Manufacturing Energy Orchestration for Peak Load Control
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Solution Overview
Problem
Manufacturing facilities face challenges in managing energy consumption efficiently, particularly with the increasing complexity of connected devices and the need for precise energy traceability to meet regulatory requirements and optimize energy use, given the variability of energy sources and costs.
Innovation Solution
An energy management system with a graphical user interface that orchestrates the actions of manufacturing components, monitors energy consumption, and adjusts operations to keep energy usage within predetermined limits, using closed-loop control to distribute and throttle power as needed, while providing predictive maintenance through pattern recognition and data analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of connected devices and systems in factories is increased to improve manufacturing capabilities and data collection, then productivity and manufacturing precision are improved, but device complexity and network management complexity increase
Solution Approach 1:
The patent introduces an energy management system that acts as an intermediary layer between the programmable logic controller and the numerous connected devices. This system provides centralized energy monitoring, tracking, and optimization capabilities without requiring direct complex connections to each individual device, thereby managing the complexity of having hundreds of connected components while maintaining improved manufacturing capabilities
2Productivity
If energy consumption is increased to power more devices and systems, then productivity and manufacturing precision are improved, but use of energy worsens
Solution Approach 1:
The energy management system implements continuous feedback loops that monitor energy consumption in real-time and provide data to the programmable logic controller. This enables dynamic adjustment of device operations to optimize energy usage while maintaining required productivity levels. The system tracks energy consumption by device, identifies optimization opportunities, and implements control strategies that reduce overall energy consumption without sacrificing manufacturing output
Solution Approach 2:
The system enables dynamic parameter changes in device operation based on energy consumption patterns and manufacturing priorities. By adjusting operational parameters such as cycling schedules, power levels, and operational sequences, the system optimizes the balance between energy consumption and productivity, allowing manufacturing output to be maintained or improved while reducing total energy usage
3Use of energy by moving object
If energy consumption is optimized by reducing power usage, then use of energy is improved, but productivity may worsen due to reduced operational capacity
Solution Approach 1:
The energy management system implements dynamic control strategies that continuously adapt device operation based on real-time conditions. Rather than static energy reduction, the system dynamically adjusts power distribution, device cycling, and operational priorities to optimize energy efficiency while maintaining required productivity levels. This dynamic approach ensures that energy optimization does not come at the cost of manufacturing output
Data Source
AI summary
An energy management system or plugin thereto includes a graphical user interface that displays visual elements corresponding to at least one manufacturing component and an energy management module instantiated in the graphical user interface. The energy management module is enabled to receive and display energy consumption status information from the manufacturing component and can control and modify the energy consumption of the manufacturing component by instructions sent from the energy management system to the component. The instructions can comprise a throttle instruction, an orchestrate instruction, or a disabled instruction which can be configured as predetermined presets corresponding to a desired energy protocol. The energy management module can also be used to group or sequence the components to distribute energy consumption to avoid exceeding the energy capacity of the manufacturing setting.