Intermediate Circuit Power Management for Peak Load Balancing
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Solution Overview
Problem
Current systems for managing energy in plastics processing machines, such as injection molding systems, lack effective load management between individual consumers, leading to inefficiencies and energy peaks that can result in excess energy being dissipated or lost.
Innovation Solution
A management method and system that determines and analyzes the power requirements and recoveries of multiple system parts connected to an intermediate circuit, allowing for decentralized control and regulation to optimize energy usage, prevent overload, and minimize energy peaks by adjusting workflow parameters like speed, torque, and timing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If multiple plant components operate independently without coordination, then each component can function autonomously, but energy peaks occur and overall energy efficiency deteriorates
Solution Approach 1:
The patent combines multiple independent plant components into a coordinated system where energy management is integrated across all components. The control system merges information from multiple sources (power demand, power feed-in, workflow parameters) and coordinates their operation to optimize overall energy efficiency and prevent energy peaks.
Solution Approach 2:
The system implements feedback mechanisms by continuously monitoring power demand and power feed-in of individual plant components, comparing these values against predefined thresholds, and automatically adjusting workflow parameters in response to maintain optimal energy efficiency and prevent energy peaks.
2Productivity
If power demand exceeds predefined values, then more work can be performed, but the intermediate circuit becomes overloaded and system reliability deteriorates
Solution Approach 1:
The system performs preliminary analysis of power demand and power feed-in values before executing workflows. By evaluating whether the sum of these values exceeds predefined thresholds in advance, the control system can prevent intermediate circuit overload before it occurs, maintaining both productivity and system reliability.
Solution Approach 2:
The system applies preliminary anti-action by detecting potential power demand peaks and counteracting them through workflow parameter adjustments before the intermediate circuit becomes overloaded. This preventive approach maintains system stability while preserving productive capacity.
3Use of energy by moving object
If workflow parameters are adjusted to reduce energy peaks, then energy efficiency improves, but production time may increase
Solution Approach 1:
The system dynamically adjusts workflow parameters based on real-time power demand and feed-in conditions. Rather than using fixed parameter settings, the control system continuously optimizes parameters to balance energy efficiency improvements with minimal impact on production time, adapting to changing operational conditions.
Data Source
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AI summary
A management method for controlling and/or regulating a complete plant (10) with at least two plant components (12) connected by an intermediate circuit (14) is disclosed.By determining and analyzing the power demand and/or power feed-in of at least two plant components (12) in relation to each other, and then controlling and regulating the total power demand and/or total power feed-in of at least one plant component (12) in such a way that the total power demand and/or total power feed-in of the entire plant is less than or equal to at least a predetermined value, preferably less than or equal to a maximum power demand and/or power feed-in of the plant component (12) that exhibits the maximum power demand and/or power feed-in at the at least one specific time or within the at least one specific time interval, energy-optimized operation of the plant is ensured.