Manufacturing Line Power Control via Energy Monitoring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for controlling power supply in manufacturing lines and similar systems fail to accurately determine the cause of changes in electric energy consumption, leading to inefficient power management and potential inconvenience to users, as they do not distinguish between scheduled stops and unscheduled downtime or material waits, resulting in unnecessary power-offs and restarts.
Innovation Solution
A control device that monitors the electric energy consumption of one machine and adjusts the power supply of another based on both the consumption data and scheduled operation information, using thresholds and timers to differentiate between scheduled and unscheduled stops, thereby optimizing power usage without inconveniencing users.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If power supply is controlled based solely on electric energy consumption monitoring, then energy saving is improved, but user convenience deteriorates due to unnecessary power-offs during scheduled stops
Solution Approach 1:
The control device monitors electric energy consumption in real-time and uses this feedback to determine whether to control power supply. By continuously comparing actual energy consumption against expected consumption patterns, the system can distinguish between scheduled stops (where energy consumption naturally drops) and unscheduled downtime (where energy consumption should remain stable), enabling intelligent power management that preserves user convenience while reducing waste.
Solution Approach 2:
The control device acts as an intermediary between the machine's power supply system and the energy consumption monitoring system. It receives both electric energy consumption data and scheduled stop information, processes this information through logical comparison, and then generates appropriate power supply control signals. This intermediary function allows the system to make informed decisions about power management without directly interfering with machine operation.
2Loss of energy
If power supply is turned off during scheduled stops to save energy, then energy saving is improved, but productivity deteriorates due to unnecessary restarts
Solution Approach 1:
The system uses feedback from scheduled stop information alongside energy consumption monitoring to determine power supply control decisions. When the control device detects that a stop corresponds to a scheduled stop time, it maintains power supply despite reduced energy consumption, thereby avoiding unnecessary restarts and preserving productivity while still achieving energy savings during actual unscheduled downtime.
Solution Approach 2:
The control device receives scheduled stop information in advance, allowing it to prepare appropriate power supply control actions before the scheduled stop occurs. This preliminary knowledge enables the system to maintain power supply during anticipated stops, ensuring machines are ready for immediate resumption of work without requiring time-consuming restart sequences.
3Measurement precision
If multiple sensors are used to monitor workpiece state for each machine, then control precision is improved, but device complexity increases
Solution Approach 1:
The control device serves multiple functions: it monitors electric energy consumption, receives scheduled stop information, determines machine status, and controls power supply. By consolidating these diverse functions into a single control system rather than using separate sensors and controllers for each function, the invention reduces overall device complexity while maintaining comprehensive monitoring and control capabilities.
Solution Approach 2:
The invention merges the power supply control function with the energy consumption monitoring function into a single integrated control device. Instead of using separate sensors to monitor workpiece state, machine operation, and power consumption, the system combines these monitoring tasks and uses the integrated data to make power supply decisions, thereby reducing the number of components while improving system efficiency.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A control device (20) includes: an electric energy monitoring section (21) which monitors an amount of electric energy of a machine A; a stop time period information storing section (23) which stores stop time period information indicative of a scheduled stop time period of a manufacturing line; a stop control section (25) which controls power supply of machines B though D in accordance with the amount of electric energy of the machine A and the stop time period information; and a start-up control section (26).