content and execution results generated by the closed-loop control unit.

[0013] As a further improvement to this technical solution, the closed-loop control unit includes a control command generation module, a safety constraint module, an actuator interface module, and a feedback loop module; The control instruction generation module is used to generate control instructions for the root cause devices based on the root cause device list and the excess contribution rate. The control instructions include at least one of the following: adjusting the frequency of the frequency converter, adjusting the valve opening, adjusting the equipment start-stop status, and switching the energy supply ratio. The safety constraint module is used to verify whether the control command exceeds the safe operating range of the device before it is generated. If it does, the generation of the command is prohibited and an alarm is output. The actuator interface module is used to send the control commands to the field actuators using industrial communication protocols and to receive execution receipts; The feedback loop module is used to re-trigger the data acquisition and mapping unit and the three-level verification unit after a preset waiting time following the issuance of the control command, and re-acquire the judgment result and traceability result. If there are still cases in the new judgment result that exceed the corresponding preset threshold, the control command generation module is triggered to execute again. If all indicators meet the standards, the closed-loop control is recorded as successful and the process exits.

[0014] As a further improvement to this technical solution, the preset waiting time is a configurable parameter between 5 minutes and 30 minutes; the feedback loop module is also configured with an adaptive adjustment strategy: when there is still a situation that exceeds the corresponding preset threshold after three consecutive closed-loop adjustments, the first preset threshold or the second preset threshold is automatically temporarily relaxed to 1.5 times the original value, and the abnormal state is recorded for manual intervention analysis.

[0015] As a further improvement to this technical solution, the carbon emission intensity value includes carbon emissions per unit product, carbon emissions per unit output value, or carbon emissions per unit added value; the preset carbon emission benchmark value is determined based on industry standards, the company's historical best value, or carbon quotas.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. In this closed-loop control system for energy-saving evaluation oriented towards comprehensive energy consumption and carbon emission analysis of projects, through the collaborative work of a three-level verification unit and a cross-layer traceability module, this invention achieves automatic verification of energy consumption consistency at two levels: equipment-process and process-project, as well as hierarchical anomaly root cause tracing from project through process to equipment. When the first deviation rate, the second deviation rate, or the carbon emission intensity value exceeds a preset threshold, the system automatically calculates the excess contribution rate of each device and sorts and outputs a list of root cause devices, solving the problem of inconsistent energy consumption data and the inability to quantitatively locate the root cause of anomalies in existing technologies, reducing the investigation time from days to minutes.

[0017] 2. In this closed-loop control system for energy-saving evaluation oriented towards comprehensive energy consumption and carbon emission analysis of projects, the invention directly converts evaluation results into control commands for root cause devices (such as adjusting inverter frequency, valve opening, or switching energy ratios) through the safety constraint module, actuator interface module, and feedback loop module in the closed-loop control unit. It also introduces feedback iteration and adaptive threshold relaxation strategies. When the target is still not met after multiple consecutive adjustments, the system automatically relaxes the threshold to 1.5 times the original value, avoiding excessive device adjustment caused by infinite iteration. This achieves closed-loop linkage between energy-saving evaluation and control, significantly improving the real-time performance of energy efficiency optimization. Attached Figure Description

[0018] Figure 1 This is a flowchart illustrating the overall process of the present invention. Detailed Implementation

[0019] 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.

[0020] Example: Please refer to Figure 1 As shown, an energy-saving evaluation closed-loop control system for comprehensive energy consumption and carbon emission analysis of projects is provided, including a data acquisition and mapping unit, a timing alignment unit, a three-level verification unit, an anomaly locking and report generation unit, and a closed-loop control unit: The data acquisition and mapping unit is used to acquire equipment ledgers, power load meters, energy type tables and project comprehensive energy consumption entry data, extract equipment energy consumption data from power load meters and energy type tables, and associate each piece of equipment with its corresponding process and each process with the project as a whole. The data acquisition and mapping unit includes an equipment ledger acquisition module, an energy data acquisition module, a project energy consumption entry acquisition module, and a mapping configuration module; The equipment ledger data collection module is used to obtain equipment identification, type, rated parameters, and associated process from the equipment ledger management system. Specifically, it reads the following fields from the "Equipment Master Data Table" in the enterprise asset management system via database connection or REST API: equipment unique identifier (ID), equipment name, equipment type (centrifugal pump, transformer, fan, air compressor, boiler, motor, etc.), rated power (kW), rated voltage, rated flow rate, rated head, factory efficiency curve parameters, and associated workshop / production line. The data collection frequency is once daily or manually triggered.

