Method for generating and providing heat and / or cold in a treatment system for workpieces

Abstract

The present invention relates to a method (200) for generating and providing heat and / or cold in a treatment system (102) for workpieces, preferably in a paint shop (103) for vehicle bodies or parts thereof, wherein the method (200) comprises the following steps: determining at least one power requirement (202) of the consumer processes of the treatment system in a predetermined time interval; prioritising a water network (204); determining a power profile (208) for the at least one heat pump device of the prioritised water network on the basis of the determined power requirement; controlling the at least one heat pump device of the prioritised water network on the basis of the determined power profile; providing cold and / or hot water to the consumer processes (146) of the treatment system (102); and temporarily storing cold water and / or hot water in the at least one storage device.

Description

[0001] Method for generating and providing heat and / or cold in a workpiece treatment plant

[0002] The present invention relates to a method for generating and providing heat and / or cold in a treatment plant for workpieces, in particular a paint shop for vehicle bodies or parts thereof.

[0003] In practice, it is known that, in the fight against global warming, more and more automotive manufacturers are considering electrifying their processing facilities, such as their paint shops. If the electricity used for this comes from renewable energy sources, the production can be considered carbon neutral. Besides the direct electrification of processes, such as drying processes, other processes are supplied via, for example, hot and / or cold water networks.

[0004] The provision of heat, heat quantities, heat output, heat energy or heat flows or cold, cold quantities, cooling outputs, cooling energy or cold flows for consumer processes in a system with at least one cold and one hot water network, such as a paint shop, is implemented by means of at least one heat pump device or heat pump.

[0005] For the sake of simplicity, the following will refer only to heat, quantity of heat, heat output, heat energy, or heat flow; however, the same applies analogously to cold, quantity of cold, cooling output, cooling energy, or cooling flow. Cold, quantity of cold, cooling output, cooling energy, or cooling flow can therefore preferably be considered as heat, quantity of heat, heat output, heat energy, or heat flow with a negative sign.

[0006] The heat flow is usually adjusted via the volume flow of the heat pump device, whereby the return temperature of the

[0007] The heat pump device operates at a constant temperature. If the system lacks a storage device such as a tank as an intermediate buffer, the required flow rate is determined by the consumer processes, and the heat pump device must provide a corresponding heat flow to maintain the constant return temperature. The demand from the consumer processes thus determines the required flow rate, and the heat pump device responds to this demand by providing the corresponding heat flow.

[0008] If the system includes a storage device, the operation of the heat pump becomes more flexible. The proportion of heat output fed into the storage device is determined by the difference between the heat output supplied by the heat pump and the heat output demanded by the consumer processes. For example, all the heat output supplied by the heat pump is fed into the system's storage device if the consumer processes do not demand any heat output. Conversely, no heat or heat output is fed into the storage device if the consumer processes demand all the heat output that the heat pump can supply.Furthermore, heat energy is extracted or dissipated from the storage device when the consumer processes require a higher heat output than the heat pump device provides or can provide. These operating states can transition seamlessly into one another.

[0009] The heat pump is typically operated at full power until the associated storage tank is completely filled. The heat pump is then switched off and only switched back on when a set time has been exceeded, the temperature level in the storage tank has dropped below a certain limit, and / or the fill level of the storage tank has fallen below a certain limit.

[0010] In very large systems, multiple heat pump units can be used. During system analysis, it is permissible to consider these units as a single, large heat pump unit. The control system is then optimized within this combined unit. Furthermore, in such systems, the heat pump and storage unit must simultaneously provide heat during peak loads in the consumer processes, as the heat pump unit is typically designed to generate only a daily average output for cost reasons.

[0011] It should also be taken into account that the network of heat pump devices in a system of this type for generating hot and / or cold water is operated with a priority depending on the season; that is, one of the two water networks is prioritized. The power requirements for the non-prioritized water network are significantly lower than for the prioritized network depending on the season and are balanced by one or more heat exchangers in the non-prioritized water network, which are provided, for example, for heat recovery measures or for dissipating waste heat via the roof, i.e., from the treatment plant.

[0012] Excess heat is preferably either released via the roof or fed back into the system through heat recovery measures.

[0013] Since the temperatures of the hot water network and the cold water network are fixed, the required volume flows can be derived from them.

[0014] Through the direct or indirect connection of all components of the water networks, the consumer processes that are coupled to or integrated into the lower-priority water network are supplied with sufficient heat output, and the excess heat output is dissipated or recovered through the aforementioned measures. Therefore, explicit control of the heat pump system is generally not required in this water network.

[0015] A system for generating heating and cooling capacity in a workpiece processing plant is already known from WO 2024 / 074171 A1. The system comprises at least one cold water network, which includes at least one cold water storage device and / or at least one cold water network heat transfer device, at least one hot water network, which includes at least one hot water storage device and / or at least one hot water network heat transfer device, and at least one heat pump device, wherein the cold water network is connected to the hot water network by means of the at least one heat pump device.

[0016] Existing systems and associated methods for generating and supplying heat in workpiece processing plants, such as vehicle bodies, are purely reactive systems; that is, no prediction is made or provided for. Consequently, the heat pump devices used are operated according to the required output of the consumer processes.

[0017] Existing systems without a storage device must therefore be operated conservatively, as it must be ensured at all times that sufficient heat can be supplied to the treatment plant's consumer processes. Consequently, flexible use of the installed heat pump devices is not possible.

[0018] Existing systems with storage devices, however, cannot account for variable electricity costs. Therefore, the heat pumps used are also operated during the day when, for example, electricity prices are high. Furthermore, the storage devices are only fully utilized during peak loads in consumer processes, meaning the potential for energy flexibility during partial load operation is not exploited.

