Process Energy Profiling Using Sequence-Based Consumption Attribution
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Solution Overview
Problem
Existing methods for determining energy consumption in industrial settings are either costly and intrusive, requiring multiple sensors per process, or complex and non-intrusive, relying on device models that struggle to generalize across the wide variety of industrial devices.
Innovation Solution
A method that involves obtaining energy-consumption-relevant measurement data for multiple processes, determining an energy consumption profile, matching this profile with process sequence information, assigning changes in energy consumption to individual processes based on sequence information, and finally determining energy consumption information for each process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If direct measurement with dedicated sensors is used for each process, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent segments the energy consumption measurement problem by separating the measurement function into two parts: a single central measuring device that captures total energy consumption, and a separate information processing system that uses process sequence information to attribute consumption to individual processes. This eliminates the need for multiple physical sensors while maintaining measurement precision.
Solution Approach 2:
The patent introduces process sequence information as an intermediary element that mediates between the central energy measurement and individual process attribution. This intermediary data enables the system to determine which process consumed energy at any given time without requiring direct sensing at each process point.
2Device complexity
If non-intrusive load monitoring with device models is used, then device complexity is reduced, but adaptability to various industrial devices deteriorates
Solution Approach 1:
The patent creates a universal measurement system that can handle diverse industrial devices by using a single central measuring device combined with process sequence information. The system is not tied to specific device types or behaviors, making it universally applicable across different machines and processes in industrial settings.
Solution Approach 2:
Instead of using device-specific models to infer energy consumption (as in conventional NILM), the patent inverts the approach by using centrally measured total consumption combined with process sequence information to determine individual process consumption. This reversal eliminates the need for device-specific modeling while maintaining accuracy.
3Measurement precision
If ground truth data collection through direct measurements is performed, then measurement precision is improved, but loss of time and productivity increase due to production interruptions
Solution Approach 1:
The patent eliminates the need for preliminary ground truth data collection that requires production interruptions. By using process sequence information from the control system, the measurement can be performed continuously during normal production without requiring separate calibration phases or stopping the production line.
Data Source
AI summary
A method includes the low-complexity ascertainment of process-related energy consumption information for a plurality of automated processes based on measurement data which have been recorded for all of the processes. The energy consumption profile of the plurality of processes is matched to sequence information of the individual processes and changes in the energy consumption of the plurality of processes are assigned to the individual processes based on the sequence information thereof. Energy consumption information for the individual processes is then determined based on changes in the energy consumption of the plurality of processes assigned to the respective processes. A device, a system, a computer program and a computer program product are also provided.