Tagged Energy Data Allocation for Industrial Process Optimization
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Solution Overview
Problem
Current industrial energy management systems lack direct incentives to reduce energy consumption on the plant floor, as energy costs are fixed and not measurable against production volumes, and existing tools primarily focus on overall facility energy data without real-time production-related information.
Innovation Solution
An industrial control system that monitors sustainability factors like energy across industrial processes and associates them with manufacturing models, such as a bill of material, to optimize and mitigate energy usage by tagging data to specific process portions, enabling real-time or offline analysis for energy efficiency improvements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If energy costs are fixed allocations without measurement against production volumes, then facility-wide energy management is simple, but plant floor energy efficiency cannot be optimized
Solution Approach 1:
The patent segments energy consumption data by associating it with specific bill of materials components and production processes. Energy data is divided and allocated to individual products, process steps, and equipment units, enabling granular analysis and optimization at the plant floor level rather than facility-wide averages.
2Area of stationary object
If existing tools focus on overall facility energy data, then macro-level energy monitoring is achieved, but real-time production-related energy information is unavailable
Solution Approach 1:
The system segments energy monitoring into facility-wide and product-specific levels. By tagging energy data with bill of materials identifiers and process information, the system provides both macro-level facility monitoring and micro-level product-specific measurements simultaneously.
Solution Approach 2:
The patent introduces an intermediary layer that connects facility-wide energy data with production records. This intermediary associates energy consumption with specific bills of materials, process steps, and equipment, translating macro-level data into actionable production-level insights.
3Ease of operation
If there are no direct incentives on the plant floor to reduce energy consumption, then operational simplicity is maintained, but energy cost reduction is limited
Solution Approach 1:
The patent implements feedback mechanisms by providing energy consumption information directly to production operators and planners through bills of materials. This feedback enables operators to see the energy impact of their decisions and make real-time adjustments to reduce energy costs while maintaining production targets.
Solution Approach 2:
The system enables self-service energy management by providing production teams with the tools and information to independently analyze and reduce their own energy consumption. Operators can identify energy-intensive processes and make optimization decisions without requiring external energy management intervention.
Data Source
AI summary
An industrial control system is provided. The system includes tagged data that is collected from a plurality of sustainability factor-associated data sources across an industrial automation environment, where the tagged data is associated with a portion of a process that is attributed to the sustainability factor data sources. A manufacturing model is associated with the tagged data, where the manufacturing model is employed to enhance the efficiencies of the process.