Production Line Start-Stop Controller for Energy Reduction
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Solution Overview
Problem
Current production lines lack efficient energy-saving and environmentally friendly start-stop systems, leading to significant energy wastage during downtime, as existing control technologies and architectures are inadequate for seamless shutdown and restart processes.
Innovation Solution
A centralized or decentralized start-stop controller system that integrates energy and machine controllers, using fieldbuses or Ethernet for data transmission, manages energy and media supplies to enable automatic and efficient startup and shutdown of production lines, with defined sequences and timer controls to minimize energy consumption and ensure smooth operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the production line is shut down during downtime, then energy consumption is reduced, but restarting the production line becomes complex and time-consuming
Solution Approach 1:
The control system performs preliminary actions during the shutdown phase by automatically executing a predefined restart sequence. The master controller stores and retrieves startup parameters and machine states, preparing the system in advance for rapid restart without manual intervention, thus reducing both energy waste during downtime and restart complexity.
Solution Approach 2:
The production line control system serves itself by automatically managing the shutdown and restart processes. The master controller autonomously coordinates all machines and processing units, eliminating the need for manual operator intervention during restart, thereby simplifying operation while enabling energy-efficient shutdowns.
2Productivity
If all systems remain fully operational during downtime, then immediate production resumption is enabled, but large amounts of energy are wasted
Solution Approach 1:
The control system dynamically adjusts the operational state of machines and processing units based on the anticipated downtime duration. For short downtimes, systems remain in a reduced-power ready state; for longer downtimes, they enter deeper shutdown modes. This dynamic adaptation enables immediate resumption when needed while minimizing energy waste during extended idle periods.
Solution Approach 2:
The master controller changes operational parameters of connected machines and processing units based on downtime predictions. Parameters such as power consumption levels, media supply rates, and machine readiness states are adjusted according to the expected duration of interruption, optimizing the balance between energy savings and production resumption speed.
3Loss of energy
If a start-stop system is implemented for the production line, then energy efficiency is improved, but the control architecture and energy supply infrastructure become more complex
Solution Approach 1:
The master controller is designed with multi-functionality, serving both as the central production line controller and as the start-stop system controller. By integrating the energy management functions into the existing master controller architecture, the system achieves improved energy efficiency without adding separate complex control infrastructure, thus minimizing the increase in device complexity.
Data Source
Figure 1
AI summary
The invention proposes a method and an arrangement for controlling a production line (1) generally having a multiplicity of processing units or machines (2,3,4) which are controlled, via a master controller (11), using data provided by a production planning system (12). In addition to a machine controller (5), each machine (2,3,4) contains a power controller (6) which is supplied with data by a master power controller (10) as part of the master controller (11). The master controller (11) is provided with a master machine controller (16) which is extended with functions for starting and stopping the production line (1) such that a current production process of the production line (1) is concluded such that an automatic restart can be carried out after the production line (1) has been at a standstill. Furthermore, the master power controller (10) is designed with functions for starting and stopping the production line (1) such that the power for the individual machines (2,3,4) is increased and decreased in a defined manner, with the result that an automatic restart can be carried out after the production line (1) has been at a standstill.