[0021] The energy data acquisition module is used to obtain the electricity, natural gas, heat and water consumption of each device from the power load meter and energy type table; The project energy consumption inlet acquisition module is used to obtain comprehensive energy consumption inlet data from all primary and secondary energy inlet metering points within the project boundary. The project boundary refers to the physical area covered by the project being evaluated, which usually includes production workshops, auxiliary facilities (such as boiler rooms and air compressor stations) and ancillary facilities (such as office building lighting). All energy input points included in the evaluation should be located within this boundary.

[0022] The mapping configuration module is used to configure the affiliation between equipment and processes, and supports energy consumption splitting rules for equipment shared by multiple processes. The mapping configuration module provides a visual configuration interface to establish affiliation between equipment and processes, and to configure energy consumption splitting rules when multiple devices share metering points.

[0023] The equipment-process hierarchy is displayed in a tree structure: Project → Process → Equipment. Users can drag and drop equipment from the equipment list on the left to the process node on the right. The system automatically records the mapping between equipment IDs and process IDs. A piece of equipment can only belong to one main process, but it can be marked as "serving multiple processes" (for public facilities).

[0024] The energy consumption splitting rule is as follows: When multiple devices are connected to a single metering point (e.g., one electricity meter), the user needs to select a splitting rule for that metering point. This embodiment supports the following rules: Energy consumption is allocated proportionally based on rated power: When multiple devices are connected to a single metering point, first calculate the sum of the rated power of all devices at that point. Then calculate the percentage of each device's rated power relative to this sum. Finally, allocate the total energy consumption of the metering point to each device according to this percentage. This rule applies to scenarios where similar devices operate continuously and have stable loads.

[0025] The energy consumption is divided according to the percentage of runtime: First, the actual runtime of each device on the day is obtained (from the device start-stop record or current detection), and the sum of the runtime of all devices is calculated. Then, the percentage of the runtime of each device to the total sum is calculated. Finally, the total energy consumption of the metering points is allocated to each device according to the percentage.

[0026] By production ratio: When common power (such as compressed air) needs to be allocated to each process, first obtain the output of each process on the day, and calculate the sum of the output of all processes. Then calculate the percentage of each process's output to the total sum. Finally, allocate the total energy consumption of the metering point to the equipment corresponding to the process according to the percentage or directly include it in the energy consumption of the process.

[0027] The mapping configuration module also includes a consistency check function. When a user saves the configuration, the system checks: whether there are any devices not included in any process (isolated device alarm); whether there are any processes not associated with any devices (empty process prompt); and whether the sum of the split ratios of multiple devices is greater than 100% or less than 99% (metering error warning). After the verification passes, the mapping relationship takes effect.

[0028] The timing alignment unit is used to unify the time granularity of equipment energy consumption data with the time granularity of independent metering points of the process to the same time window; The time-series alignment unit includes an upward aggregation module, a downward interpolation module, and a sliding window matching module. It addresses the incomparability of time windows between equipment energy consumption data and process-independent metering point data due to differences in sampling frequency or data gaps. Equipment energy consumption data is typically collected at the second or minute level, while process-independent metering points (such as process electricity meters or process natural gas flow meters) may record data at the hour or shift level. Conversely, equipment data frequencies may be lower than those of process metering points. Furthermore, data may be missing at certain time points. This unit automatically selects the appropriate alignment mode based on the actual data conditions.

