Automatic Load Power Allocation Under Current Limit Constraints
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Solution Overview
Problem
Existing power control methods for multiple loads, such as heaters in semiconductor manufacturing or injection molding machines, face challenges in managing current and power values within predetermined limits during time-proportional control, leading to increased capacity and size requirements for power supply facilities.
Innovation Solution
A power control device and method that automatically allocates power supply by calculating combinations of loads to ensure total current or power values do not exceed a limiter value, setting simultaneous ON periods, and integrating these periods to optimize power distribution, thereby reducing facility capacity and size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If power is supplied to multiple loads simultaneously without time-proportional control, then each load receives sufficient power, but the total current and power values exceed the capacity of power supply facilities
Solution Approach 1:
The patent applies periodic action by implementing time-proportional control that divides power supply into discrete ON and OFF periods. The control unit calculates optimal ON periods for each load based on their power consumption characteristics and sequentially activates loads within these periods, ensuring that the sum of simultaneous power consumptions does not exceed the power supply facility's capacity. This periodic switching approach allows multiple loads to receive adequate power over time while maintaining instantaneous power within safe limits.
2Device complexity
If time-proportional control is used to reduce power supply facility capacity, then the size of power supply facilities can be reduced, but manual allocation of power supply periods is complex and time-consuming
Solution Approach 1:
The patent implements self-service by enabling the control unit to automatically calculate and determine the optimal ON periods for each load based on their power consumption characteristics. The system autonomously performs the complex allocation calculations, identifies suitable time slots for each load, and adjusts power supply timing without requiring manual intervention. This automated self-allocation eliminates the time-consuming manual planning process while optimizing power supply facility utilization.
3Power
If ON periods of multiple loads are made to overlap to ensure each load receives sufficient power, then each load's power requirement is met, but the total current exceeds the power supply facility's capacity
Solution Approach 1:
The patent applies dynamics by implementing flexible and adjustable ON period allocations for each load. The control unit dynamically calculates the optimal ON periods based on real-time power consumption characteristics and system conditions. This dynamic approach allows the system to adaptively balance power distribution, ensuring each load receives adequate power during its allocated ON periods while preventing simultaneous activation that would cause current overload and maintain power supply stability within facility capacity limits.
Data Source
AI summary
The power control device performs power supply to each of a plurality of loads (231 to 234) by a time-proportional control, where a maximum load factor and a current value or a power value during on-control are made to correspond to each of the plurality of loads. The power control device 1 is characterized by being provided with an automatic power supply allocation unit 12 that performs: processing of calculating a combination of loads in which a total value of the current value or the power value during the on-control, which are made to correspond to the respective loads, does not exceed a limiter value that specifies an upper limit to the total of the current value or the power value output to the plurality of loads; processing of setting a period in which the respective loads in the combination are simultaneously on-controlled and subtracting the period from the maximum load factor of each of the loads in the combination; and automatic allocation processing of power supply to each load by repeating each of the above processing until all maximum load factors of the respective loads become zero.