[0019] The present invention is based on the objective of providing a method which supplies consumer processes of a workpiece treatment plant with thermal energy in an energy-optimized, cost-efficient and sustainable manner.

[0020] This problem is solved according to the invention by a method having the features according to claim 1.

[0021] The process is used to generate and provide heat and / or cold in a workpiece treatment plant.

[0022] The treatment plant can preferably be a paint shop for vehicle bodies or parts thereof, such as hoods or vehicle doors. The treatment plant preferably comprises the following: at least one cold water network for supplying cold water to consumer processes; at least one hot water network for supplying hot water to consumer processes; at least one storage device, in particular a cold water storage device and / or a hot water storage device; and at least one heat pump device, in particular at least one first heat pump device, which is connected to the at least one cold water network and the at least one hot water network.

[0023] The method according to the invention comprises the following steps:

[0024] Determine at least one power requirement of the consumer processes of the treatment plant within a predetermined time interval;

[0025] Prioritize one of the water networks;

[0026] Determining a performance profile for the at least one heat pump device of the prioritized water network based on the determined power demand;

[0027] Rules for at least one heat pump device of the prioritized water network based on the determined performance profile;

[0028] Providing cold and / or hot water to the consumer processes of the treatment plant; and

[0029] Intermediate storage of cold water and / or hot water in at least one storage device.

[0030] The present invention is based on the fundamental idea that the power requirements for the consumer processes of a workpiece processing plant, such as a paint shop for vehicle bodies or parts thereof, are predetermined for planning the operation of the installed or used heat pump devices. By pre-planning the power requirements, i.e., forecasting the power consumption of the consumer processes, it is possible, among other things, to minimize the energy consumption per vehicle body, keep the installed power of the processing plant's units as low as possible, reduce operating costs, such as energy charges or grid fees, to a minimum, and promote grid-friendly operation. This approach is intended to take into account the principles of sustainability and energy conservation.

[0031] The future power demand is determined for each of the water networks used in a treatment plant. From this, a prioritization of one of the water networks can be derived. Based on the determined power demand of the prioritized water network, a power curve or profile is then calculated for the heat pumps, ensuring that the total amount of heat generated covers the total consumption of the processes during the period under consideration. Plant-specific parameters, such as the storable energy capacity of the storage devices or the maximum load of the heat pumps, must be taken into account. From the power curve, a control variable curve or profile for the heat pumps is then derived, and the corresponding control signals are applied.

[0032] Overall, performance forecasts that take into account the characteristics of the treatment plant and utilize or provide for energy flexibility can optimize the operating costs of the treatment plant in question.

[0033] Depending on which water network a storage device is located in or which water network a storage device is assigned to, it is a cold water storage device or a hot water storage device.

[0034] Furthermore, if a cold water storage device but no hot water storage device is provided, then the cold water network is preferably prioritized and vice versa.

[0035] A predetermined time interval is preferably understood to be the time interval to which the power demand of the consumer processes, and thus also the power profile for the at least one heat pump device, relates. The predetermined time interval is, in particular, a future time interval, which is determined, for example, by the electricity cost trend or the weather forecast for the following day. In a preferred embodiment of the invention, it may be provided that the at least one cold water network includes at least one cold water storage device and / or the at least one hot water network includes at least one hot water storage device.

[0036] It can be advantageous if the treatment plant further includes the following: at least one cold water network heat transfer device for heat recovery from consumer processes, which is arranged in the at least one cold water network; and at least one hot water network heat transfer device for heat recovery from consumer processes, which is arranged in the at least one hot water network.

[0037] Preferably, the process also includes the following step: recovering heat energy from the exhaust air of one or more consumer processes.

[0038] The recovery of heat energy is achieved in particular via the heat transfer devices of the water networks.

[0039] It can be advantageous if the treatment plant further comprises: at least one hot water network for supplying consumer processes with hot water, which has at least one hot water network heat transfer device; and at least one further heat pump device, in particular at least one second heat pump device, wherein a) the at least one hot water network is supplied by means of the at least one second

[0040] Heat pump device with at least one hot water network; or b) the at least one hot water network by means of at least one second

[0041] Heat pump device to which at least one cold water network is connected.

[0042] Furthermore, the process may include the following additional steps: providing hot water to the consumer processes of the treatment plant; and intermediate storage of hot water in at least one further storage device.

[0043] The at least one additional storage device can in particular be a hot water storage device.

[0044] In a preferred workpiece processing plant, in which the inventive method is carried out, a central hot, warm, and cold water generation system is provided in three corresponding networks by means of at least two heat pump devices or heat pumps, wherein the networks are interconnected via the heat pumps. The different seasonal climatic conditions in summer (warm and humid ambient air) and winter (cold and dry ambient air) are to be taken into account, so that in summer the excess heat from the cold water generation is supplied to the warm and hot water network.

[0045] If additional heat is present, it is transferred to the exhaust air via heat transfer devices or heat exchangers, or supplied to the environment of the treatment plant.

[0046] In winter, however, the cold water network is used as a heat collector through the application of heat recovery measures. Heat pumps then use this recovered heat to produce usable warm and / or hot water.

[0047] Furthermore, in order to achieve CC>2-neutral generation of the required cooling, warm, and heating water in the treatment plant, the units for cold, warm, and hot water generation must be fully electrified, with the installed power of the units being kept as low as possible to reflect the principles of sustainability and energy conservation. The energy consumption per workpiece or vehicle body should be reduced accordingly, for which, among other things, the heat recovery measures according to the invention are integrated into the system.

[0048] Basically, the interconnected system of the three water networks can be divided into three functional areas: The first area represents heat recovery, the second area includes heat pump devices and storage devices, and the third area contains the consumers or consumer processes of the treatment plant.

[0049] In this description and the attached claims, the term "network" or "water network" refers to an interaction of several circuits through which water of the respective temperature level or temperature flows.

