Production Line Module Temperature Control During Shutdowns
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Solution Overview
Problem
Current production line systems, particularly shrink-wrapping modules, face significant energy consumption issues during unplanned shutdowns, leading to increased downtime and energy wastage, as existing solutions do not effectively manage thermal means to optimize energy use during non-production periods without impacting operational efficiency.
Innovation Solution
An automatic learning system that records and analyzes past data to adjust the temperature of thermal means, such as ovens, to minimize energy consumption during shutdowns by determining optimal lowering and raising temperatures based on historical data, ensuring rapid return to operational conditions when production resumes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the oven temperature is maintained at production temperature during shutdown, then the return to production is rapid, but energy consumption increases significantly
Solution Approach 1:
The system performs preliminary actions by lowering the oven temperature during shutdown periods. The control system detects shutdown conditions and automatically reduces heating power or stops heating, preparing the system for energy-saving operation before the shutdown is complete. This preliminary temperature reduction resolves the contradiction by saving energy during idle periods while maintaining the ability to quickly resume production when needed.
2Use of energy by stationary object
If the oven temperature is lowered during shutdown, then energy consumption is reduced, but the return to production time increases
Solution Approach 1:
The system applies dynamics by making the oven temperature control adaptive and variable rather than static. The control system dynamically adjusts the heating power based on real-time detection of shutdown conditions and the current temperature state. During shutdown, the system lowers temperature to save energy, but when production resumes, it dynamically increases heating power to quickly reach the required operating temperature, thus resolving the time-energy tradeoff.
Solution Approach 2:
The system uses feedback mechanisms to continuously monitor the oven temperature and shutdown status. The control system receives feedback about the current temperature and adjusts the heating power accordingly. When a shutdown is detected, the feedback loop triggers temperature reduction; when production resumes, the feedback triggers rapid reheating. This closed-loop control resolves the contradiction by optimally balancing energy savings with return-to-production speed.
3Use of energy by stationary object
If manual temperature adjustment is used during shutdown, then energy consumption is reduced, but operational complexity and human intervention increase
Solution Approach 1:
The system implements self-service by automatically detecting shutdown conditions and adjusting the oven temperature without human intervention. The control system monitors production status, identifies shutdown periods, and autonomously lowers the temperature to save energy. When production resumes, the system automatically restores the temperature. This automation eliminates the need for manual temperature adjustment while achieving energy savings, resolving the contradiction between energy reduction and operational simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for precise prediction and adaptation of temperature changes in real-time, reducing energy waste and ensuring minimal downtime by anticipating the return to optimal operating conditions, thus improving energy management and operational efficiency.
Implementation Method 1
a downstream heating station, consisting of at least one oven, generally consisting of several heating zones, through which each batch of coated products passes, allowing said film to shrink
Implementation Method 2
The batch thus coated and enclosed by said shrunk film is cooled at the outlet of the oven, in order to provide sufficient mechanical strength to the batch thus kept coated
Data Source
Figure 1
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AI summary
The invention relates to a method for managing a main module (1) of a production line, said main module (1) being equipped with thermal means operating in production at a setpoint temperature (1000), a method in which, during production, in the event of a production interruption at said main module (1), the temperature of said thermal means is lowered and then restored to said setpoint temperature (1000). Advantageously, data is recorded for at least one past event including at least one duration of temperature rise of said thermal means from a first to a second temperature, and the temperature of said thermal means is automatically adjusted, based on said data, until said setpoint temperature (1000) is reached, at the latest when production resumes at said main module (1).The invention also relates to a corresponding management device.