Industrial Automation Energy Usage Inference
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Solution Overview
Problem
Current methods for determining energy usage in industrial automation systems often require direct measurement, which can be costly and impractical, especially when trying to monitor energy consumption across multiple levels of granularity such as components, cells, areas, and factories.
Innovation Solution
An industrial automation system that infers energy usage by measuring power supplied to components and using models based on physics principles, manufacturer specifications, and operational data to estimate energy consumption without the need for direct measurement at every point, allowing for energy usage to be determined at various levels of granularity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If direct measurement methods are used to determine energy usage at every component level, then measurement precision is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent combines multiple measurement points into a single aggregate measurement. By measuring total power at one location and using mathematical allocation based on operational parameters, the system achieves comprehensive energy monitoring without installing sensors at every component, thus reducing device complexity while maintaining measurement precision through computational methods
Solution Approach 2:
The patent introduces mathematical models and allocation algorithms as intermediaries between the single aggregate measurement and the individual component energy usage. These computational intermediaries process the total power measurement combined with operational data to derive accurate energy consumption for each component, eliminating the need for direct physical measurement at every point
2Measurement precision
If sensors are placed at every component to measure power directly, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive, permanent sensor installations with a cost-effective computational approach. By using mathematical allocation based on readily available operational parameters, the system achieves accurate energy measurement without the high manufacturing costs associated with installing and maintaining sensors at every component location
Solution Approach 2:
The patent creates a virtual model of energy distribution that copies the physical power flow relationships. Through mathematical models that replicate how power is allocated across components based on operational data, the system achieves measurement precision equivalent to physical sensors without the manufacturing cost of actual sensor deployment
3Device complexity
If aggregate power measurement is used without detailed component-level data, then device complexity is reduced, but measurement precision deteriorates
Solution Approach 1:
The patent segments the aggregate power measurement into individual component contributions through mathematical allocation. By dividing the total power based on operational parameters and model-based relationships, the system achieves component-level measurement precision while maintaining the simplicity of a single aggregate measurement point
Solution Approach 2:
The patent uses dynamic operational parameters to continuously adjust the power allocation ratios. As components operate at different loads and efficiencies, the mathematical model dynamically recalculates energy distribution, maintaining measurement precision without increasing system complexity
Data Source
AI summary
The present disclosure describes system and methods for inferring energy usage at multiple levels of granularity. One embodiment describes an industrial automation system including a first industrial automation component, a first sensor coupled to the first industrial automation component, in which the first sensor measures a first amount of power supplied to the first industrial automation component, a second industrial automation component that couples to the first industrial automation component, and an industrial control system that infers energy usage by the first industrial automation component and the second industrial automation component based at least in part on the first amount of power supplied to the first industrial automation component.