[0050] The term "cycle" 1In this description and the accompanying claims, a pipe network, which may be formed from pipes, hoses or the like, forms an open or closed circuit and through which water of the respective temperature level can flow in one direction, preferably in two directions, is to be understood, wherein further elements such as consumer processes, heat transfer devices, storage devices or are indirectly or directly integrated into the circuit.

[0051] They can be heat pump devices.

[0052] In this description and the attached claims, the term "consumer process" or "consumer" means any process or plant equipment which requires the provision of cold, warm or hot water in the course of processing workpieces.

[0053] The different temperature levels of the three networks supply a wide variety of consumer processes and consumers, with a large number of consumer processes and consumers potentially connected to the cold and hot water networks.

[0054] Such processes or consumers are predominantly ventilation systems that must be regulated to adapt to changing external conditions. Therefore, particularly in the cold and hot water networks, significant fluctuations in required output are found throughout the day.

[0055] The processes or consumers of the hot water network include, for example, pretreatment stations and / or intermediate dryers, which exhibit a very constant heat demand from the network or distribution network. Therefore, boilers or burners are generally only required for start-up purposes. In other words, the hot water network is preferably connected to continuous consumer processes.

[0056] The different temperature levels of the networks allow for the use of different storage devices. A balance must preferably be struck between the available space in the treatment plant and the complexity of the storage device.

[0057] Regarding the first heat pump device between the cold water network and the hot water network, due to the low temperature level of preferably a maximum of 60°C and the prevailing temperature difference of preferably 30°C to 40°C, one or more conventional industrial heat pump devices can be used.

[0058] Heat recovery via heat transfer devices allows for the energetic reuse of the consumer process streams leaving the treatment plant. Heat pumps raise these streams to a usable temperature level for the respective network. The waste heat from the various consumer processes can then be fed into the chilled water network for optimal energy utilization. However, it is important to note that the first heat pump has a limited installed capacity, which is generally based on the maximum cooling capacity. Once this cooling capacity (including consumer processes in the chilled water network) is exceeded, heat recovery measures must be implemented in the hot water network. Process streams where the dew point is reached are particularly important for heat recovery.Examples of process flows for heat recovery in a paint shop for vehicle bodies include cooling zone exhaust, dryer exhaust, spray booth exhaust, waste heat from compressed air generation, exhaust from pretreatment (VBH) or from cathodic dip coating (KTL), dryer waste heat, etc.

[0059] A heat pump device of a prioritized water network shall be understood to be the one or more heat pump devices that provide or supply the required cooling, heating or warming capacity to the prioritized water network, even if the heat pump device is connected to at least two water networks with different temperature levels due to its operation.

[0060] In a further embodiment of the invention, it may be provided that one or more consumer-specific input parameters and / or one or more consumer-specific model parameters are taken into account when determining the power requirement.

[0061] Consumer-specific input parameters, which are particularly variable over time, can include the following parameters: the workpiece throughput, i.e., workpieces per unit of time, whereby the throughput may depend on the workpiece type; the operating mode of the treatment system, whereby a distinction is made in particular between the three modes "operation", "standstill" and "pause";

[0062] Weather data, which may include, for example, a weather forecast for temperature and / or humidity and / or the measured actual weather conditions; the actual power requirement, which results from the current heat demand of the consumer processes; derived parameters such as the mass throughput, i.e., the workpiece weight of all workpieces per unit of time, the surface area of ​​all workpieces to be treated per unit of time, etc.; and

[0063] Target and actual values ​​of the treatment processes of the treatment plant, such as the pool temperatures of the plant pools, the air conditioning of the plant hall and / or the treatment rooms of the plant, the amount of air conveyed in the plant, etc.

[0064] Consumer-specific model parameters can include, among others, the following parameters:

[0065] Workpiece metadata, such as weight, size, material, surface finish, etc.; and

[0066] Key figures for physical models, such as heat transfer coefficients, the separation equivalent of the system, pump efficiencies, etc., can also be used to determine the power requirement. Furthermore, historical and / or machine-learned empirical values ​​can be incorporated.

[0067] Furthermore, when determining the power requirements, the plant configuration is preferably taken into account, which includes which weather-dependent, production-dependent, and continuous consumption processes are planned in the treatment plant. In the case of a paint shop for vehicle bodies, for example, the plant configuration specifies whether one or more pretreatments are planned and / or whether cathodic dip painting is carried out.

[0068] The power demand is preferably predicted for consumer processes for a predetermined time interval. This prediction, as already mentioned, is determined by factors such as the available electricity cost trend and / or the weather on the following day or within the next 24 hours. The interval for the electricity cost trend in the following period thus defines the time interval for determining the power demand.

[0069] It can be advantageous to consider one or more pump-specific input parameters and / or one or more pump-specific model parameters when determining the performance profile for the at least one heat pump device of the prioritized water network.

[0070] In addition to the specific power requirements of the consumer processes, pump-specific parameters are also included in determining the power curve for the at least one heat pump device of the prioritized water network.

[0071] Pump-specific input parameters, which are particularly variable over time, can include the following: the primary energy price, for example, the electricity price, the gas price, the district heating price, etc.; the availability of electricity, which also includes the availability of green electricity, whereby green electricity is not necessarily cheaper, but may be more sustainable; the on-site generation of electricity; the grid charges and other contractual conditions of the electricity tariff to which the operator of the associated treatment plant is subject, such as the permissible peak load or grid-friendly operation; the availability of other energy types as auxiliary or secondary energy; and

[0072] Measured values ​​concerning the energy state of the entire treatment system, such as the temperatures in the storage device(s).

