WO2014016188A1 - Control device for the energy-efficient operation of a process system and/or production system - Google Patents

Control device for the energy-efficient operation of a process system and/or production system

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Publication number
WO2014016188A1
WO2014016188A1 PCT/EP2013/065145 EP2013065145W WO2014016188A1 WO 2014016188 A1 WO2014016188 A1 WO 2014016188A1 EP 2013065145 W EP2013065145 W EP 2013065145W WO 2014016188 A1 WO2014016188 A1 WO 2014016188A1
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WO
Grant status
Application
Patent type
Prior art keywords
process
control
device
energy
production
Prior art date
Application number
PCT/EP2013/065145
Other languages
German (de)
French (fr)
Inventor
Dominic BUCHSTALLER
Jörg HASSEL
Johannes Reinschke
Original Assignee
Siemens Aktiengesellschaft
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date

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Classifications

    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B13/00Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion
    • G05B13/02Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric
    • G05B13/04Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric involving the use of models or simulators
    • G05B13/047Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric involving the use of models or simulators the criterion being a time optimal performance criterion
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00Programme-control systems
    • G05B19/02Programme-control systems electric
    • G05B19/418Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
    • G05B19/41865Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by job scheduling, process planning, material flow
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LELECTRIC EQUIPMENT OR PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES, IN GENERAL
    • B60L11/00Electric propulsion with power supplied within the vehicle
    • B60L11/18Electric propulsion with power supplied within the vehicle using power supply from primary cells, secondary cells, or fuel cells
    • B60L11/1809Charging electric vehicles
    • B60L11/1824Details of charging stations, e.g. vehicle recognition or billing
    • B60L11/1838Methods for the transfer of electrical energy or data between charging station and vehicle
    • B60L11/1844Methods for the transfer of electrical energy or data between charging station and vehicle the charging being dependent on network capabilities
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00Program-control systems
    • G05B2219/10Plc systems
    • G05B2219/15Plc structure of the system
    • G05B2219/15125Multiple kernels
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00Program-control systems
    • G05B2219/20Pc systems
    • G05B2219/22Pc multi processor system
    • G05B2219/2205Multicore
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00Program-control systems
    • G05B2219/20Pc systems
    • G05B2219/26Pc applications
    • G05B2219/2639Energy management, use maximum of cheap power, keep peak load low
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00Program-control systems
    • G05B2219/30Nc systems
    • G05B2219/32Operator till task planning
    • G05B2219/32021Energy management, balance and limit power to tools
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/70Systems integrating technologies related to power network operation and communication or information technologies mediating in the improvement of the carbon footprint of electrical power generation, transmission or distribution, i.e. smart grids as enabling technology in the energy generation sector
    • Y02E60/72Systems characterised by the monitored, controlled or operated power network elements or equipments
    • Y02E60/721Systems characterised by the monitored, controlled or operated power network elements or equipments the elements or equipments being or involving electric vehicles [EV] or hybrid vehicles [HEV], i.e. power aggregation of EV or HEV, vehicle to grid arrangements [V2G]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/10Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes
    • Y02P70/16Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes related technologies for metal working by removing or adding material
    • Y02P70/161Power management, e.g. limiting power to tools
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P80/00Climate change mitigation technologies for sector-wide applications
    • Y02P80/10Efficient use of energy
    • Y02P80/11Efficient use of energy of electric energy
    • Y02P80/114Control systems or methods for efficient use of energy
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/60Other road transportation technologies with climate change mitigation effect
    • Y02T10/70Energy storage for electromobility
    • Y02T10/7072Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T90/00Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02T90/10Technologies related to electric vehicle charging
    • Y02T90/12Electric charging stations
    • Y02T90/121Electric charging stations by conductive energy transmission
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T90/00Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02T90/10Technologies related to electric vehicle charging
    • Y02T90/12Electric charging stations
    • Y02T90/128Energy exchange control or determination
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T90/00Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02T90/10Technologies related to electric vehicle charging
    • Y02T90/14Plug-in electric vehicles
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T90/00Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02T90/10Technologies related to electric vehicle charging
    • Y02T90/16Information or communication technologies improving the operation of electric vehicles
    • Y02T90/163Information or communication technologies related to charging of electric vehicle
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y04INFORMATION OR COMMUNICATION TECHNOLOGIES HAVING AN IMPACT ON OTHER TECHNOLOGY AREAS
    • Y04SSYSTEMS INTEGRATING TECHNOLOGIES RELATED TO POWER NETWORK OPERATION, COMMUNICATION OR INFORMATION TECHNOLOGIES FOR IMPROVING THE ELECTRICAL POWER GENERATION, TRANSMISSION, DISTRIBUTION, MANAGEMENT OR USAGE, i.e. SMART GRIDS
    • Y04S10/00Systems supporting electrical power generation, transmission or distribution
    • Y04S10/10Systems characterised by the monitored, controlled or operated power network elements or equipment
    • Y04S10/12Systems characterised by the monitored, controlled or operated power network elements or equipment the elements or equipment being or involving energy generation units, including distributed generation [DER] or load-side generation
    • Y04S10/126Systems characterised by the monitored, controlled or operated power network elements or equipment the elements or equipment being or involving energy generation units, including distributed generation [DER] or load-side generation the energy generation units being or involving electric vehicles [EV] or hybrid vehicles [HEV], i.e. power aggregation of EV or HEV, vehicle to grid arrangements [V2G]