[0029] The upward aggregation module aggregates high-frequency equipment energy consumption data to the same time granularity as the independent metering points of the process. For example, when equipment energy consumption data records cumulative electricity consumption (in kWh) every 5 minutes, while the independent metering points of the process record it every hour, the system first determines the target time window as 1 hour, then calculates the actual consumption within that hour by subtracting the initial value from the final value of all equipment data points. If instantaneous power values ​​(in kW) are collected, the system sums the power values ​​every 5 minutes within that hour and multiplies them by the time interval (5 minutes is converted to 1 / 12 hours) to obtain the total energy consumption. By default, the system uses cumulative summation to process cumulative data (such as electricity meter readings and flow meter cumulative values) and arithmetic average to process instantaneous data (such as power and instantaneous flow). The aggregated data is aligned with the process metering point data at the hour level to facilitate subsequent calculations of energy consumption deviations within the same time window.

[0030] The down-interpolation module is used to match low-frequency equipment energy consumption data with higher-frequency process-independent metering data through linear interpolation. For example, a natural gas flow meter records cumulative consumption every hour, while process-independent metering records every 15 minutes. In this case, it is necessary to extend the low-frequency equipment data to a higher frequency to match the process metering points. This module uses a linear interpolation method: setting a time interval... Internal device data value and Then for any time within the interval ( Instantaneous energy consumption rate is Based on this, the estimated energy consumption value at the corresponding time of each process metering point is calculated. For boundary processing, if the interpolation point is located before the first data point, the nearest neighbor extrapolation is used, that is, the first data value is used directly; if it is located after the last data point, the last data value is used; if the boundary is missing and interpolation cannot be performed, the time point is marked as "unavailable", will not participate in subsequent verification, and the reason is recorded in the log.

[0031] The sliding window matching module is used to fill in the gaps when independent measurement point data of a process is temporarily missing by averaging the values ​​of the preceding and following time windows. In this system, "temporary missing" is defined as a missing duration not exceeding twice the normal sampling period of the measurement point (for example, if the normal sampling period is 1 hour, then a missing period of 2 hours or less is considered temporary missing).

[0032] When a missing point is detected, the module automatically retrieves the values ​​before and after the missing point. The arithmetic mean of the valid data points is used as the filler value, where The default value is 2, and users can adjust it in the configuration interface according to the degree of data fluctuation (the value range is 1 to 5). If the missing point is located at the beginning of the time series, only backward propagation is used. The average of all valid data points; if it is at the end, only the forward pass is used. The system records the average of the valid data points after the data is filled. Once the data is filled, the system logs the time, location, filled value, and the source of the valid data points used, allowing for data reliability tracking in subsequent energy consumption analysis. If the missing duration exceeds the "temporary missing" threshold, the system will not automatically fill the missing data but will mark the period as insufficient in the verification report, recommending manual verification of the metering instruments.

[0033] The overall workflow of the time alignment unit is as follows: First, acquire the equipment energy consumption data sequence and the process independent metering point data sequence, and compare the timestamp ranges of the two to extract a common time interval; after extracting the common time interval, if the equipment data sequence or process metering point sequence has incomplete time windows at both ends of the interval (e.g., only covering half a sampling period), then discard the incomplete window and do not participate in subsequent verification; if it covers more than half a sampling period, then calculate the estimated value of the complete period according to the time ratio of the existing data.

[0034] Then, it checks whether there are any missing independent measurement points in the process. If they exist and meet the condition of transient absence, the sliding window matching module is called to fill them. If the absence exceeds the threshold, the alignment stops and an anomaly is reported. Next, the sampling frequency of the equipment data and the process measurement points is compared. If the frequency of the equipment data is higher than that of the process measurement points, the upward aggregation module is called; otherwise, if the frequency of the equipment data is lower than that of the process measurement points, the downward interpolation module is called. If the frequencies are the same and there are no missing points, no processing is required and the data is output directly. The aligned data sequence retains the original data and generates an aligned temporary view for the third-level verification unit to use.