[0073] Pump-specific model parameters can include, among others, the following: the operating conditions for the heat pump devices, which include the minimum runtime and the coefficient of performance (COP) curve over load and temperatures; and aggregate characteristics, such as the size of the heat pump devices, the storage volume of the storage devices, the volume of the water networks, the size of additional chillers, boilers or cooling towers, etc.

[0074] The time-varying input parameters used to determine the power requirements of the consumer processes and the power profile of the at least one heat pump device preferably define the minimum possible temporal resolution. Accordingly, the coarsest resolution of the time-varying input parameters represents the smallest increment of the forecast, and it may be necessary to reduce this increment through intermediate calculations.

[0075] Furthermore, it can be advantageous if the performance profile of at least one heat pump device of the prioritized water network is optimized taking into account the framework conditions of the electricity contract.

[0076] The optimization can preferably be geared towards ensuring that the power consumption profile shows a power output greater than zero during intervals with low electricity costs and a power output equal to or close to zero during intervals with high electricity costs. The electricity costs or the electricity cost profile are usually published by the grid operator at night for the entire following day, with electricity costs varying depending on the time of day and the weather. For example, on sunny days, electricity costs reach their maximum daily value in the morning and evening hours.

[0077] It is therefore advantageous if the predetermined time interval is the 24 hours of the following day.

[0078] Should the electricity prices be published hourly by the grid operator in the future, the power profile can be predetermined accordingly for the following hour.

[0079] It can be advantageous if the consideration of the contractual framework for electricity supply also includes self-generated electricity, for example through photovoltaic systems, or involves this in the course of optimization.

[0080] According to another optimization criterion, the performance profile can be additionally or alternatively geared towards the time-of-day-dependent availability of a specific energy source. So-called green electricity, for example, is generally only available during the day and, in a sustainable or environmentally conscious operating concept, is primarily fed into and consumed by the treatment plant at this time, even if the green electricity is actually more expensive during this period.

[0081] Furthermore, it may be provided that the regulation of at least one heat pump device of the prioritized water network includes the following:

[0082] Determining a corresponding control variable profile from the determined power curve;

[0083] Location of at least one heat pump device of the prioritized water network;

[0084] Recording actual performance;

[0085] Determining a performance correction; and

[0086] Adjusting the performance curve.

[0087] Preferably, the total heat output of the heat pump devices is selected over the predetermined time interval such that it covers the total demand or total consumption in this interval, preferably in the next 24 hours.

[0088] During peak load times, simultaneous power provision of the heat pump device and storage device may be necessary to adequately serve the consumer processes, with this being taken into account in particular when determining the control variable profile.

[0089] The heat pump device of the prioritized water network is preferably set to a high COP utilization rate.

[0090] It is particularly advantageous if the amount of heat in a storage device never drops to zero. This is preferably ensured by ensuring that the difference between the heat consumed from a storage device and the amount of heat stored in this device is never less than a predetermined limit or buffer. This allows the consumer processes to be supplied simultaneously by both the storage device and the heat pump, which is particularly necessary during peak loads.

[0091] The limit value or buffer is usually chosen by the operator of the treatment plant depending on their risk tolerance.

[0092] When determining the manipulated variable profile, it is preferably possible to convert the manipulated variables into pump frequencies or valve positions.

[0093] It can be advantageous to include treatment plant data, characteristic curves and / or models of the consumer processes and other characteristics of the treatment plant or the consumer processes when determining the control variable profile.

[0094] The conversion of the control signals into frequencies for the heat pump devices preferably takes place in a subordinate control architecture. In a further embodiment of the invention, it can be provided that the actual power output is determined based on a) the fill level of one or more water storage devices; and / or b) at least one first measuring device in one or more consumer processes; and / or c) at least one second measuring device in one or more pipes of one or more water networks.

[0095] It can be advantageous if the time interval in which the actual performance is recorded is smaller than the predetermined time interval for determining the performance requirement.

[0096] The time interval for recording the actual performance is, for example, one hour or less.

[0097] It can be advantageous if the regulation includes recording the actual heat in one or more of the non-prioritized water networks.

[0098] Preferably, the fill level of one or more storage devices of one or more non-prioritized water networks is monitored or checked in order to be able to initiate appropriate countermeasures in the event of a threshold being exceeded or fallen below.

[0099] These countermeasures can include, for example, heat recovery measures or heat removal via the roof, i.e., removal from the treatment plant.

[0100] In the event of an excessive supply, the operating mode of the corresponding heat pump devices should be adjusted. This can be achieved, for example, by reducing output and / or providing additional generators, such as chillers or boilers, to ensure the supply of the consumer processes of the prioritized water network.

[0101] Furthermore, it can be advantageous if the rules include a provision that a performance correction is determined from the specified performance trend and the recorded actual performance, by means of which the performance trend for the following predetermined time interval is determined.

[0102] Preferably, deviations between a specific performance trend and the recorded actual performance are logged.

[0103] The power correction is preferably used to change the control variable profile and thus adjust the operating points of the heat pump devices of the treatment plant.

[0104] It can be advantageous if the heat pump devices are controlled via the return temperatures of the respective water networks.

[0105] The object of the present invention is further achieved by a method having the features according to the further independent method claim.

[0106] The process also serves to generate and provide heat and / or cold in a treatment plant for workpieces, preferably in a paint shop for vehicle bodies or parts thereof.

[0107] The treatment plant comprises the following: at least one cold water network for supplying consumer processes with cold water; at least one hot water network for supplying consumer processes with hot water; at least one storage device, in particular a cold water storage device and / or a hot water storage device; and at least one heat pump device.

[0108] The procedure preferably further comprises the following steps:

[0109] Determine at least one power requirement of the consumer processes of the treatment plant within a predetermined time interval;

[0110] Determining a performance profile for the at least one heat pump device based on the specified power requirement; controlling the at least one heat pump device based on the specified performance profile.