Abstract

The invention relates to a control device (12) for a process system and/or production system (14), comprising a signal input for receiving at least one characteristic value (d2, d3) of at least one component (34) of the process system and/or production system (14), and a main processor (16), which has a memory, in which a predetermined automation instruction is stored, wherein the control device (12) has an energy monitoring apparatus (24) for recording at least one energy consumption value (d1) of the at least one component (34), and the main processor (16) is designed to determine a model for the process system and/or production system (14) during operation of the process system and/or production system (14), on the basis of the automation instruction, the characteristic value (d2, d3), and an energy consumption value (d1) recorded by means of the energy monitoring apparatus (24) at at least one time before the operation of the process system and/or production system (14).

Description

description

CONTROL DEVICE FOR ENERGY EFFICIENT OPERATION OF A PROCESS AND / OR PRODUCTION PLANT The present invention relates to a control device for a process and / or manufacturing facility. Moreover, the present invention relates to a process and / or production facility. Finally, the present invention relates to a method of operating a process and / or Fertigungsan- would.

Control devices for process and / or production plants, for example, by the company Siemens under the product name "SIMATIC S7" known. Control devices of this kind make it possible to regulate the operating variables of individual components of a system, thus for example of conveyor belts, filling or rolls, or the components or switch. aggregates themselves in order to disable, for example, whenever they are not needed. the control apparatus of such a system may be connected via an external communication bus, for example, according to the standard Profinet to the periphery, ie with the control units of the aggregates themselves or with sensor and actuators to the system. About the external communication receiving input signals, the control device then concerning current parameters of the system. These inputs can be for example measurement signals of the sensor units. Other constraints of the the state quantities of the individual components, which may also be transmitted from the control units via the communication bus to the control device.

For economical and optimized energy management of process and / or manufacturing facilities energy management solutions such as B.Data by Siemens are known. These solutions focus or are currently limited to the visualization and automatic documentation or report generation of energy flows. This may include con- version into corresponding measures, such as the C0 2 emissions include. Simple energy consumption forecasts as

Basis for optimized power purchasing can also be calculated with energy management solutions such as B.Data. Suitable solutions to an energy consumption optimization can be conducted online, is currently unknown.

It is an object of the present invention, zess- a process and / or to operate manufacturing system more energy efficient.

This object is achieved by a control apparatus according to claim 1 and by a process and / or production plant according to claim. 8 In the same manner the object is achieved by a method having the features of patent claim 10. Advantageous further developments of the present invention are given in the subclaims. The control device according to the invention for a process and / or production line comprises a signal input for receiving at least one characteristic of at least one component of the process and / or production line, and a main processor having a memory in which a predetermined automation rule is stored, wherein the control device, a power monitoring means for detecting at least one energy consumption value of the at least one component, and the main processor is configured to, during operation of the process and / or manufacturing facility on the basis of automation provision of the characteristic variable, and a means of the energy monitoring means at at least one point in time before the operation process and / or manufacturing plant energy consumption value acquired to determine a model for the process and / or manufacturing facility.

The control device comprises a control device with the main processor and the coprocessor. The control means may detect the characteristics or operating parameters of the components or units of the process and / or production facility. The parameters can include process-relevant data or measured values ​​of the individual components. In addition, the control device includes a power monitoring device, with which the power consumption of the individual components can be detected. The additional energy monitoring device can be formed by the already described energy management solutions B.Data. sierungsvorschrift a corresponding automation or a basic configuration can be entered via an engineering station.

