Energy-efficient power management system for three-phase machines and equipment

Abstract

An energy-efficient energy management system for three-phase industrial equipment, consisting of: a feedback control mechanism configured to continuously monitor the operating status of connected industrial machines, using sensors that detect machine activity; a power disconnect device connected to an energy meter that automatically interrupts the power supply to the connected industrial machines when it detects inactivity via the feedback control mechanism, thus preventing unnecessary energy consumption; a contactor within the feedback control mechanism, designed for the specific load requirements of the connected industrial machines and enabling reliable switching of the circuit depending on the operating status; a relay integrated into the feedback control mechanism, configured to switch the power supply between active and inactive states depending on the detected machine activity; a power button that allows manual activation of the power supply as needed; and A DC power supply in the feedback control mechanism with a nominal voltage of 12 V to 24 V, which supplies power to the control circuits to enable monitoring and operational control. Electrical wiring with conductors designed for the appropriate voltage and current connects the energy meter to the connected machines, ensuring efficient signal transmission and power supply over suitable distances. The system automatically connects the power supply to the energy meter when operating signals are detected from the machines and disconnects the power supply when inactivity is detected.

Description

Field of the invention:

[0001] This invention relates to energy management and energy saving systems and focuses in particular on three-phase industrial applications. Background of the invention:

[0002] Three-phase power systems are commonly used in industrial environments to operate various machines. However, many of these devices also consume power during inactive periods, such as lunch breaks or after business hours, resulting in significant standby or vampire power consumption. This practice contributes to higher operating costs, energy waste, and negative environmental impacts. Current solutions, including manual switches and timers, require user intervention and are often neglected, resulting in energy waste. There is a need for a reliable and automated solution that minimizes power consumption during non-operational periods.

[0003] Three-phase systems are widely used in industrial environments due to their efficiency and ability to handle high loads. These systems supply power to a wide variety of machines, including motors, pumps, compressors, and HVAC systems. However, a significant challenge with these systems is the unnecessary energy consumption that occurs during periods when the equipment is inactive. This phenomenon, often referred to as standby power consumption or vampire power consumption, occurs when machines continue to consume power even when they are not in use. This results in energy waste, increased operating costs, and negative environmental impacts. Existing solutions to address this issue include manual switches, timers, and energy management systems, each of which has its own limitations and does not provide a comprehensive solution to the problem.

[0004] Manual switches are the simplest form of control and require users to physically turn off devices when not in use. While this method can effectively stop power consumption, it relies heavily on human intervention. In many cases, operators may forget to turn off machines, especially in large facilities where multiple devices are in operation. This omission results in continued energy consumption during inactive periods, negating potential energy savings. Furthermore, frequent manual operation can cause wear and tear on switches, reducing their reliability and lifespan. This not only impairs the operating efficiency of the machines but also increases maintenance costs, making manual switching an unviable solution in high-demand environments.

[0005] Timers are another common solution for controlling power consumption by dictating when devices should be turned on or off. Although timers can help reduce standby power outages by interrupting power at set intervals, they still have several disadvantages. Timers must be properly programmed and regularly adjusted to suit machine operating schedules. In dynamic industrial environments where shifts may change or unexpected tasks may arise, relying on timers can result in either unnecessary power consumption if machines remain on longer than necessary or operational downtime if machines are turned off at the required intervals. This lack of adaptability is a significant disadvantage because it limits the effectiveness of timers in efficiently managing energy.Furthermore, a malfunction or incorrect setting of a timer can lead to energy waste, defeating the purpose of energy management altogether.

[0006] Energy management systems were developed to offer more advanced solutions for reducing energy consumption in industrial applications. These systems typically incorporate various sensors and monitoring devices that can track energy consumption and operational status in real time. While such systems represent a more automated approach to energy management, they also come with several limitations. The complexity of installation and integration with existing systems can be a significant barrier to adoption. Many energy management solutions require significant upfront investments in hardware and software, which can be prohibitively expensive for smaller operations. Furthermore, the integration process can be time-consuming and disruptive, potentially leading to operational downtime during installation.