[0035] The three-level verification unit is used to perform equipment-process energy consumption consistency verification to calculate the first deviation rate, process-project energy consumption consistency verification to calculate the second deviation rate, and carbon emission intensity index verification to calculate the carbon emission intensity value, and output the verification results. When the verification results are abnormal, the unit traces down the hierarchical path from the project through the process to the equipment, and outputs a list of root cause equipment and the contribution rate of exceeding the standard. The verification results include the first deviation rate, the second deviation rate, the carbon emission intensity value, and whether each index exceeds the corresponding preset threshold. An abnormal verification result means that any index exceeds the corresponding preset threshold.

[0036] In existing energy-saving assessment tools, equipment energy consumption, process energy consumption, and total project energy consumption are independent of each other, lacking automated hierarchical verification and anomaly tracing capabilities. To solve this problem, this invention sets up a three-level verification unit, which includes an equipment-process consistency verification module, a process-project consistency verification module, and a cross-level traceability module; The equipment-process consistency verification module is responsible for comparing the sum of energy consumption data of all equipment in the same process with the independent metering data of that process to detect equipment-level metering deviations or misclassifications. The system first extracts the energy consumption data of all associated equipment in the current process (already aligned to a unified time window according to the time sequence) from the data acquisition and mapping unit, and calculates the sum of the energy consumption values ​​of these equipment, denoted as... .

[0037] If a device is associated with multiple processes (e.g., an air compressor supplies air to multiple workshops), energy consumption will be allocated according to the user's pre-configured splitting rules: by default, the runtime ratio splitting will be prioritized, that is, the runtime of the device in each process will be obtained from the device start-stop record, and energy consumption will be allocated according to the runtime ratio; when runtime data is missing, the rated power ratio splitting will be automatically switched.

[0038] Subsequently, the system retrieves the independent metering point data (such as process meter readings) for this process from the energy consumption category table, and records it as follows: First deviation rate Calculate using the following formula: , Among them, the denominator It should be a positive value (if it is zero or an extremely low value, the system will skip the verification and issue a "process measurement anomaly" alarm). When the first preset threshold is exceeded, the module outputs a device-level abnormality signal and automatically locates the device that contributes the most to the deviation—that is, the device with the largest |actual energy consumption of the device - proportionally allocated theoretical energy consumption|. The default value of the first preset threshold is 3%, which can be adjusted individually by the user for different processes (e.g., 1% for high-precision processes and 5% for rough processes).

[0039] The process-project consistency verification module is used to calculate the sum of independent metering point data of all processes, obtain the comprehensive energy consumption input data of the project, calculate the second deviation rate, and output process-level abnormal signal when the second deviation rate exceeds the second preset threshold and locate the process with the largest deviation contribution. , In the formula, This is the second deviation rate; This is the sum of the energy consumption values ​​of all processes; This serves as the entry point for the project's overall energy consumption data; This refers to the comprehensive energy consumption value collected directly from all primary and secondary energy inlet metering points within the project boundary and converted to standard coal equivalent. When When the second preset threshold is exceeded (default 2%, configurable), the module outputs a process-level abnormality signal and locates the process with the largest deviation contribution—that is, the process with the largest |process measurement value - theoretical value allocated according to the total energy consumption ratio|.

[0040] The cross-layer traceability module is triggered when any of the above-mentioned verification deviation rates exceeds the corresponding threshold, or when the carbon emission intensity value exceeds the preset carbon emission benchmark value. If the triggering reason is energy consumption deviation, the excess contribution rate is calculated according to the following formula; if the triggering reason is excessive carbon emission intensity, and If the contribution rate is not calculated, then it is directly calculated as follows: Sort the absolute values ​​of the elements from largest to smallest and output them.

[0041] The core function of this module is to automatically trace down the hierarchical path of "project → process → equipment" to find the root cause equipment that causes the overall energy efficiency abnormality, and quantify the contribution of each piece of equipment to the event of exceeding the standard.