The main processor detects the inputted basic configuration, the characteristic values ​​and past values ​​of energy consumption and creates a current dynamic model of the plant. For example, a specified by the manufacturer energy usage profile for each component can be selected on the engineering station. With the control apparatus, the model of the process and / or production facility may be end adapted to the basic configuration, so are based, that it matches with the detected characteristics. The control device has the advantage that it can be easily integrated into an existing process control system of a process and / or manufacturing facility.

Preferably, the control device includes a coprocessor having a plurality of cores for parallel calculating at least one manipulated variable for the at least one component as a function of the characteristic size and the Automatisierungsvor- writing on and the main processor controls the coprocessor to compute the at least one manipulated variable as a function of the model process and / or production plant and a predetermined optimization criterion. A control device having a main processor and a coprocessor with multiple cores, is known from the patent application of the applicant with the internal character

known 201129202nd With a processor core is in this case the difference to a full processor, and more particularly to a processor core, meaning that it is an electronic circuit which eingerich- exclusively for performing a limited number of arithmetic operations is tet. With the main processor, the input signals of the components of the process and / or manufacturing facility can be received. These can in a memory for the Kopro- cessor so stored that the cores can process the stored signals. Actual encryption processing of the input signals, which leads to the generation of the control signals or at least intermediate sizes for further calculation of the output signals is thus done by the cores of the coprocessors. The main processor is only for coordinating the calculations and, where appropriate, for the loading of the control signals from the intermediate sizes expected necessary, which requires both a relatively low computing power. Thus it is. B. possible to provide a coprocessor having 16 or more cores, in particular with more than 100 cores, with these coprocessor controlling the main processor in the control device. On the main processor, a real-time operating system can be brought to the end. The main processor supplies the coprocessor arithmetic problems. In one embodiment, the control device is adapted to the NEN calculated in dependence on a detected by means of the energy monitoring means during operation of the process and / or production facility power consumption value at least one manipulated variable with the coprocessor additionally. From the model for the plant, the optimization criterion, the current process-relevant data and the characteristic quantities and the current energy consumption value, the control device may determine a manipulated variable or a result. This power management problem involves online ER- summed up model of the process and / or manufacturing facility and an optimization criterion and an optimization goal. With the main processor processes the data correspond based on the target hardware. For example, an appropriate formulation of the problem in the form of appropriate data structures for the calculation on the cores. The control device may use a mathematical optimization procedure to determine the energetically optimal operating condition of the individual components of the system.

In another embodiment, the control device is adapted to transmit the at least one manipulated variable to the at least one component. The control device and a signal output of the control device can be coupled to the process automation system of the plant such that the calculated by the control device energetically optimal operation state from the process automation system can be adjusted automatically. the units or components may direction the tax regulations, in the case of a smaller electric energy consumer, which consists of several units or components directly, for example by setting desired values ​​or limits control with respect to energy consumption or power consumption.

Alternatively or additionally, the control device is adapted to transmit the at least one control signal to a display and / or operating means of the process and / or production facility. When the process and / or production anläge formed for example as industrial plant, a plant operator or an operator as the energetically optimum operation condition of the plant can be displayed. The plant operator can then adjust by hand the plant. In one embodiment, the co-processor is adapted to at least in addition anläge a manipulated variable in response to a predetermined for a predetermined period of energy consumption of the process and / or production line, from a predetermined throughput of the process and / or production and / or from a at least to calculate utilization of one component. In the optimization criterion can be considered as a constraint that an energy consumption of the plant, for example, in a period of 15 minutes is not exceeded. Further, in the optimization criterion energy efficiency or the throughput increase can be considered. Thus, the process and / or manufacturing facility can be operated optimally necessary, depending on the application.

the cores of the coprocessor are preferably each formed as FPGA and / or GPU. The control device can can be used as massively parallel computing unit as a FPGA or GPU board be formed. The coprocessor can in this case have several hundred to several thousand cores, wherein the cores can each have access to a memory of more than 100 kilobytes to several megabytes. For the control device as a massively parallel processing unit, there are two hardware technical implementation options. First, the control device can be designed as a plug-in module for a process automation system. This allows a designed for industrial environments Hardwarelö- solution and thus a faster, safer and more reliable data communication with the process automation system. On the other hand, the control device can be designed as plug-in module for an industrial PC, which is connected via an OPC interface to the process automation system. This makes it possible enables a more cost-effective hardware development, as it can be made of current graphics cards are available as a mass product on the market.