[0111] The control process step preferably includes providing cold and / or hot water to the consumer processes as well as intermediate storage of cold and / or hot water.

[0112] The second method preferably has one or more of the features and / or advantages described in connection with the first method. Preferably, the first method also has one or more of the features and / or advantages described in connection with the second method.

[0113] Further features and / or advantages of the invention are the subject of the following description and the graphic representation of exemplary embodiments.

[0114] The figures show:

[0115] Fig. 1 shows a schematic representation of a system for generating heating and cooling power in a workpiece treatment plant;

[0116] Fig. 2 shows a schematic representation of a heat pump device with an associated storage device and associated consumer process;

[0117] Fig. 3 shows a schematic representation of a first embodiment of a method according to the invention for generating and providing cold and / or heat in a workpiece treatment system; and

[0118] Fig. 4 shows a schematic representation of determining the power requirements of the consumer processes and the power curve of at least one heat pump device according to a second embodiment of a method according to the invention.

[0119] Identical or functionally equivalent elements are designated with the same reference numerals in all figures. A system shown in Fig. 1, designated as a whole by 100, serves to generate heating and cooling capacities in a treatment plant 102 for workpieces and is known from WO 2024 / 074171 A1.

[0120] Further embodiments of the system are known from WO 2024 / 074171 A1 than the embodiment shown in Fig. 1.

[0121] Treatment facility 102 is in particular a paint shop 103 for vehicle bodies.

[0122] The architecture and arrangement of the components of the system 100 of the treatment plant 102 are also the basis for the inventive method 200, which is explained in detail in connection with Fig. 3.

[0123] System 100 includes at least one cold water network 104, at least one warm water network 106 and at least one hot water network 108.

[0124] Water networks 104, 106, 108 preferably exhibit different

[0125] temperature levels or different temperatures occur, i.e., in particular the temperature of the water carried in the respective network differs from the temperature of the water carried in the other two networks.

[0126] The cold water network 104 preferably has a temperature level of 0°C to 25°C, the warm water network 106 preferably 25°C to 60°C and the hot water network 108 preferably 60°C to 100°C.

[0127] The cold water network 104 has at least one cold water storage device 110 and at least one cold water network heat transfer device 112.

[0128] Furthermore, the cold water network 104 comprises at least one consumer process circuit 114, at least one heat pump circuit 116, and at least one heat recovery circuit 118, in which the cold water network heat transfer device 112 is arranged. The hot water network 106 has at least one hot water storage device 120 and at least one hot water network heat transfer device 122.

[0129] Furthermore, the hot water network 106 comprises at least one consumer process circuit 124, at least one first heat pump circuit 126, at least one second heat pump circuit 128 and at least one heat recovery circuit 130 in which the hot water network heat transfer device 122 is arranged.

[0130] The cold water network 104 and the hot water network 106 are connected to each other by means of a first heat pump device 132, in particular the heat pump circuit 116 of the cold water network 104 and the first

[0131] Heat pump circuit 126 of the hot water network 106 to the first

[0132] Heat pump device 132 connected.

[0133] The first heat pump storage device 132 is preferably a conventional industrial heat pump.

[0134] The hot water network 108 has at least one hot water storage device 134 and at least one hot water network heat transfer device 136.

[0135] Furthermore, the hot water network 108 also includes at least one consumer process circuit 138, at least one heat pump circuit 140 and at least one heat recovery circuit 142, in which the hot water network heat transfer device 136 is arranged.

[0136] The hot water network 106 and the hot water network 108 are connected to each other by means of a second heat pump device 144, in particular the second heat pump circuit 128 of the hot water network 106 and the heat pump circuit 140 of the hot water network 108 are connected to the second heat pump device 144.

[0137] The second heat pump device 144 is preferably a high-temperature heat pump. The first and second heat pump devices 132, 144 are electrically operated pump devices with a defined installed power, wherein the defined power is preferably based on the maximum power to be provided for the necessary cooling or heating in system 100 during periods of peak climatic conditions.

[0138] The consumer process circuits 114, 124, 138 of the water networks 104, 106, 108 provide cold, warm and / or hot water to one or more consumer processes 146.

[0139] Consumer processes 146, whose exhaust air 148 is essentially supplied to one or more cold water network heat transfer devices 112, are, for example, cooling zones or pretreatment stations in a paint shop 103. Consumer processes 146, whose exhaust air 148 is essentially supplied to one or more hot water network heat transfer devices 122, are, for example, dryers in a paint shop 103.

[0140] Exhaust air 148, extracted from one or more consumer processes 146, is discharged via an exhaust air duct 150 to an exhaust air outlet above the roof 152 from the treatment plant 102.

[0141] The exhaust air duct passes through the heat transfer devices 112, 122, 136 of the water networks 104, 106, 108, whereby the exhaust air or discharged process media 148 flow through these and thereby transfer at least some of the heat energy contained in the exhaust air back into the heat recovery circuits 118, 130, 142.

[0142] The exhaust air 148 of the consumer processes 146 is cooled with cold water in the cold water network heat transfer device 112 before reaching the exhaust air outlet above the roof 152, thereby reducing the exhaust air temperature above the roof to a minimum.

[0143] The storage devices 110, 120, 134 are connected to the supply and return lines of the respective water networks 104, 106, 108 and dampen the fluctuations in the respective water networks 104, 106, 108 when supplying water for the consumer processes 146, wherein the capacity of the storage devices 110, 120, 134 is preferably designed to smooth the load profile of the consumer processes 146 within a day. As a result, the heat pump devices 132, 144 can, among other things, be designed to a minimum.

[0144] In particular, in a paint shop 103, all consumer processes 146, which depend on the external conditions, i.e. the climatic conditions outside the paint shop, are supplied almost exclusively by the cold water network 104 and the hot water network 106, which is why the storage capacity of the cold water storage device 110 and the hot water storage device 120 must be dimensioned larger than the capacity of the hot water storage device 134.