[0042] For root cause devices Its contribution rate to the excessive energy consumption of its respective processes Specifically: , In the formula, The actual energy consumption of the equipment; the baseline energy consumption of the equipment, which is the energy consumption value of the equipment under the historical best operating conditions or the corresponding value of the factory efficiency curve (the historical best operating conditions are defined as the continuous 48-hour operating data with the lowest unit product energy consumption in the past 90 days under the same or similar production range). This represents the actual energy consumption of the process. The benchmark energy consumption for the process is the historical best energy consumption or industry benchmark value for the process under the same output (the industry benchmark is preferred, and if there is no benchmark, the best monthly average value of the company over the past year is used). If the denominator ( If the value is zero or negative (indicating that the overall energy consumption of the process is within the standard or better than the benchmark), the contribution rate formula loses its physical meaning. In this case, the system does not calculate the contribution rate, but directly uses ( Sort the absolute values ​​of the devices from largest to smallest; the larger the absolute value, the more severe the device malfunction.

[0043] After calculating the out-of-range contribution rate of all root cause devices, they are sorted from highest to lowest contribution rate, and a list of root cause devices and their respective contribution rates is output. This list is directly passed to the closed-loop control unit, which can then generate control commands (such as adjusting the frequency of a frequency converter or the opening of a valve) for the device with the highest contribution rate.

[0044] The carbon emission intensity value is calculated based on the energy consumption and real-time carbon emission factor. The specific calculation formula is: Total carbon emissions = Σ(Energy consumption × Carbon emission factor), Carbon emission intensity = Total carbon emissions / Product output. When it exceeds the preset benchmark value, the cross-layer traceability module is also triggered, and the traceability logic is the same as for energy consumption exceeding the standard.

[0045] Through the above three-level verification and cross-layer traceability mechanism, this invention realizes the automated and quantitative location of abnormal energy efficiency indicators from project level to specific equipment, filling the technical gap of existing tools that can only count the total amount but cannot trace the root cause.

[0046] The anomaly locking and report generation unit is used to receive the verification results and automatically generate a verification report containing the anomaly level, deviation rate or carbon emission intensity value and the location object when any indicator exceeds the corresponding preset threshold. The verification report also includes at least one of the following additional contents: historical deviation rate trend chart, snapshot of the operating parameters of the abnormal equipment, priority ranking of processing suggestions and estimated energy saving potential. The report also records the control command content and execution results generated by the closed-loop control unit.

[0047] Existing energy-saving evaluation systems typically stop at "identifying problems" and outputting reports, lacking the closed-loop control capability to "solve problems." This invention, based on a three-level verification unit and an anomaly locking reporting unit, further incorporates a closed-loop control unit. This unit consists of four modules: a control command generation module, a safety constraint module, an actuator interface module, and a feedback loop module, forming an automated control loop of "evaluation → decision → execution → re-evaluation."

[0048] The control command generation module receives the root cause device list and the contribution rate of exceeding the standard output by the three-level verification unit. After sorting the devices by contribution rate from high to low, it generates control commands for the devices with the highest contribution rates.

[0049] The type of control command is automatically selected based on the equipment type and the reason for exceeding the limit, including but not limited to: For variable frequency drive equipment (such as centrifugal pumps, fans, and air compressors), generate instructions to adjust the frequency of the frequency converter (with a step size of ±1% to ±5% of the rated frequency). For equipment controlled by regulating valves, generate instructions to regulate the valve opening (in increments of ±2% to ±10% of the rated opening). For equipment that can operate intermittently (such as lighting and non-critical auxiliary equipment), generate equipment start-stop commands; For multi-energy supply systems (such as boilers that can switch between natural gas and biomass), generate instructions to switch the energy supply ratio.

[0050] By default, the adjustment range is determined based on the deviation ratio between the equipment's baseline energy consumption and actual energy consumption; the larger the deviation, the larger the adjustment step. If multiple devices exceed the limit simultaneously, instructions are generated sequentially according to their contribution rate to avoid conflicts between multiple instructions.