The process according to the invention and / or production system environmentally summarizes the control device described above. In one embodiment, the process and / or production facility is designed as a station for electric vehicles. The components of the system may be formed by the individual charging points or charging by this points feeding converter. As optimization criterion, the maximum power supply capacity of the gas station can here be considered. The inventive method for operating a process and / or production system includes receiving at least one characteristic of at least one component of the process and / or production plant, storing a predetermined automation provision to a memory of a main processor of the control device, detecting at least one energy consumption value of the at least one component by means of a power monitoring device to the control device and determining a model for the process and / or production plant by means of the main processor during operation of the process and / or manufacturing facility on the basis of automation provision of the characteristic variable, and a means of the energy monitoring means at at least one time prior to the operation of the process and / or production system detected power consumption value.

The advantages and developments described above in connection with the inventive control device can be transferred equally to the inventive process and / or manufacturing facility and the inventive method.

The present invention will now be explained in more detail with reference to the accompanying drawings. They show:

1 shows a schematic representation of a control device of a process and / or production facility;

2 shows a schematic representation of a process and / or production facility;

3 shows a schematic representation of a process and / or production line in a further embodiment; and

4 shows a schematic representation of a process and / or manufacturing plant of an electric steel plant. The closer follow-described embodiments represent preferred embodiments of the present invention. 1 shows a control device 10 of a control device 12 of a process and / or manufacturing system 14 in a schematic representation. The controller 10 comprises a main processor 16 and a coprocessor 18. The only shown schematically here coprocessor 18 includes a plurality of cores. The individual cores can thereby as a graphics processor - be designed graphics processing unit (GPU) or FPGA (Field Programmable Gate Array).

2 shows a system 14, which may be from a manufacturing plant, a process plant or a combination thereof. At installation, it may be for example a rolling mill and an associated treatment line, a plant for processing of foods and beverages, a pulp and paper factory, a power plant, an industrial furnace, a cement factory, a chemical plant or a refinery, or a act petrochemical plant.

The process and / or manufacturing system 14 comprises a plurality of components 34, each of the components 34 can perform at least one process step. In a process and / or

Manufacturing facility 14 are commonly found several hierarchical levels of process control and automation. In a process scheduler 20, the Execu- tion system is referred to as management, production sequence or the specific production plan is determined. The production plan is then passed to a guide means 22 of the process and / or manufacturing facility 14, which has the task to control the process so that the conditions laid down in the production plan products are produced in the right order at the right time with the right quality. The bulkhead 22 includes the process automation and the basic automation. Process automation records the parameters of the process and / or production facility 14. The parameters may include the processing progress, noise or the like. Here, the functions operating data and machine data collection be considered. Process Automation reacts with appropriate changes in process control dynamically to variations in parameters captured from their desired values.

Furthermore, the process and / or production system 14 includes the controller 12, processing through the Steuereinrich- 10 and a power monitoring device is formed 24th The power monitoring device 24 may be formed by the system B.Data Siemens with corresponding extensions. The energy monitoring means 24 detects cyclically every relevant for the solution of energy management problem parameters and / or energy

dl consumption values ​​and passes them to the controller 10th

The power monitoring device 24 may include an interface 26 through which can be specified the objective of energy management and energy optimization means of the control device 10, or at least modified. The

Interface 26 may be an extension to the system B.Data. Also can foundry via the interface 26, the generated energy energy cost savings or increased throughput by better utilization of the energy consumption quota and displayed or are automatically recorded and documented. Instead of the interface 26 of the power monitoring device 24 also includes an interface 28 of the drying apparatus 20 can Prozesspla- or an interface 30 of the guide can be used. This is schematically shown in Fig. 3 The controller 10 sends the to be displayed, or data to be processed to the respective interface 26, 28, 30. If the control device 12 is to be used for a smaller ren electric power consumers, the existing and advanced features of B.Data described above can also be in the controller 10 are integrated. The control device 12 performs the function of an online model and parameter identification. First, a basic function is k, provided by means of a display and / or Bedienein- direction 32, which is also referred to as an engineering station and transmitted to the control device 10th Based on this basic function k detected in the main processor 16 of the control device 10, the past energy consumption values ​​dl and d2 and d3, the parameters. The parameters d2 and d3 the process-relevant data from the bulkhead 22 and the process scheduler comprise 20. The controller 10 creates a current dynamic model of the process and / or production facility 14. For example, by means of the display and / or operating means 32 a specified by the manufacturer energy consumption profile be chosen for certain of the components 34th The control device 12 is then based on this basic configuration, adjust the energy consumption profile so that it matches the recorded measurement data.