[0145] By coupling the cold water network 104 with the hot water network 106 via the first heat pump device 132, the heat energy fed into the cold water network 104 can be raised to a temperature level usable for the consumer processes 146, which are supplied by the hot water network 106, by means of the first heat pump device 132.

[0146] Connecting the first heat pump unit 132 to the cold water network 104 and the hot water network 106 generates both cooling and heating, thus achieving maximum efficiency and utilization. Furthermore, simultaneous generation of cooling and heating output is possible outside of the extreme months of winter and summer. The installed electrical power is preferably based on the maximum cooling capacity to be provided.

[0147] By means of the second heat pump device 144, consumer processes 146 of the hot water network 108, which have a requirement for a higher temperature level, i.e. in particular a water temperature level of over 60°C, can be supplied with the necessary heat energy.

[0148] If sufficient thermal energy is available or remaining in the cold water network 104 and / or in the hot water network 106, it can be raised to the temperature level of the hot water network 108 by means of the second heat pump device 144 or by means of the first and the second heat pump devices 132, 144.

[0149] Thus, advantageously, apart from the heat pump devices 132, 144, no additional units are necessary to generate the heating and cooling capacities during the normal operation of a treatment plant 102 such as a paint shop 103. Exceptions to this are consumer processes 146, which require temperatures above 100°C, such as drying processes, in accordance with the previously mentioned temperature levels of the water networks 104, 106, 108.

[0150] Furthermore, to reduce the temperature level of the hot water network, 106 heat wheels (not shown) can be integrated between the supply and exhaust air of all consumer processes 146 that require humidified supply air. Due to the moisture transfer of a heat wheel, preconditioning of the supplied fresh air is possible, and the temperature level of the fresh air before entering the humidifier can be lowered accordingly. Conditioning of fresh air down to a relative humidity of 65% is therefore possible even in winter under dry and cold outdoor conditions.

[0151] In summer, the temperature level of the hot water network 106 is preferably lowered, thus increasing the efficiency of the first heat pump device for cold water production. However, if excess heat energy from the hot water network 106 is to be fed into the outside air outside the treatment plant 102 or into the exhaust air 148 of the consumer processes 146, then raising the temperature level of the hot water network 106 should be considered.

[0152] In winter, the temperature level of the cold water network 104 is lowered, enabling more efficient heat recovery. Due to the resulting reduced COP, the first heat pump device 132 can supply a higher quantity of heat to the hot water network 106 from the same amount of thermal energy drawn from the cold water network 104.

[0153] In its minimal configuration, the system 100 preferably comprises only two of the water networks 104, 106, 108, in particular a cold water network 104 and a hot water network 106, which are connected to each other by only one heat pump device.

[0154] Fig. 2 shows in detail the arrangement and interaction of one of the heat pump devices 132, 144 with one of the storage devices 110, 120, 134, which is designed as a tank 153, and a consumer process 146 in one of the water networks 104, 106, 108.

[0155] For the purposes of further describing Fig. 2, it is assumed by way of example that the water network shown is the hot water network 106 of the system 100 with the hot water storage device 120 and that the heat pump device shown is the first heat pump device 132 which, according to the arrangement of the system 100 in Fig. 1, connects the cold water network 104 and the hot water network 106.

[0156] The following described functionality applies analogously to the cold water network 104 and the hot water network 108.

[0157] The first heat pump device 132 is connected to the hot water storage device 120 via the first heat pump circuit 126.

[0158] The heat pump circuit 126 is in turn connected to the consumer process circuit 124, in which at least one consumer process 146 is integrated.

[0159] The hot water network 106 shown can also be assigned to further consumer processes 146, which are integrated into the consumer process circuit 124 shown or are alternatively supplied via a separate consumer process circuit, which is connected to the heat pump circuit 126 of the hot water network 106.

[0160] In the heat pump circuit 126 at least one pump device 154 and upstream of the pump device 154 a valve device 156, preferably a motor-driven valve device 158, is arranged.

[0161] Furthermore, a pump device 154 is also arranged in the consumer process circuit 124, as well as a further valve device 156, preferably a motor-driven valve device 158, upstream of this pump device 154. A bypass line 160 can also be provided in the heat pump circuit 126, through which the hot water can be returned to the first heat pump device 132 via the valve device 156 before it enters the consumer process circuit 124 and the hot water storage device 120.

[0162] A bypass line 160 is also provided in the consumer process circuit 124, in which a throttling device 162 is arranged. The bypass line 160 in the consumer process circuit 124 allows the consumer process 146 to be at least partially bypassed or circumvented upstream of the associated pump device 154.

[0163] The arrangement and the cycles 124, 126 between the first

[0164] The heat pump device 132, the hot water storage device 120 and the consumer process 146 enable the first heat pump device 132 to supply the consumer process circuit 124 or the consumer process 146 with hot water on the one hand and to fill the hot water storage device 120 on the other.

[0165] The hot water storage device 120 is also integrated into the circuits 124, 126 in such a way that stored hot water can be released towards the consumer process circuit 124 when needed, especially during peak load times in the consumer process(s) 146.

[0166] The first heat pump device 132 preferably fills the hot water storage device 120 completely or up to a specified fill level and is then switched off until the temperature and / or the fill level of the hot water storage device 120 falls below a specified limit value or a specified waiting time has elapsed.

[0167] Consequently, the hot water storage device 120 can preferably supply the consumer process circuit 124 or the associated consumer process 146 with hot water on its own. In such a phase, energy for the operation of the first heat pump device 132 can be saved, which is particularly advantageous when electricity prices are high. Figure 3 schematically illustrates a first embodiment of a method 200 according to the invention for generating and providing cold and / or heat in a workpiece treatment plant.

