Mover System Dynamic Fleet Sizing for Energy Reduction
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Solution Overview
Problem
Mover systems in industrial automation consume excessive electrical power, leading to increased greenhouse gas emissions and reduced productivity, necessitating improved design and control techniques to optimize energy usage and production efficiency.
Innovation Solution
A system comprising a track and multiple movers controlled by processors that receive user inputs for operational parameters, determining and implementing operating settings to minimize energy consumption, maximize production, and adjust the number of movers in use, including the option to park movers when not in use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the mover system operates with a larger number of movers to increase production capacity, then productivity is improved, but electrical power consumption increases
Solution Approach 1:
The system dynamically adjusts the number of active movers based on real-time production demands and energy constraints. The controller continuously monitors operational parameters and modifies the fleet size by parking or activating movers as needed, transforming a static system into a dynamic one that adapts to changing conditions to optimize both productivity and energy usage.
Solution Approach 2:
The system changes operational parameters including the number of active movers, speed profiles, acceleration rates, and power consumption thresholds. By adjusting these parameters based on user-defined constraints (maximum power per unit, maximum cost per unit), the system finds optimal operating points that balance production capacity with energy consumption.
2Productivity
If the mover system consumes more electrical power to increase production output, then productivity is improved, but environmental impact (greenhouse gas emissions) worsens
Solution Approach 1:
The system incorporates feedback mechanisms that monitor energy consumption and translate it into operational decisions. By continuously measuring power usage and comparing it against user-defined thresholds (maximum power per unit, maximum cost per unit), the controller adjusts mover operations to minimize environmental impact while maintaining acceptable production levels. This feedback loop enables the system to reduce greenhouse gas emissions by optimizing energy consumption patterns.
3Use of energy by moving object
If the system dynamically adjusts the number of active movers to reduce energy consumption, then energy efficiency is improved, but system complexity increases
Solution Approach 1:
The control system performs self-service by automatically monitoring operational parameters, determining optimal fleet sizes, and executing parking/activation decisions without requiring complex external intervention. The controller uses built-in algorithms to analyze power consumption data and adjust the number of active movers autonomously, reducing the need for additional complex control infrastructure while achieving energy efficiency goals.
4Use of energy by moving object
If the mover system operates fewer movers to reduce power consumption, then energy efficiency is improved, but productivity decreases
Solution Approach 1:
The system applies partial action by activating only the necessary number of movers required to meet production targets within energy constraints, rather than operating all movers continuously. By determining the minimum viable fleet size based on real-time demands and power availability, the system achieves adequate production output with reduced energy consumption, avoiding the excessiveness of running more movers than needed.
Data Source
AI summary
A mover system includes a track, a plurality of movers configured to move along the track, and one or more processors. The one or more processors are configured to receive a user input indicative of operational parameters for the mover system, determine operating settings for the mover system based on the operational parameters, and cause the plurality of movers to operate in accordance with the operating settings.