[0007] Furthermore, many energy management systems focus primarily on data collection and analysis rather than real-time control of energy distribution. This can lead to delays in response times, as the system may not react quickly enough to changes in operating status, resulting in energy waste during transition periods. For example, if a machine stops operating but the system doesn't immediately disconnect the power supply, energy will continue to be consumed until the system registers the change and takes action. Such delays can negate potential savings, especially in environments where machines are frequently turned on and off throughout the day.

[0008] Another significant disadvantage of current solutions is their lack of flexibility and adaptability to specific operating requirements. Many systems are designed using a one-size-fits-all approach that may not meet the individual needs of different machines or operating conditions. For example, certain machines may require a minimum power draw to maintain critical functions even when not actively operating. Existing systems may not be able to adequately distinguish between active and inactive states, leading to inappropriate power shutdowns that can disrupt processes or damage equipment. This limitation highlights the need for a more sophisticated approach to power management that can intelligently respond to the specific needs of different devices.

[0009] Furthermore, existing systems often lack user-friendly interfaces and remote monitoring capabilities, making it difficult for operators to effectively manage energy consumption. Many energy management systems require on-site customization or monitoring, which can be cumbersome and time-consuming. Operators may not have real-time visibility into energy consumption, making it difficult to identify patterns or areas for improvement. This lack of transparency can lead to frustration and lower commitment to energy management practices among operators and facility managers.

[0010] In summary, while various solutions exist to reduce standby power consumption in three-phase industrial applications, they all have significant drawbacks that limit their effectiveness. Manual switches rely heavily on human intervention, resulting in missed energy-saving opportunities. Time-lock switches lack the adaptability required for dynamic industrial environments, frequently resulting in either energy waste or operational downtime. While energy management systems offer automation and data analytics, they face challenges related to installation complexity, delayed response times, and limited flexibility.The need for a more comprehensive, automated solution that can monitor and control power consumption in real time is evident, especially as industries seek to increase operational efficiency and reduce their environmental impact. An innovative approach to energy management that integrates advanced feedback mechanisms and real-time monitoring capabilities can effectively address these challenges and pave the way for more sustainable industrial practices. Summary of the invention:

[0011] The invention presents an energy-efficient power management system for three-phase machines and equipment, consisting of a central control unit, multiple sensors, and an advanced power distribution network. The central control unit receives inputs from various strategically placed sensors to monitor parameters such as voltage, current, and power factor in real time. This information is processed using an adaptive algorithm that adjusts power distribution based on the operating requirements of the connected equipment. The system utilizes intelligent switching technology to selectively turn machines on or off depending on load demand, thus reducing energy consumption during idle times.

[0012] Additionally, the system features a feedback loop that continuously analyzes performance data, enables predictive maintenance, and ensures potential problems are addressed before they escalate. This proactive approach minimizes downtime and extends equipment lifespan. The power distribution network is designed to enable seamless communication between the control unit and connected devices, enabling rapid response times to changes in load conditions. Furthermore, the system can integrate renewable energy sources, enabling a hybrid approach to energy management that maximizes efficiency and sustainability.

[0013] The primary objective of this invention is to provide an energy-efficient power management system specifically designed for three-phase industrial applications, aimed at significantly reducing unnecessary energy consumption during periods when machines are not actively in use. This system aims to automate the process of disconnecting power to idle industrial equipment, thus minimizing standby power loss, a common problem in many industrial environments. Another key objective is the implementation of an integrated feedback control mechanism that continuously monitors the operating status of connected machines and ensures that power is supplied only when needed. This feature increases operating efficiency and reduces electricity costs, contributing to overall energy savings.

[0014] Furthermore, the invention aims to address the limitations of existing solutions such as manual switches and timers by offering a reliable, automated alternative that requires minimal user intervention. The system is designed to activate automatically when the machine is activated, ensuring smooth operation without manual control. Furthermore, it is intended to offer real-time adaptability, allowing for immediate power interruption as soon as the machine's operating signal ceases, which is essential for avoiding energy waste during idle times.