[0051] Before issuing control commands, the safety constraint module performs hard constraint verification on the commands to prevent safety accidents or equipment damage caused by automatic adjustment. The system pre-configures safe operating ranges for each type of equipment. For example, the lower limit of the frequency of a frequency converter is 30% of the rated frequency, and the upper limit is 100% of the rated frequency; the lower limit of valve opening is 5% (to prevent pressure buildup caused by complete closure), and the upper limit is 95%; the minimum start-stop interval of a motor is 20 minutes; and a centrifugal pump must wait 5 minutes after stopping before restarting.

[0052] The safety constraint module obtains the real-time operating parameters of the current device and determines whether the instruction will cause the device to exceed the aforementioned safety range. If it does, the generation of the instruction is prohibited, and an alarm message (including device identifier, original instruction content, and violated security rules) is output. The device is then skipped, and the instruction is generated for the next device in the root cause list instead. If all instructions from root cause devices are blocked by safety constraints, the system records a "safety constraint blocked" status and notifies manual intervention.

[0053] Commands constrained by safety restrictions are issued from the actuator interface module to the field actuator. The actuator interface module supports multiple industrial communication protocols, including Modbus TCP / RTU, Profibus DP, OPC UA, MQTT, and Profinet. The system automatically selects the protocol based on the communication configuration of the field device. After issuing the command, the actuator interface module waits for a response from the actuator (such as a "frequency adjusted" signal from the frequency converter). If no response is received within the set timeout period (default 30 seconds), the module will retry up to three times. If the attempt still fails, the device will be marked as having a "communication failure" and an alarm will be triggered.

[0054] After the command is issued, the system enters a waiting period. The preset waiting time can be configured by the user, with a default range of 5 to 30 minutes. This waiting time needs to be determined based on the equipment's response characteristics and the process stabilization time. For equipment with low inertia (such as a frequency converter whose power load can stabilize within 1 minute after frequency adjustment), a 5-minute timeout can be set; for equipment with high thermal inertia (such as a boiler whose steam parameters need 15 minutes to stabilize after adjusting the fuel ratio), a 20-minute timeout can be set; and for production batch switching scenarios, a 30-minute timeout can be set. After the waiting period, the feedback loop module automatically re-triggers the data acquisition and mapping unit and the three-level verification unit to obtain new verification results.

[0055] If all indicators in the new verification result have met the standards (i.e., the first deviation rate ≤ the first preset threshold, the second deviation rate ≤ the second preset threshold, and the carbon emission intensity ≤ the benchmark value), then the closed-loop control is recorded as successful and exited. At the same time, the control command and effect are stored in the knowledge base for reference in similar situations in the future.

[0056] If the new verification results still contain cases exceeding the corresponding preset threshold, an iterative loop is entered: the system calls the control command generation module again (based on the updated root cause device list) to generate new commands, which then undergo security constraints, issuance, waiting, and re-verification. The maximum number of iterations is 5 by default.

[0057] If the new verification results still fail to meet the standard after three consecutive closed-loop adjustments (i.e., after three consecutive iterations), the system determines that there may be underlying causes such as hardware failure, process changes, or overly stringent baseline settings. In this case, the system automatically and temporarily relaxes either the first or second preset threshold to 1.5 times its original value (e.g., from 3% to 4.5%) to prevent excessive equipment adjustment or production interruption due to infinite iteration. Iteration continues after the relaxation, and the system records the current abnormal state (including the exceeded indicators, the sequence of executed control commands, and the final deviation rate), generating an "Advanced Anomaly Report" for engineer analysis. If the standard is still not met after reaching the iteration limit (5 times), the loop terminates and is marked "Manual Intervention Required," while maintaining the relaxed threshold for manual analysis; the original threshold can be manually restored or the baseline value adjusted.

