Power Equalization Device for Manufacturing Lines
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Solution Overview
Problem
Existing power control methods for manufacturing lines fail to equalize power supply when multiple materials are processed simultaneously at different locations, leading to inefficiencies and potential power imbalances.
Innovation Solution
A power equalization device with a power demand prediction function and a power equalization control function that utilizes a power storage device to manage power consumption by predicting and adjusting production timing and discharging power to maintain balanced external power supply, incorporating a combination of storage batteries, flywheels, and capacitors for efficient energy management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If private power generation is used to generate power when maximum demand power exceeds contract demand, then power supply can be maintained, but power equalization cannot be achieved when multiple materials are simultaneously processed at different locations
Solution Approach 1:
The system performs preliminary prediction of power consumption for multiple materials being processed simultaneously at different locations. By predicting power demand before peaks occur, the system can pre-charge power storage devices or pre-schedule production adjustments, enabling effective power equalization rather than merely maintaining supply during crises.
Solution Approach 2:
The patent introduces a power storage device as an intermediary between the manufacturing line and the external power system. This mediator absorbs power fluctuations by charging during low-demand periods and discharging during high-demand periods, enabling power equalization across multiple simultaneous processing operations.
2Productivity
If power consumption is not predicted and controlled, then production can proceed without restrictions, but power supplied from external power system exceeds prescribed values causing inefficiency
Solution Approach 1:
The system implements a feedback mechanism where actual power consumption is continuously monitored and compared against predicted values. This feedback loop enables real-time adjustments to production scheduling and power storage operations, ensuring that power consumption is optimized while maintaining production continuity.
Solution Approach 2:
The system dynamically changes operational parameters such as production timing, material processing schedules, and power storage charge/discharge rates based on predicted and actual power consumption patterns. These parameter adjustments enable the system to reduce excessive power consumption while maintaining productivity.
3Ease of operation
If power storage devices are used to equalize power, then power supplied from external system can be controlled, but additional equipment and infrastructure are required
Solution Approach 1:
The power storage device serves multiple functions: it equalizes power supply, stores energy for later use, provides backup power capability, and enables production scheduling optimization. This multi-functionality justifies the added infrastructure by delivering multiple benefits from a single system component.
Solution Approach 2:
The system uses its own predicted power consumption patterns to automatically control charging and discharging of the power storage device, eliminating the need for external manual intervention or complex external control systems. The system serves itself by using its operational data to manage its power infrastructure.
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
Enables effective power equalization across manufacturing lines, reducing the need for large power supply equipment and infrastructure, while optimizing energy usage and cost by predicting and managing power demand in real-time.
Implementation Method 1
a power storage device to make the manufacturing plant or the manufacturing line perform discharging
Implementation Method 2
incorporating a combination of storage batteries, flywheels, and capacitors for efficient energy management
Implementation Method 3
incorporating a combination of storage batteries, flywheels, and capacitors for efficient energy management
Data Source
AI summary
Provided is a power equalization device capable of equalizing the power supplied to a manufacturing line from outside even in the case where a plurality of materials are simultaneously processed at different locations. For this purpose, the power equalization device has a power demand prediction function of predicting power consumption expected when a plurality of materials are simultaneously processed at different locations of a manufacturing plant or manufacturing line of a metallic material, and a power equalization control function of causing a power storage device to make the manufacturing plant or the manufacturing line perform discharging in the case where power consumption predicted by the power demand prediction function exceeds a prescribed value, so that power supplied to the manufacturing plant or the manufacturing line from an external power system becomes not more than the prescribed value.