[0168] The sequence of part of the process 200 shown in Fig. 3 focuses on predicting and correcting the power for the heat pump devices 132, 144 and the consumer processes 146.

[0169] In a first step 202, the power requirement of the consumer processes of a system 100 of a treatment plant 102 for workpieces is determined in a predetermined time interval.

[0170] The time interval includes, for example, the 24 hours of the following day.

[0171] This performance forecast takes into account weather data, production figures, consumer process values, machine runtimes, plant configuration, historical experience and / or machine-learned experience.

[0172] In a second step 204, it is determined which of the planned water networks of the treatment plant 102 or of the system 100 is to be prioritized.

[0173] An example of prioritization is shown below in Tables 1 and 2 in the form of prioritization matrices, where Table 1 relates to summer operation and Table 2 accordingly to winter operation.

[0174] For the sake of clarity, the following abbreviations are used in Tables 1 and 2:

[0175] Cold water network = KW;

[0176] Hot water network = WW;

[0177] Hot water network = HW; weather-dependent consumption = WEV; production-dependent consumption = PRV; and permanent consumption = PEV. Weather-dependent consumption processes or consumers of a processing plant for workpieces such as vehicle bodies can be ventilation systems for hall ventilation and / or for paint mixing rooms.

[0178] Production-dependent consumer processes can include pretreatment tanks, tanks for cathodic dip coating (e-coating tanks) and / or dryers, preferably dryers without a cooling zone.

[0179] Weather- and production-dependent consumer processes can include ventilation systems for paint booths, ventilation systems for workplaces and / or dryers or intermediate dryers, preferably those without a cooling zone.

[0180] Permanent consumer processes can include paint cooling for the KTL tank, paint cooling, hall ventilation and / or paint mixing room ventilation.

[0181] The ratings assigned in Tables 1 and 2 represent the importance of the respective water network for the specific consumption of the respective column.

[0182] Table 1 - Summer:

[0183] Table 2 - Winter:

[0184] In a third step 206, the electricity cost trend for the predetermined time interval is recorded.

[0185] Network operators usually publish the electricity price trend for the following day, in which factors such as the time of day and the weather have an influence on the electricity price.

[0186] The third step 206 can be carried out in parallel with the first step 202 or with the second step 204.

[0187] Based on the determined power requirement and the recorded electricity cost profile, in a fourth step 208 the power profile for the one or more heat pump devices of the prioritized water network is determined.

[0188] The total amount of heat supplied by this heat pump device or these heat pump devices is determined over the predetermined time interval in such a way that the total consumption of all consumer processes in the predetermined time interval is covered.

[0189] During peak load times, simultaneous power provision from the heat pump device(s) and the associated storage device may be required.

[0190] When determining the power profile, it is taken into account that the corresponding heat pump device of the prioritized water network has a power output greater than zero in interval sections with low electricity costs and that, conversely, in interval sections with high electricity costs, the power output is preferably equal to zero.

[0191] In a fifth step, the control variable profile of the heat pump devices of system 100 is derived from the determined performance profile.

[0192] From the determined performance profile, control signals such as pump frequencies or valve positions are derived. In the subsequent sixth step 212, the heat pump devices of the prioritized water network are then supplied with the determined control signals; that is, at least one heat pump device of the prioritized water network is set, with the conversion of the control signals being carried out, for example, by a subordinate control system.

[0193] In a seventh step 214, the actual performance of the consumer processes 146 is recorded, with the recording preferably taking place several times within the predetermined time interval.

[0194] In an eighth step 216, the actual heat in one or more of the non-prioritized water networks is recorded, whereby step 216 can take place before, parallel to or after step 214.

[0195] In a ninth step (218), the recorded actual performance is compared with the determined performance requirement, and a performance correction is determined for the following time interval if an unacceptable deviation is found.

[0196] Preferably, deviations between forecasts and measured values ​​are logged.

[0197] In a tenth step 220, the performance profile of step 208 is recalculated or adjusted, taking into account the specified performance correction. Consequently, when step 210 is repeated, the manipulated variable profile is adjusted. The affected heat pump devices are then supplied with the adjusted control signals in a further step 212.

[0198] Preferably as a result of step 212, cold, warm and / or hot water is supplied to the consumer processes 146.

[0199] Furthermore, in one or more of the water networks, the respective water is directed or pumped into the associated storage device until it is preferably completely filled, in order to be able to supply water of the corresponding temperature level to the connected consumer processes 146 as needed. Figure 4 shows part of the steps of a second embodiment of the method 200 according to the invention, namely step 202, in which the power requirement of the consumer processes is determined in the predetermined time interval, and step 208, in which the power profile for one or more heat pump devices is determined over the predetermined time interval.

[0200] When determining the power requirement in step 202, consumer-specific input parameters 222 are taken into account, which are particularly variable over time. Consumer-specific model parameters 224 are also considered.

[0201] The specified power requirement as well as pump-specific input parameters 226, which are also particularly variable over time, and pump-specific model parameters 228 are then the input variables when determining the power curve in step 208.

[0202] The coarsest or lowest resolution of the time-varying input parameters represents the smallest time increment for the forecast. Therefore, if the time-varying input parameters are available in different aggregations, the lower resolution defines the predetermined time interval.

