Method and control device for saving energy in complex energy consumers

Abstract

The problem addressed by the invention described in claim 1 is that of reducing the energy consumption of electrical systems to the minimum required value depending on the operating conditions, without having to make changes to the existing system structure. The method and the device for reducing the energy consumption of existing electrically operated systems containing consumers whose power feed from a network (#1A) is controlled in each case via control modules are characterized in that the power is supplied to the control modules of the existing system via a control device according to the invention having a power supply (#1B) that is independent of the network (#1A) and in that all relevant operating parameters of the consumers of the existing system are updated in the control modules of the existing system and are maintained in the event of the consumers of the existing system losing power. The device according to the invention is thus used to achieve considerable economic advantages by virtue of reducing the energy consumption of existing electrical systems with minimal changes to the existing systems.

Description

[0001] Patent application:

[0002] Method and control device for saving energy in complex energy consumption systems

[0003] 2.1 Description

[0004] Minimizing the energy consumption of electrically operated systems is a pressing concern that affects all sectors of the economy and, in particular, industrial processes. This requirement is already taken into account in the design of many electrically operated systems. For example, DE / 102015122584 / 22.12.2015 / A describes a switching device that records the consumption behavior of energy-consuming devices within a system containing household appliances in order to minimize their energy consumption. DE / 102004039810 / 11.08.2004 / A describes a device in which energy consumers are connected to a power supply network via a control network, the latter being controlled by a computer. The control unit can also be powered by an energy source that is independent of the power supply network for the energy consumers.

[0005] It is also known to use control systems for energy management that, for example, employ a blockchain module to optimize the electricity consumption of household appliances (DE 20 2023 102 734 Ul 2023.08.03).

[0006] 2.1.1 State of the art

[0007] These plant configurations described above have in common that control devices were already provided during the plant design phase to minimize energy consumption.

[0008] Many electrical installations in industry and other economic sectors lack specific devices to ensure minimal energy consumption. This applies particularly to the continued operation of electrical systems or their components during downtime or periods of underutilization. Older systems are also frequently insufficiently protected against unplanned power outages, leading to difficulties immediately after a power failure and during restart. 2.1.2 Task Definition

[0009] The invention described in claim 1 aims to reduce the energy consumption of electrical systems to the minimum required value, depending on the operating conditions, without requiring any modifications to the existing system structure. System components that are not active due to operational requirements still consume a significant amount of energy even when idle, but in many existing systems, these components continue to operate during idle periods. The invention according to claim 1 is intended to largely avoid this unnecessary energy expenditure. Furthermore, the invention is designed to prevent damage to the system during power outages and to safeguard data for restarting the system.

[0010] 2.1.3 Inventive solution

[0011] The aforementioned problem is solved by supplying power to the control modules of an existing system via a control device according to the invention with a power supply (#1B) independent of the mains (#1 A), and by updating all relevant operating parameters of the loads in the control modules of the existing system, and by retaining these parameters even in the event of a power failure. Since the solution according to the invention requires no further modifications to the hardware and software of the existing system, significant economic advantages arise during installation.

[0012] The invention has the particular advantage of minimizing the energy consumption of unused system components, especially during operational downtime, without requiring any changes to the existing system's structure. The invention thus ensures significant energy savings at moderate costs for equipping the existing system with the device according to the invention.

[0013] An advantageous embodiment of the invention is specified in claim 3. A further increase in the efficiency of the existing system is achieved by reducing the restart time in the event of a power outage or system shutdown. Furthermore, potential damage to system components caused by undesirable operating conditions can be avoided. Claims 4-6 describe further advantageous embodiments of the invention, whereby adverse effects of a power outage on the existing system are avoided by means of separate power supplies.

[0014] 2.1.4 Example of implementation

[0015] Figure 1 shows an embodiment in which the existing system consists of three units (#1 to #3), each unit having consumers (E) with an associated control module (D). The control module is typically composed of various components. For the sake of simplicity, the consumers (E) and their associated control modules (D) have been omitted from system sections (#2) and (#3). In principle, the number of units comprising a system can be arbitrary. The connection to the existing power supply and the control supply, respectively, is established via the switching devices (A and B) within the existing system (#1) to (#3).

[0016] Using existing converter(s) (C), different voltage forms are prepared and provided for the supply of the control modules (D) within the existing system (#1) to (#3).

[0017] The device according to the invention includes in the electrical assembly (#4) a switching device (#4B) and a process control computer (#4A), which provides the necessary control signals to the components involved within the device according to the invention and to the existing system. The control modules of the existing system (#1D) are supplied by the uninterruptible power supply (#9) via the control supply.

[0018] These components are powered via the switching device (#4B) from the grid (#6), a generator or emergency power supply (#7), or optionally by renewable energy (#8). The connection to the existing power supply (#10) can be interrupted via the module (#5A) if necessary to save energy. The process control computer (#4A) ensures that the control modules of the existing system are always powered and that the control functions are guaranteed for all operating states of the existing system. This applies particularly in the event of an unplanned power supply failure (#10) or an emergency shutdown. The charge level of the battery supply (#9) is continuously monitored and maintained.The battery (#9) is always connected to the control modules of the existing system, thus independent of the power supply of the existing system and would therefore also be functional if the power supply of the existing system fails.

Claims

AMENDED CLAIMS received by the International Bureau on 13 September 2025 (13.09.2025) 1. Method and device for reducing the energy consumption of existing electrically operated systems containing consumers whose power supply from a network (#1A) is controlled via control modules, characterized in that the power supply to the control modules of the existing system is provided via a control device according to the invention with a power supply (#1B) independent of the network (#1A), and that in the control modules (#1D) of the existing system all operating parameters defining the current operating state of the consumers of the existing system are updated and retained when the consumers (#1E) of the existing system are without power.

2. Device according to claim 1, characterized in that the existing electrically operated system is a program-controlled production system.

3. Device according to claim 1 or 2, characterized in that, in the event of an interruption of the power supply to the consumers of the existing system, the power supply to the control modules of the existing system is maintained by the control device according to the invention, and, if necessary, the system is continued to operate using further power sources, such as an emergency power generator or an energy storage device, wherein the operating state is restored with the operating parameters of the existing system stored at the time of the power interruption. AMENDED SHEET (ARTICLE 19) 4. Device according to claim 3, characterized in that only selectable parts of the consumers of the existing system are disconnected from the power supply by (#5A) of the control device according to the invention, wherein the supply of the control modules via the power supply (#1B) is ensured.

5. Device according to claim 1, characterized in that the control device according to the invention is always supplied with power via a buffer storage device (#9) with monitored charge status.

6. Device according to claim 1, characterized in that the control device according to the invention enables an uninterrupted switching of the supply to the control modules via a switching device in (#1B), and thus the power supply (#1B) can be interrupted for maintenance, repair or failure scenarios.

7. Device according to claim 1, characterized in that in the device according to the invention the electrical power consumed by the existing system is continuously measured (#5B), stored and consumers of the existing system are switched off or on by means of selectable criteria (#5A). AMENDED SHEET (ARTICLE 19)

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