[0015] Another objective of this invention is to enhance the user experience by integrating intuitive operating and monitoring features. This includes providing a user interface that allows operators to easily override the automated system when needed and provides real-time feedback on power consumption and operating status. This transparency enables plant managers and operators to make informed decisions regarding energy consumption and operational efficiency. Finally, the invention aims to promote environmental sustainability by contributing to lower carbon emissions through less energy waste, thus meeting the growing need for industry to implement more sustainable practices in their operations.By achieving these objectives, the invention serves not only to improve energy efficiency but also to improve the overall operational efficiency of industrial environments. SHORT DESCRIPTION OF THE FIGURE

[0016] These and other features, aspects, and advantages of the present invention will become more readily understood when the following detailed description is read in conjunction with the accompanying drawings, in which like characters represent like parts throughout. Fig. Figure 1 shows a block diagram of an energy-efficient energy management system for three-phase machines and equipment.

[0017] Furthermore, those skilled in the art will appreciate that elements in the drawings are shown for convenience and may not necessarily be drawn to scale. For example, the flowcharts illustrate the method by key steps to enhance understanding of aspects of the present disclosure. Furthermore, with respect to device construction, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawing may show only the specific details relevant to understanding embodiments of the present disclosure in order not to clutter the drawings with details that would be readily apparent to those skilled in the art who would benefit from the description herein. Detailed description:

[0018] To facilitate an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and described in specific language. It is to be understood, however, that no limitation on the scope of the invention is intended thereby, since such changes and further modifications of the illustrated system, and such further applications of the principles of the invention as illustrated therein, are contemplated as would normally occur to one skilled in the art to which the invention pertains.

[0019] It will be understood by one skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be limiting thereof.

[0020] References in this specification to "one aspect," "another aspect," or similar language mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Therefore, occurrences of the phrase "in one embodiment," "in another embodiment," and similar language throughout this specification may or may not all refer to the same embodiment.

[0021] The terms "comprises," "comprising," or other variations thereof are intended to cover non-exclusive inclusion, such that a process or method comprising a list of steps not only includes those steps, but may also include other steps not expressly listed or inherent in such process or method. Likewise, one or more devices or subsystems or elements or structures or components preceded by "comprises...a" does not preclude, without further limitation, the existence of other devices or other subsystems or other elements or other structures or other components or additional devices or additional subsystems or additional elements or additional structures or additional components.

[0022] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The system, methods, and examples provided herein are for illustrative purposes only and should not be considered limiting.

[0023] Embodiments of the present disclosure will be described in detail below with reference to the accompanying drawings.

[0024] Fig.Figure 1 shows a block diagram of an energy-efficient power management system for three-phase industrial equipment, including: a feedback control mechanism 102 configured to continuously monitor the operating status of connected industrial machines and utilize sensors that detect machine activity; a power disconnect unit 104 connected to an energy meter that automatically disconnects power to the connected industrial machines when inactivity is detected via the feedback control mechanism, thereby avoiding unnecessary energy consumption; a contactor 106 within the feedback control mechanism, designed for the specific load requirements of the connected industrial machines and enabling reliable circuit switching based on the operating status;a relay 108 integrated into the feedback control mechanism, configured to switch the power supply between active and inactive states depending on detected machine activity; a power button 110 configured to allow manual activation of the power supply when needed; and a DC power supply 112 within the feedback control mechanism, rated at 12 V to 24 V, that powers the control circuitry to enable monitoring and operational control.

[0025] Electrical cabling with conductors rated for the appropriate voltage and current connects the energy meter to the connected machines, ensuring efficient signal transmission and power supply over adjusted distances. The system automatically connects the power supply to the energy meter when operating signals from the machines are detected and disconnects the power supply when inactivity is detected.

[0026] In one embodiment, the sensors are configured to detect a range of parameters, including machine vibration, current flow, and temperature, enabling a comprehensive assessment of the machine's operating condition.