Furthermore, can be performed with the control device 12 is a synthesis of the online energy management to be solved the problem. The energy management problem comprising the model of the process and / or manufacturing system 14 and an optimization mierungskriterium p and an optimization goal. The power management problem is processed by the main processor 16 such that the can be passed from the parallel cores of Kopro- zessors 18th The preparation includes the creation of an efficient formulation of the problem, based on which the cores to carry out the calculation.

When the cores are formed as a GPU, for example, is an appropriate formulation of the problem in the form of appropriate data structures as vectors and matrices, and so-called "compute kernel" necessary to onli- runtime ne be created. The same applies to the embodiment of the cores are created as FPGA in data structures and possibly also the configuration of the FPGA online be adapted to the problem. Finally, an online calculation of the optimization or energy management problem with the controller 12 carried out. it is based on the model of the Pro - zess- and / or manufacturing facility 14, the optimization criterion p, actual energy consumption values ​​dl of the components 34 and the characteristic values ​​d2 and d3 and the current process-relevant data from the process automation and process planning device calculates a result using the control device 10 20 the optimization criterion. p is from En ergieüberwachungseinrichtung 24 transmitted to the control device 10th Also, the current energy consumption values ​​dl are detected by the power monitoring device 24 and transmitted to the control device 10th

The result may include the optimum production sequence. In addition, the result may contain an optimum switching sequence of the components 34, with a predetermined energy quota is not exceeded. Moreover The result may comprise a production plan, the zess- the throughput in compliance with a predetermined energy consumption of the process and / or production line 14 for a predetermined period (e.g., 15 minutes) is maximized. Alternatively, the result may comprise a production plan that minimizes the cycle time with respect to the predetermined power consumption of the process and / or production line 14 for a predetermined period of time. In the result, all optimization goals mentioned above can be combined. In FIG. 4, the operation of the control device 12 is illustrated a process and / or production line 14 on the example of an electric steel plant. An electric steel plant comprising in the simplest case an electric arc furnace 36 for melting metal. Furthermore, the electric steel plant includes a ladle furnace 38 for alloys. The liquid steel, which is produced by the electric steel plant may be used directly in a subsequent casting plant 40th In order to increase throughput, but the components are designed 34 of an electric steel plant several times in practice, which operate in parallel in the production flow. Since steel production is very energy intensive, a volume contract is made typically with egg nem power company, which covers a certain amount of energy per 15- minute interval. If this pre-determined amount is exceeded, high overdraft fees are due. If the amount is not reached, the steel plant operators must nevertheless pay the the specified amount of energy. It is therefore in the interest of the operator of the electric steel plant to exploit fully the previously negotiated amount of energy per time, but never exceed. Therefore, the underlying energy management problem is as follows: The objective is the maximum utilization of the negotiated 15-minute energy quota by selective switching of dominant energy consumers, such as the electric arc furnaces 36 and / or the ladle furnace 38. In addition to the

Cycle time can be minimized. Furthermore, the following additional conditions to be met: The order of the necessary process steps must correspond to the physical reality. The transition times between the process steps must be in a physically realistic, predetermined range. For example, too long a transition time results in too large a cooling of the melt. In addition, can no longer be edited as a certain amount of steel per process step. be Moreover, the continuous casting plant 40 must always involve a predetermined amount of material provides. Finally, the maximum electric power may not be exceeded.

In operation of the electric arc furnace is with the power monitoring device 24 via a configuration model, the energy management problem that the objective and the constraints comprising specified and sent to the main processor 16 of the controller 10th In addition, based on a preset automation task and past process data for a current model of the plant, ie, the arc furnace 36 and the oven pan 38 created. As in the present embodiment, the arc furnace 36 more than once, the model for the respective arc furnace 36 can be different. The main processor 16 then reads all the information necessary for calculating the information from the power monitoring device 24, process scheduler 20 and the guide 22 have been transferred to it from. This information can be a aktuel- les optimization goal, a process order, a current assignment of the components 34, current disorders, an available amount of power, current processing times (as long as a charge is already processed already in the ladle furnace 38) include a current power consumption and the like. This infor- mation be passed to the main processor 16 together with a corresponding formulation of the optimization criterion p parallel to the cores of the coprocessor 18th

When the calculation is finished, the result of the main processor 16 of the parallel cores of the coprocessor 20 is sent read 18 and planning device as the manipulated variable E to the process. This result includes specific response times for consumers and the time production process, eg. As the dates for taps. In addition, the decisions taken by a Analgenfahrer based on the calculation result now influence the further process flow and lead to a new operating state of the process and / or manufacturing facility 14. This Analgenzustand then after a certain cycle time by re-reading the information from the Energy Monitoring device 24, the process scheduler 20 and the guiding means 22 detects the part of the main processor 16 and processed again. This cyclical process is repeated indefinitely.