[0203] If the weather forecast data, which belongs to the consumer-specific input parameters 222, is only available once per hour, and the electricity prices, which belong to the pump-specific input parameters 226, are available every 15 minutes, then all required or relevant input parameters are aggregated to an hourly interval. In other words, the power demand of the consumer processes and the power profile for one or more heat pump devices are determined for a one-hour time interval. If individual values ​​are missing, they can be supplemented by intermediate calculations, in particular by interpolation. Reference symbol list

[0204] system

[0205] Treatment facility

[0206] paint shop

[0207] cold water network

[0208] hot water network

[0209] Hot water network

[0210] cold water storage device

[0211] Cold water network heat transfer device

[0212] Consumer cycle

[0213] Heat pump circuit

[0214] Heat recovery circuit

[0215] Hot water storage device

[0216] Hot water network heat transfer device

[0217] Consumer process circuit, first heat pump circuit, second heat pump circuit

[0218] Heat recovery circuit, first heat pump device

[0219] Hot water storage device

[0220] Hot water network heat transfer device

[0221] Consumer cycle

[0222] Heat pump circuit

[0223] Heat recovery circuit, second heat pump device

[0224] Consumer process

[0225] Exhaust air

[0226] Exhaust duct

[0227] Exhaust air outlet via roof

[0228] tank

[0229] Pump device

[0230] Valve device motor-driven valve device

[0231] Bypass line throttle device

[0232] Procedure first step second step third step fourth step fifth step sixth step seventh step eighth step ninth step tenth step consumer-specific input parameters consumer-specific model parameters pump-specific input parameters pump-specific model parameters

Claims

Patent claims 1. A method (200) for generating and providing heat and / or cold in a treatment plant (102) for workpieces, preferably in a paint shop (103) for vehicle bodies or parts thereof, wherein the treatment plant (102) comprises: at least one cold water network (104) for supplying consumer processes (146) with cold water; at least one hot water network (106) for supplying consumer processes (146) with hot water; at least one storage device, in particular a cold water storage device (110) and / or a hot water storage device (120); and at least one heat pump device, in particular at least one first heat pump device (132), which is connected to the at least one cold water network (104) and the at least one hot water network (106), characterized in that the method (200) comprises the following steps: Determine at least one power requirement (202) of the consumer processes of the treatment plant in a predetermined time interval; Prioritizing one of the water networks (204); Determining a performance profile (208) for the at least one heat pump device of the prioritized water network based on the determined power demand; Rules for at least one heat pump device of the prioritized water network based on the determined performance profile; Providing cold and / or hot water to the consumer processes (146) of the treatment plant (102); and Intermediate storage of cold water and / or hot water in at least one storage device.

2. Method (200) according to claim 1, characterized in that the at least one cold water network (104) has at least one has a cold water storage device (110) and / or has at least one hot water network (106) that has at least one hot water storage device (120).

3. Method (200) according to claim 1 or 2, characterized in that the treatment plant (102) further comprises: at least one cold water network heat transfer device (112) for heat recovery from consumer processes (146), which is arranged in the at least one cold water network (104); and at least one hot water network heat transfer device (122) for heat recovery from consumer processes (146), which is arranged in the at least one hot water network, wherein the method (200) further comprises the following step: Recovery of heat energy from the exhaust air (148) of one or more consumer processes (146).

4. Method (200) according to one of claims 1 to 3, characterized in that the treatment plant (102) further comprises: at least one hot water network (108) for supplying Consumer processes (146) with hot water, which has at least one hot water network heat transfer device (136); and at least one further heat pump device, in particular at least one second heat pump device (144), wherein a) the at least one hot water network (106) is connected to the at least one hot water network (108) by means of the at least one second heat pump device (144); or b) the at least one hot water network (108) is connected to the at least one cold water network (104) by means of the at least one second heat pump device (144).

5. Method (200) according to claim 4, characterized in that the method (200) further comprises the following steps: Providing hot water to the consumer processes (146) Treatment facility (102); and Intermediate storage of hot water in at least one further storage device, in particular at least one hot water storage device (134).

6. Method (200) according to one of claims 1 to 5, characterized in that when determining the power requirement (202) one or more consumer-specific input parameters and / or one or more consumer-specific model parameters are taken into account.

7. Method (200) according to one of claims 1 to 6, characterized in that when determining the performance profile (208) for the at least one heat pump device of the prioritized water network, one or more pump-specific input parameters and / or one or more pump-specific model parameters are taken into account.

8. Method (200) according to one of claims 1 to 7, characterized in that the performance profile of the at least one heat pump device of the prioritized water network is optimized taking into account electricity contract framework conditions.

9. Method (200) according to any one of claims 1 to 8, characterized in that the control of the at least one heat pump device of the prioritized water network comprises the following: Determining a corresponding control variable curve (210) from the determined power curve; Locations of at least one heat pump device (212) of the prioritized water network; Recording actual performance (214); Determining a performance correction (218); and Adjusting the performance curve (220).

10. Method (200) according to claim 9, characterized in that the actual power (214) is detected based on a) a fill level of one or more water storage devices; and / or b) at least one first measuring device in one or more consumer processes; and / or c) at least one second measuring device in one or more pipes of one or more water networks.

11. Method (200) according to one of claims 1 to 10, characterized in that the control comprises a detection of the actual heat (216) in one or more of the non-prioritized water networks.

12. Method (200) according to one of claims 9 to 11, characterized in that the rule comprises determining a performance correction from the determined performance profile and the recorded actual performance, by means of which the performance profile for the following predetermined time interval is determined.

13. Method (200) for generating and providing heat and / or cold in a treatment plant (102) for workpieces, preferably in a paint shop (103) for vehicle bodies or parts thereof, wherein the treatment plant (102) comprises: at least one cold water network (104) for supplying consumer processes (146) with cold water; at least one hot water network (106) for supplying consumer processes (146) with hot water; at least one storage device, in particular a cold water storage device and / or a hot water storage device; and at least one heat pump device, characterized in that the method (200) comprises the following steps: Determine at least one power requirement (202) of the consumer processes of the treatment plant in a predetermined time interval; Determining a performance profile (208) for the at least one heat pump device based on the determined power requirement; controlling the at least one heat pump device based on the determined performance profile.

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