Control Loop Efficiency Monitoring for Energy and Maintenance
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Solution Overview
Problem
Industrial and building control systems face challenges in maintaining constant energy consumption due to performance degradation and aging, leading to increased energy usage and potential failures, which can impact Leadership in Energy and Environmental Design (LEEDS) compliance and require continuous monitoring for preventive maintenance.
Innovation Solution
Monitoring settling time and error values in control loops to calculate control loop efficiency, allowing for energy consumption tracking and early detection of potential defects, thereby enabling energy compliance and preventive maintenance without additional hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If control loops operate continuously to maintain system performance, then system reliability is improved, but energy consumption increases
Solution Approach 1:
The patent implements periodic monitoring of control loop performance parameters (settling time, error values) at scheduled intervals rather than continuous monitoring. This allows the system to maintain reliability by detecting performance degradation when it occurs, while reducing energy consumption by allowing control loops to operate in a lower-power state between monitoring cycles. The periodic assessment of control loop efficiency enables the system to intervene only when necessary.
2Measurement precision
If additional monitoring hardware is installed to track energy consumption and detect defects, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent enables control loops to self-monitor their own performance by utilizing existing control loop data (settling time, error values) that is already being collected for process control. The system calculates control loop efficiency metrics using existing controllers and sensors without requiring additional dedicated monitoring hardware. This self-service approach provides precise energy consumption tracking and defect detection while avoiding the complexity and cost of additional monitoring infrastructure.
3Productivity
If control loops are continuously tuned and commissioned to optimize performance, then productivity is improved, but loss of time increases
Solution Approach 1:
The patent establishes baseline control loop efficiency metrics during initial commissioning and sets performance thresholds in advance. This preliminary configuration enables the system to autonomously detect when performance degradation occurs without requiring continuous manual intervention. The pre-defined thresholds and automated monitoring reduce the need for repeated commissioning activities, allowing productivity to be maintained while minimizing the time lost to manual tuning and commissioning.
Data Source
AI summary
An approach for monitoring energy consumption and detecting preventive maintenance issues in a system having control loops and associated devices. Settling time and error value in a control loop may be indicative of the loop's efficiency. Error value may be a difference between a measurement of a parameter and a setpoint for the parameter. Degradation of a loop's efficiency may be an indication of increased energy consumption by the system. Such degradation may also be indicative of a future defect in a control loop or devices associated with the control loop. Thus, the present approach may provide for energy monitoring and preventive maintenance of the system.