Mathematically, the described energy management problem in the electric steel plant as a "job-shop scheduling" problem formulation. This problem is in the literature a standard dardpro ​​lem, which is a generalization of the problem of the traveling salesman. This problem can be solved in a simple known manner be. the problem belongs to the class of NP-complete problems, that it is extremely difficult to solve the problem at hand and requires very powerful computing hardware. at the basic complexity is the fact that the computational problem in a short time, eg., 5 seconds This combination must be online to be solved in order to respond quickly to current events in the process. of a complex computational problem and high demands on the real-time capability of the energy management solution results in a calculation volume, not with conventional solutions, such. as a PC can be managed with multi-core processor. Therefore, it is absolutely not nimble on highly parallel computing cores, as described in connection with the control device 12 according to the invention to resort.

Claims

claims
1. Control device (12) for a process and / or production system (14) with
- a signal input for receiving at least one characteristic value (d2, d3) of at least one component (34) of the process and / or production system (14), and
- a main processor (16) having a memory in which a predetermined automation rule is stored,
characterized, in that
- the control device (12) includes a power monitoring device (24) for detecting at least one energy consumption value (dl) of the (34) comprises at least one component, and
- the main processor (16) is adapted, during operation of the process and / or production system (14) based on the automation provision of the characteristic variable (d2, d3) and a means of the energy monitoring means (24) at at least one time prior to the operation of the process and / or production system (14) power consumption value detected to determine (dl) a model for the process and / or production line (14).
2. Control device (12) according to claim 1, characterized thereby marked, that the control device (12) comprises a coprocessor
(18) (having a plurality of cores for parallel calculating at least one manipulated variable (s) for the at least one component (34) in dependence on the characteristic variable (d2, d3) and the automation provision and Hauptpro- cessor (16) the coprocessor 18) controls the calculation of the at least one manipulated variable (e) in dependence on the model of the process and / or production system (14) and a predetermined optimization criterion (p).
3. Control device (12) according to claim 2, characterized in that the control device (12) is adapted to the at least one manipulated variable (s) with the co-processor (18) additionally while in response to a gieüberwachungseinrichtung means of energy (24) the operation of the process- and / or production system (14) detected energy value to be calculated.
4. Control device (12) according to claim 2 or 3, characterized in that the control device (12) is adapted to at least transfer the at least one manipulated variable (e) a component (34).
5. Control device (12) according to one of claims 2 to 4, characterized in that the control device (12) is adapted to the at least one manipulated variable (e) to a display and / or operating device (32) of the process and / to transmit or manufacturing plant (14).
6. The control apparatus (12) according to one of claims 2 to 5, characterized in that the coprocessor (18) is adapted to the at least one manipulated variable (e) additionally as a function of a for a predetermined period of pre-given energy consumption of the process and / or manufacturing plant (14), from a predetermined throughput of the process and / or production system (14) and / or to calculate a workload of the at least one component (34).
7. Control device (12) according to one of claims 2 to 6, characterized in that the cores of the coprocessor (18) are each formed as FPGA and / or GPU.
8. Process and / or production system (14) with a control device (12) according to any one of the preceding claims.
9 is process and / or production system (14) according to claim 8, characterized in that the forming process and / or production system (14) designed as charging station for electric vehicles.
10. A method of operating a process and / or production plant (14) by - receiving at least one characteristic value (d2, d3) of at least one component (34) of the process and / or production system (14), and
- storing a predetermined automation provision to a memory of a main processor (16) of the control device (12),
marked by
- at least detecting a power consumption value of the at least one component (34) by means of a power monitoring device (24) of the control device (12), and
- determining a model for the process and / or production system (14) by means of the main processor (16) during operation of the process and / or production system (14) based on the automation provision of the characteristic variable (d2, d3) and a power monitoring device by means of the (24) at at least one time prior to the operation of the process and / or production system (14) detected power consumption value (dl).
PCT/EP2013/065145 2012-07-25 2013-07-18 Control device for the energy-efficient operation of a process system and/or production system WO2014016188A1 (en)

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