[0058] Carbon emission intensity values ​​include carbon emissions per unit of product, carbon emissions per unit of output value, or carbon emissions per unit of added value; preset carbon emission benchmark values ​​are determined based on industry standards, the company's historical best values, or carbon quotas; when the carbon emission intensity value exceeds the preset carbon emission benchmark value, the closed-loop control unit will preferentially select at least one of the following control strategies: reduce the proportion of high-carbon-emission energy use, increase the consumption of renewable energy, and adjust production scheduling to periods with low carbon emission factors.

[0059] The above closed-loop control unit process enables the present invention not only to evaluate energy consumption and carbon emissions, but also to automatically perform adjustments, iterative optimizations, and degradation processing in case of anomalies, truly achieving a closed-loop process.

[0060] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely preferred examples and are not intended to limit the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed invention.

Claims

1. A closed-loop control system for energy-saving evaluation oriented towards comprehensive energy consumption and carbon emission analysis of projects, characterized in that, include: The data acquisition and mapping unit is used to acquire equipment ledgers, power load meters, energy type tables and project comprehensive energy consumption entry data, extract equipment energy consumption data from the power load meters and energy type tables, and associate each piece of equipment with its corresponding process and each process with the project as a whole. A timing alignment unit is used to unify the time granularity of equipment energy consumption data with the time granularity of independent metering points of processes into the same time window. The three-level verification unit is used to perform equipment-process energy consumption consistency verification to calculate the first deviation rate, process-project energy consumption consistency verification to calculate the second deviation rate, and carbon emission intensity index verification to calculate the carbon emission intensity value. It also determines whether the first deviation rate exceeds a first preset threshold, whether the second deviation rate exceeds a second preset threshold, and whether the carbon emission intensity value exceeds a preset carbon emission benchmark value. When any index exceeds the corresponding preset threshold, it traces down the hierarchical path from the project through the process to the equipment and outputs a list of root cause equipment and the contribution rate of exceeding the standard. An anomaly locking and report generation unit is used to receive judgment results and traceability results, and automatically generate a verification report containing the anomaly level, deviation rate or carbon emission intensity value and the location object when any indicator exceeds the corresponding preset threshold. The closed-loop control unit is used to generate control commands based on the root cause device list and the contribution rate of exceeding the standard, send the control commands to the field actuators, and re-trigger the data acquisition and mapping unit and the three-level verification unit after the command is sent to obtain new judgment results and traceability results. If there are still cases that exceed the corresponding preset threshold in the new judgment results, new control commands are generated iteratively until all indicators meet the standard or the upper limit of the number of iterations is reached. The three-level verification unit includes an equipment-process consistency verification module, a process-project consistency verification module, and a cross-layer traceability module; Among them, the equipment-process consistency verification module is used to calculate the sum of the equipment energy consumption data of all related equipment under the same process, and obtain the independent metering point data of the process, calculate the first deviation rate, and output the equipment-level abnormal signal and locate the equipment with the largest deviation contribution when the first deviation rate exceeds the first preset threshold. The process-project consistency verification module is used to calculate the sum of independent metering point data of all processes, obtain the comprehensive energy consumption input data of the project, calculate the second deviation rate, and output process-level abnormal signal when the second deviation rate exceeds the second preset threshold and locate the process with the largest deviation contribution. The cross-layer traceability module is used to respond to events such as the first deviation rate exceeding the first preset threshold, the second deviation rate exceeding the second preset threshold, or the carbon emission intensity value exceeding the preset carbon emission benchmark value, to calculate the excess contribution rate of each root cause device to the energy consumption of its respective process, and output the data in descending order of contribution rate. The closed-loop control unit includes a control command generation module, a safety constraint module, an actuator interface module, and a feedback loop module; The control instruction generation module is used to generate control instructions for the root cause devices based on the root cause device list and the excess contribution rate. The control instructions include at least one of the following: adjusting the frequency of the frequency converter, adjusting the valve opening, adjusting the equipment start-stop status, and switching the energy supply ratio. The safety constraint module is used to verify whether the control command exceeds the safe operating range of the device before it is generated. If it does, the generation of the command is prohibited and an alarm is output. The actuator interface module is used to send the control commands to the field actuators using industrial communication protocols and to receive execution receipts; The feedback loop module is used to re-trigger the data acquisition and mapping unit and the three-level verification unit after a preset waiting time following the issuance of the control command, and re-acquire the judgment result and traceability result. If there are still cases in the new judgment result that exceed the corresponding preset threshold, the control command generation module is triggered to execute again. If all indicators meet the standards, the closed-loop control is recorded as successful and the process exits.

