Printing Machine Power Load Control via Dynamic Speed Adjustment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Large electrically driven machines, such as printing presses, impose high and variable power loads on the grid, leading to increased electricity costs and peak demand issues, which existing methods have not adequately addressed.
Innovation Solution
A method using control software in a control computer and operating device that allows operators to set a maximum permissible power consumption, with sensors monitoring the machine's state to calculate and enforce this limit, adjusting production speed if necessary, and optimizing job sequencing to maintain power within set constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the machine operates at maximum power consumption to maintain high production speed, then productivity is improved, but power consumption increases leading to higher electricity costs and peak load issues
Solution Approach 1:
The patent implements dynamic adjustment of machine operating parameters (speed, power consumption) based on real-time monitoring and predictive calculations. The control computer continuously adapts the movement profiles of electrical drives to balance productivity requirements with power consumption limits, transitioning from static maximum power operation to dynamic optimized operation.
Solution Approach 2:
The system performs preliminary calculations of future power requirements based on the production schedule and job characteristics. By predicting peak load requirements in advance, the control computer can proactively adjust operating parameters before peak demand occurs, preventing power consumption exceedance while maintaining optimal productivity.
2Loss of energy
If power consumption is limited to reduce electricity costs, then energy efficiency is improved, but production speed may be reduced affecting productivity
Solution Approach 1:
The system dynamically changes operational parameters (speed profiles, acceleration rates, idle times) of electrical drives to optimize the balance between energy efficiency and productivity. By adjusting these parameters based on real-time conditions and predictive models, the system achieves reduced energy consumption without proportionally reducing production output.
Solution Approach 2:
The control computer continuously monitors actual power consumption and compares it against calculated requirements and limits. This feedback loop enables real-time adjustments to movement profiles and operating parameters, ensuring energy efficiency goals are met while maintaining acceptable productivity levels through adaptive control.
3Loss of energy
If the machine is shut down or switched to standby mode to reduce power consumption, then energy efficiency is improved, but production time increases affecting productivity
Solution Approach 1:
Instead of continuous operation or complete shutdown, the system implements periodic action by strategically switching individual drives or machine units to standby mode during periods of low or no production demand. The control computer optimizes these periodic standby periods based on the production schedule, achieving energy savings during idle times without extending overall production time for active operations.
Data Source
Figure 1
Figure 2
AI summary
The present invention relates to a method for controlling an electrical driven device (6) in a machine (7) having a control computer (2) and an operation device (9). The method comprises inputting a preset for limiting maximum permission power consumption of the machine (7) during an operation into the control computer (2) by means of the operation device (9).