OHT Induction Rail Power Control for Idle Energy Reduction
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Solution Overview
Problem
Automated Material Handling Systems (AMHS) in semiconductor fabrication facilities, particularly the overhead hoist transport (OHT) system, consume a significant amount of power even when idle, due to constant power consumption, which is inefficient and can impact manufacturing schedules.
Innovation Solution
A transport system that includes a rail with an induction cable and a power panel that adjusts output current based on the quantity of vehicles on the rail, using a sensor and controller to optimize power usage via noncontact power supply, and a back-up power mechanism to ensure continuous operation and prevent delays during loading/unloading and acceleration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If constant power supply is used to ensure continuous operation of OHT vehicles, then system reliability is improved, but energy consumption increases
Solution Approach 1:
The power supply system transitions from static constant power to dynamic variable power that adjusts according to the number of vehicles on the rail. The controller receives vehicle quantity information and dynamically adjusts the output current to match actual power needs, ensuring reliable operation while eliminating wasted energy when fewer vehicles are present.
Solution Approach 2:
The system implements a feedback loop where the controller continuously monitors the number of vehicles on the rail and adjusts the power output accordingly. This closed-loop control ensures that power supply matches actual demand, maintaining system reliability while optimizing energy consumption by reducing power when vehicle count decreases.
2Loss of energy
If power output is reduced to save energy, then energy efficiency is improved, but system reliability may deteriorate
Solution Approach 1:
The power supply dynamically adjusts its output based on real-time vehicle count rather than maintaining a fixed high level. This dynamic adaptation allows the system to reduce energy waste during low-activity periods while automatically scaling up power delivery when vehicle density increases, thus maintaining reliability without sacrificing energy efficiency.
Solution Approach 2:
The feedback mechanism ensures that power reduction does not compromise reliability by continuously monitoring vehicle presence and adjusting power output accordingly. When vehicles are detected, power is increased to appropriate levels; when vehicles are absent or fewer, power is reduced, preventing both energy waste and reliability issues.
3Loss of energy
If dynamic power adjustment is implemented to reduce energy consumption, then energy efficiency is improved, but device complexity increases
Solution Approach 1:
The power supply system is segmented into distinct functional modules: a sensor for detecting vehicle count, a controller for processing information and making decisions, and a power output stage for delivering adjusted power. This modular segmentation makes the complex dynamic adjustment process manageable and maintainable while achieving energy efficiency goals.
Solution Approach 2:
The controller acts as an intermediary between the sensor that detects vehicle count and the power supply that delivers energy. This intermediary processes the vehicle quantity information and translates it into appropriate power output levels, simplifying the overall control logic while enabling dynamic power adjustment for improved energy efficiency.
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
Reduces power consumption by up to 20-25% while maintaining system functionality, preventing delays and ensuring smooth manufacturing operations by adjusting power output dynamically and providing supplemental power when needed.
Implementation Method 1
A transport system includes a rail with an induction cable and a power panel that adjusts output current
Implementation Method 2
The power transferring mechanism includes a pickup coil arranged to transfer the magnetic field generated from the current on the cable extending along the rail to a driving power
Data Source
AI summary
A transport system, including: a sensor, a controller and a power panel. The sensor determines a zone and sends a quantity information in response to a quantity of vehicles in the zone. The controller is arranged to send an output signal in accordance with the quantity information. The power panel is arranged to output a current in accordance with the output signal for driving vehicles in the zone, wherein the current is outputted to a cable extending through the zone.