Industrial Control System Energy Usage Quantification
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Solution Overview
Problem
Current control systems face challenges in accurately determining and managing energy usage in industrial automation systems without directly measuring energy consumption, which can be costly and inefficient, especially when trying to monitor and control energy usage across various components and levels within a process.
Innovation Solution
An industrial control system that determines energy usage by inferring it from other components, using models based on physics principles, manufacturer specifications, and previous operation data, allowing for energy usage baselines to be set and faults to be detected, and optimizing operating strategies based on expected energy costs and value added.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If direct measurement of energy consumption is implemented, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent introduces intermediary components (current transformers, voltage transformers, power factor meters) that indirectly measure energy consumption by measuring related electrical parameters (current, voltage, power factor) and calculating energy usage from these measurements, rather than directly measuring energy consumption
Solution Approach 2:
The patent replaces direct mechanical/electrical energy measurement systems with a computational approach that calculates energy consumption from measured electrical parameters using the formula: Energy = Voltage × Current × Power Factor × Time, thereby reducing measurement complexity
2Measurement precision
If direct measurement of energy consumption is implemented, then measurement precision is improved, but loss of time increases
Solution Approach 1:
The patent performs preliminary measurements of voltage, current, and power factor parameters that can be used for multiple energy consumption calculations, and establishes baseline energy consumption profiles for different operating conditions to enable faster subsequent measurements
Solution Approach 2:
The patent replaces time-consuming direct energy measurement with rapid computational calculation from quickly measurable electrical parameters, significantly reducing the time required for energy consumption assessment
3Loss of energy
If operating strategies are optimized based on energy usage, then loss of energy is reduced, but device complexity increases
Solution Approach 1:
The patent implements feedback mechanisms that continuously monitor energy consumption and operational parameters, compare actual performance against target values, and automatically adjust operating strategies to optimize energy usage while maintaining production requirements
Solution Approach 2:
The patent employs dynamic operating strategies that can be adjusted in real-time based on changing conditions, allowing the system to adapt energy consumption patterns to match actual demand and operational requirements rather than using fixed conservative settings
4Manufacturing precision
If multiple operating parameters are monitored and controlled, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent implements a universal control system that simultaneously monitors and controls multiple operating parameters (energy consumption, production rate, product quality metrics) using integrated sensors and control algorithms, allowing one system to perform multiple functions rather than requiring separate systems for each parameter
Data Source
AI summary
The present disclosure describes systems and methods for quantifying operating strategy energy usage. One embodiment describes an industrial control system that includes a tangible, non-transitory, computer readable medium storing a plurality of instructions executable by a processor of the industrial control system. The instructions include instructions to determine a plurality of operating strategies associated with an industrial automation component that is communicatively coupled to the industrial control system, in which each of the plurality of operating strategies includes a set of operational parameters associated with the industrial automation component, determine an expected energy usage cost associated with the industrial automation component for each of the plurality of operating strategies, determine an expected value added associated with the industrial automation component for each of the plurality of operating strategies, and select one of the plurality of operating strategies for operating the industrial automation component based at least in part on the expected energy usage cost and the expected value added associated with each of the plurality of operating strategies.