2. The energy-saving evaluation closed-loop control system for comprehensive energy consumption and carbon emission analysis of a project as described in claim 1, characterized in that: The data acquisition and mapping unit includes an equipment ledger acquisition module, an energy data acquisition module, a project energy consumption entry acquisition module, and a mapping configuration module. Among them, the equipment ledger acquisition module is used to obtain equipment identification, type, rated parameters and process to which it belongs from the equipment ledger management system; The energy data acquisition module is used to obtain the electricity, natural gas, heat and water consumption of each device from the power load meter and energy type table; The project energy consumption inlet acquisition module is used to obtain the project's comprehensive energy consumption inlet data from all primary and secondary energy inlet metering points within the project boundary; The mapping configuration module is used to configure the affiliation between equipment and processes, and supports energy consumption splitting rules for equipment shared by multiple processes.

3. The energy-saving evaluation closed-loop control system for comprehensive energy consumption and carbon emission analysis of a project as described in claim 2, characterized in that: The timing alignment unit includes an upward aggregation module, a downward interpolation module, and a sliding window matching module; The upward aggregation module is used to aggregate high-frequency equipment energy consumption data into the same time granularity as the independent metering points of the process. The down-interpolation module is used to match low-frequency equipment energy consumption data with higher-frequency process-independent metering data through linear interpolation; The sliding window matching module is used to fill in the gaps when independent measurement point data of a process is temporarily missing by averaging the values ​​of the preceding and following time windows.

4. The energy-saving evaluation closed-loop control system for comprehensive energy consumption and carbon emission analysis of a project as described in claim 1, characterized in that: Both the first preset threshold and the second preset threshold are configurable parameters, with initial default values ​​of 3% and 2% respectively, and can be set individually for different processes.

5. The energy-saving evaluation closed-loop control system for comprehensive energy consumption and carbon emission analysis of a project as described in claim 4, characterized in that: The formula for calculating the contribution rate of exceeding the standard in the cross-layer tracing module is as follows: For the root cause device d, its contribution rate to the energy consumption exceeding the standard in its respective process. Specifically: In the formula, This represents the actual energy consumption of the equipment. This is the equipment's baseline energy consumption; This represents the actual energy consumption of the process. This is the baseline energy consumption for the process.

6. The energy-saving evaluation closed-loop control system for comprehensive energy consumption and carbon emission analysis of a project as described in claim 5, characterized in that: The verification report generated by the anomaly locking and report generation unit also includes at least one of the following additional contents: historical deviation rate trend chart, snapshot of the operating parameters of the abnormal equipment, priority ranking of processing suggestions, and estimated energy-saving potential; and the report also records the content of the control commands generated by the closed-loop control unit and the execution results.

7. The energy-saving evaluation closed-loop control system for comprehensive energy consumption and carbon emission analysis of projects according to claim 1, characterized in that: The preset waiting time is a configurable parameter between 5 minutes and 30 minutes; the feedback loop module is also configured with an adaptive adjustment strategy: when there is still a situation that exceeds the corresponding preset threshold after three consecutive closed-loop adjustments, the first preset threshold or the second preset threshold is automatically temporarily relaxed to 1.5 times the original value, and the abnormal status is recorded for manual intervention analysis.

8. The energy-saving evaluation closed-loop control system for comprehensive energy consumption and carbon emission analysis of a project as described in claim 7, characterized in that: The carbon emission intensity value includes carbon emissions per unit of product, carbon emissions per unit of output value, or carbon emissions per unit of added value; the preset carbon emission benchmark value is determined based on industry standards, the company's historical best value, or carbon quotas.

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