Manufacturing Load Management Reducing Power and Wear
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Solution Overview
Problem
Existing manufacturing management systems fail to optimize power consumption and component lifetime across multiple manufacturing machines within a manufacturing system, often focusing on individual machines rather than the system as a whole.
Innovation Solution
A manufacturing management apparatus that acquires load information on power consumption and component lifetime, calculates operational loads, and adjusts manufacturing machine operations to reduce peak and average power consumption while extending component lifetime, by controlling speed, acceleration, and operation timing across multiple machines without affecting overall production volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the manufacturing machines operate at high speed and high acceleration to increase productivity, then the production volume increases, but the peak power consumption and average power consumption increase
Solution Approach 1:
The system dynamically adjusts speed and acceleration parameters of manufacturing machines based on real-time operational conditions. The operation adjustment part modifies motion profiles to reduce peak power consumption while maintaining overall productivity by optimizing when high-speed operation is necessary versus when slower operation is acceptable.
Solution Approach 2:
The invention changes operational parameters (speed, acceleration) of manufacturing machines to reduce power consumption. The load calculation part analyzes power consumption patterns and the operation adjustment part implements parameter modifications that lower both peak and average power consumption while keeping production volume constant.
2Productivity
If the manufacturing machines operate continuously at high load to maintain production output, then the productivity is maintained, but the component lifetime decreases due to accelerated wear and deterioration
Solution Approach 1:
The system dynamically adjusts operational intensity based on component condition and production requirements. Rather than continuous high-load operation, the system varies load levels to extend component life while maintaining necessary production output through optimized scheduling and operation sequencing.
Solution Approach 2:
The load calculation part performs preliminary analysis of component wear patterns and power consumption characteristics before adjusting operations. This allows the system to proactively optimize operation parameters that extend component lifetime while ensuring production targets are met, rather than reacting to wear after damage occurs.
3Reliability
If the operator optimizes power consumption and component lifetime for individual manufacturing machines separately, then the performance of individual machines improves, but the overall operational load of the manufacturing system fails to be optimized
Solution Approach 1:
The invention merges the control of multiple manufacturing machines into a unified system managed by the manufacturing management apparatus. The load calculation part aggregates load information from all machines and the operation adjustment part coordinates adjustments across the entire system, achieving system-wide optimization rather than isolated individual machine optimization.
Solution Approach 2:
The system implements feedback loops where the load information acquisition part continuously monitors power consumption and operational status of all machines, the load calculation part analyzes this aggregated data, and the operation adjustment part implements coordinated adjustments. This feedback mechanism ensures that individual machine optimizations contribute to overall system optimization.
Data Source
AI summary
A cell control apparatus is provided with a load calculation part which calculates an operational load including at least one of average power consumption, maximum power consumption, and a variable indicating a component lifetime of a manufacturing cell in a predetermined period. The cell control apparatus includes an operation adjustment part which performs first control for reducing at least one of a speed and an acceleration at which the manufacturing machine drives and second control for adjusting a ratio of time of successive operations in such a manner as to reduce the operational load in such an extent that the number of products manufactured in the predetermined period is not changed.