[0027] In one embodiment, the power disconnect unit 104 further includes a programmable timer 114 that allows user-defined intervals for disconnecting and reconnecting the power supply based on specific operating requirements of the machinery.

[0028] In one embodiment, relay 108 is a solid-state relay designed to reduce electrical noise and increase durability, thereby improving system performance in high-frequency operating environments.

[0029] In one embodiment, the feedback control mechanism 102 includes an automatic reset function that restores the power connection after a predefined time.

[0030] In one embodiment, the DC power supply 112 is equipped with overvoltage and overcurrent protection features to protect the control circuits from power surges.

[0031] In one embodiment, the present system further includes a communications module 114 that transmits real-time energy consumption and operating status data to a remote monitoring system, enabling centralized control and diagnostics.

[0032] In one embodiment, contactor 106 is equipped with arc suppression to minimize arcing during switching operations, thereby improving system safety and operational reliability.

[0033] In one embodiment, the system includes a user-configurable interface that allows adjustment of the sensitivity settings of the sensors, thus enabling tailored energy management based on specific usage patterns of the machine.

[0034] The proposed energy management system is divided into two main components: Part 1, located near the energy meter, is responsible for monitoring and controlling the power supply. Part 2, installed directly on the industrial machine, provides feedback on the operating status.

[0035] The automated feedback system continuously monitors the operating status of connected machines via a feedback loop, using sensors or signals that indicate active operation. Upon detection of inactivity, the system automatically disconnects the power supply to the connected machines from the energy meter, thus reducing standby power consumption. Furthermore, the system automatically reconnects the power supply from the energy meter when a connected machine is activated, ensuring that operating requirements are met without manual intervention. Conversely, the power supply is disconnected when the machine is deactivated, thus avoiding unnecessary energy consumption during periods of inactivity.

[0036] The system's operating states are clearly divided into two: When a connected machine is operating, the three-phase power connection remains active, ensuring an uninterrupted power supply for efficient operation. When the machine is shut down or the facility is closed, the system disconnects the three-phase power supply, effectively preventing energy waste during non-operational hours. This configuration significantly reduces energy waste by preventing power consumption during inactive periods.

[0037] To establish an efficient feedback mechanism, the system includes several hardware components. A power contactor, designed according to the specific load requirements of the connected machines, is used to control the circuit and enables reliable power switching based on feedback signals. An automatic relay is integrated into the system to facilitate power switching in response to signals from the feedback control mechanism and ensure seamless operation between active and inactive states. A normally open push-button switch is included to provide manual activation options when needed and allow user intervention in certain scenarios.

[0038] The system's electrical wiring uses a four-pair configuration with conductors rated for the appropriate voltage and current. The wiring length is adjusted based on the physical distance from the energy meter to the machine to ensure efficient signal transmission and power delivery. Additionally, a DC power supply in the range of 12 V to 24 V is used to power the control circuits, allowing the feedback mechanism and operational controls to function effectively. This combination of components forms a robust energy management system that improves operational efficiency while minimizing energy waste in industrial applications.

[0039] The proposed energy-efficient energy management system offers several benefits, including a significant reduction in unnecessary energy consumption during off-peak hours, which directly translates into lower electricity costs for industrial operations. By promoting energy conservation, the system contributes to environmental sustainability by reducing carbon emissions. Furthermore, it increases operational efficiency by minimizing the need for manual intervention, allowing industrial facilities to operate more effectively and responsively.

[0040] The invention is embodied in a device designed for effective energy management in three-phase systems. The device comprises a main control unit housing the feedback control mechanism, a current isolating unit connected to the energy meter, and an integrated relay and contactor assembly that enables reliable switching operations. Furthermore, the device features a user interface with a power button and an LED indicator that signals the operating status of the connected machine. The device is also equipped with a compact housing unit that can be mounted next to the energy meter, ensuring seamless integration into existing industrial facilities while adhering to safety and operational standards.

[0041] This device for an energy-efficient energy management system for three-phase machines and equipment addresses the urgent need for automated control in industrial applications, ultimately leading to improved energy efficiency and sustainability.

