Electric Power Consumption Simulation Device for Production Line Energy Accuracy

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Solution Overview

Problem

Existing methods for simulating electric power consumption in production lines do not accurately account for suspension and standby states of equipment, leading to overestimation of power usage and inefficiencies, particularly in collaborative operations among multiple pieces of equipment.

Innovation Solution

A simulation apparatus that categorizes electric power consumption modes into six types (Types 1 to 6) based on operating and standby states, allowing for precise calculation of power usage by setting equipment types and simulating power consumption in a virtual model, taking into account specific operational and standby conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If electric power consumption is calculated by multiplying rated electric power by planned period and summing up values, then calculation is simple, but the result is far larger than actual consumption and lacks accuracy

Engineering Contradiction:

Improveease of calculationVSAvoidaccuracy of power consumption simulation

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

The patent segments electric power consumption into multiple distinct modes (operation mode, standby mode, suspension mode, idle mode) and calculates consumption for each mode separately based on actual operational data. This segmentation allows the system to capture the nuanced differences in power consumption across various equipment states, thereby improving accuracy while maintaining a structured calculation approach.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the parameters used in power consumption calculation from a single rated power value to multiple mode-specific power values (operation power, standby power, suspension power, idle power). By introducing these differentiated parameters and selecting appropriate values based on actual equipment states and operational data, the system achieves higher accuracy in simulating real power consumption patterns.

Inventive Principle:

Principle #35Parameter changes

2Measurement precision

If percentage of suspension is used to adjust power consumption calculation, then some accuracy improvement is achieved, but suspension and standby states arising from collaborative operations are not considered

Engineering Contradiction:

Improveaccuracy of power consumption simulationVSAvoidcomplexity of simulation model

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent incorporates feedback mechanisms by using actual operational data from equipment collaboration to dynamically adjust power consumption calculations. The system monitors real-world operational patterns, suspension events, and standby states resulting from equipment interactions, and feeds this information back into the simulation model to refine accuracy without requiring excessive model complexity.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent performs preliminary classification of equipment operational states (operation, standby, suspension, idle) and pre-establishes calculation methods for each state type. This preliminary structuring allows the system to handle complex collaborative operations systematically by applying appropriate calculation rules based on pre-defined state categories, thereby managing complexity while improving accuracy.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If equipment is always assumed to operate at rated capacity, then power consumption calculation is straightforward, but actual consumption is significantly overestimated

Engineering Contradiction:

Improvesimplicity of calculation methodVSAvoidoverestimation of energy consumption

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent introduces dynamics into the power consumption calculation by transitioning from a static rated power assumption to a dynamic model that adapts to actual equipment states. The system continuously determines whether equipment is in operation, standby, suspension, or idle mode and applies the corresponding power consumption value, thereby reflecting real-time variations in actual energy consumption and avoiding systematic overestimation.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS10678964B2Electric power consumption simulation device, simulation method, and recording medium

Publication Date: 2020.06.09 OMRON CORP

AI summary

A simulation apparatus has a type setting section that sets a type of mode of electric power consumption of equipment, and an output section that simulates an amount of the electric power consumption of the equipment in accordance with the type set by the type setting section and outputting the amount of electric power consumption thus simulated.