Carbon Compound Manufacturing System with Integrated Feedback Control
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Solution Overview
Problem
Conventional carbon compound manufacturing systems face challenges in efficiently controlling the operation conditions of various units, leading to fluctuations in the synthetic amount of carbon compounds due to deviations in substance amounts among units, and require costly buffer tanks to manage these deviations.
Innovation Solution
The system integrates a recovery unit, a conversion unit, and a synthesis unit, along with detectors and an integration controller, to autonomously control the operation conditions of each unit. This integration allows for real-time data collation and generation of control signals to adjust the operation conditions of the recovery, conversion, and synthesis units, thereby maintaining a consistent supply of intermediate compounds to the synthesis unit without the need for buffer tanks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If buffer tanks are used to manage deviations in substance amounts among units, then the stability of carbon compound production is improved, but the device complexity and cost increase
Solution Approach 1:
The patent implements a feedback control system where detectors continuously monitor the substance amounts of intermediates between units, and the integration controller adjusts operation conditions of each unit based on real-time deviations. This closed-loop feedback mechanism stabilizes carbon compound production without requiring buffer tanks, directly resolving the contradiction between production stability and device complexity.
Solution Approach 2:
The patent merges the control functions of multiple units under a single integration controller that coordinates operation conditions across recovery, conversion, and synthesis units. This unified control approach eliminates the need for separate buffer tanks by synchronizing substance flow throughout the system, thereby maintaining stability while reducing device complexity.
2Reliability
If buffer tanks are used to manage deviations in substance amounts among units, then the reliability of carbon compound production is improved, but the cost increases
Solution Approach 1:
The feedback control system using detectors and integration controller provides real-time monitoring and adjustment of operation conditions, ensuring reliable carbon compound production through active deviation management. This eliminates the need for expensive buffer tanks while maintaining production reliability, as the system dynamically corrects substance amount deviations before they affect output.
Solution Approach 2:
The system performs self-regulation by automatically detecting deviations in substance amounts and adjusting its own operation conditions through the integration controller. This self-service capability maintains production reliability without requiring external buffer tanks or additional manual intervention, thereby reducing manufacturing costs.
3Ease of operation
If individual control of each unit is implemented, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The patent combines individual unit controls under a single integration controller that coordinates all units (recovery, conversion, synthesis) through unified operation condition adjustments. This merged control architecture maintains ease of operation by providing centralized management while avoiding the complexity of independent control systems, as the integration controller harmonizes substance flow across all units.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively suppresses fluctuations in the synthetic amount of carbon compounds by autonomously adjusting operation conditions, reducing the need for costly buffer tanks and enhancing the utilization efficiency of raw materials, while maintaining a consistent product output.
Implementation Method 1
an anode that oxidizes water (H2O) to produce oxygen (O2)
Implementation Method 2
a cathode that reduces carbon dioxide (CO2) to produce a carbon compound
Implementation Method 3
The anode has a structure in which an oxidation catalyst to oxidize water is provided
Implementation Method 4
The cathode has a structure in which a reduction catalyst reducing carbon dioxide reaction is provided
Data Source
AI summary
A carbon compound manufacturing system includes: a recovery unit; a conversion unit; a synthesis unit; a first flow path to supply the supply gas to the recovery unit; a second flow path connecting the recovery and the conversion units; a third flow path connecting the conversion and the synthesis units; at least one of first to third detectors to respectively measure a flow rate of the supply gas flowing through the first flow path to generate a first data signal, a flow rate of the carbon dioxide flowing through the second flow path to generate a second data signal, and a value of voltage or current to the conversion unit to generate a third data signal; and an integration controller to collate at least one data of the first to third data signals with a corresponding plan data to generate at least one of first to third control signals.