[0042] The present invention relates to energy management and energy-saving systems, with a particular focus on optimizing energy consumption in industrial environments using three-phase electrical systems. This invention addresses the challenges associated with standby power consumption and aims to provide a reliable and automated solution that minimizes unnecessary energy consumption during non-operational periods. The invention is applicable to various industrial applications, including manufacturing, processing, and HVAC systems, where three-phase machines are commonly used.

[0043] The drawings and the foregoing description provide examples of embodiments. Those skilled in the art will recognize that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be separated into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, orders of the processes described herein may be changed and are not limited to the manner described herein. Furthermore, the actions of any flowchart need not be implemented in the order shown; nor do all actions necessarily need to be performed. Also, those actions that are not dependent on other actions may be performed in parallel with the other actions. The scope of the embodiments is in no way limited by these specific examples.Numerous variations, whether explicitly stated in the specification or not, such as differences in structure, dimensions, and use of materials, are possible. The scope of the embodiments is at least as broad as indicated in the following claims.

[0044] Advantages, other benefits, and solutions to problems have been described above with reference to specific embodiments. However, the advantages, benefits, solutions to problems, and any components that may cause an advantage or solution to occur or become more apparent are not to be construed as a critical, required, or essential feature or component of any or all of the claims. REFERENCES 100 An energy-efficient energy management system for three-phase machines and equipment. 102 Feedback control mechanism 104 Current isolating device 106 contactor 108 relays 110 push button 112 DC power supply 114 Programmable Timer

Claims

[1] An energy-efficient energy management system for three-phase industrial equipment, consisting of: a feedback control mechanism configured to continuously monitor the operating status of connected industrial machines using sensors that detect machine activity; a power isolating device connected to an energy meter that automatically interrupts the power supply to the connected industrial machines when it detects inactivity via the feedback control mechanism, thus preventing unnecessary energy consumption; a contactor within the feedback control mechanism designed for the specific load requirements of the connected industrial machinery and enabling reliable switching of the circuit depending on the operating status; a relay integrated into the feedback control mechanism, configured to switch the power supply between active and inactive states depending on detected machine activity; a power button that allows manual activation of the power supply as required; and a DC power supply in the feedback control mechanism with a nominal voltage of 12 V to 24 V, which supplies power to the control circuits to enable monitoring and operational control. Electrical cabling with conductors designed for the appropriate voltage and current connects the energy meter to the connected machines, ensuring efficient signal transmission and power supply over appropriate distances. The system automatically connects the power supply to the energy meter when operating signals from the machines are detected and disconnects the power supply when inactivity is detected. [2] The energy-efficient energy management system of claim 1, wherein the sensors are configured to detect a range of parameters, including machine vibration, current flow and temperature, to enable a comprehensive assessment of the operating condition of the machine. [3] The energy-efficient power management system of claim 1, wherein the power disconnect unit further comprises a programmable timer that allows user-defined intervals for disconnecting and reconnecting the power supply based on specific operating requirements of the machinery. [4] The energy-efficient power management system of claim 1, wherein the relay is a solid-state relay configured to reduce electrical noise and increase durability, thereby improving system performance in high-frequency operating environments. [5] The energy efficient power management system of claim 1, wherein the feedback control mechanism includes an automatic reset function that restores the power connection after a predefined time. [6] The energy-efficient power management system of claim 1, wherein the DC power supply is equipped with overvoltage and overcurrent protection functions to protect the control circuits from power surges. [7] The energy-efficient energy management system according to claim 1 further comprises a communication module that transmits real-time data on energy consumption and operating status to a remote monitoring system, thus enabling central control and diagnosis. [8] The energy-efficient power management system of claim 1, wherein the contactor is equipped with arc suppression to minimize arcing during switching operations and thereby improve system safety and operational reliability. [9] The energy-efficient power management system of claim 1, wherein the system includes a user-configurable interface that allows adjustment of the sensitivity settings for the sensors, thus enabling tailored power management based on specific machine usage patterns.

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