Intelligent lighting design of dairy industrial plant

With the rapid development of intelligent lighting technology, DALI digital dimmable technology came into being. However, DALI dimmable technology is still widely used in traditional buildings and office spaces, and has not been promoted in food production workshops. The main reason is that the food production workshop has higher requirements for the technology of lamps and lanterns, and at the same time, it can meet the requirements of the food workshop technology and supports DALI protocol. With the continuous development of DALI technology and the successful application in traditional office buildings, as well as the increasing emphasis on energy saving and emission reduction by countries and enterprises, the promotion of DALI digital dimmable technology in factory workshops is imperative.

Intelligent lighting design of dairy industrial plant

1 Design difficulties

The layout of the dairy industrial plant is relatively complex, and the joint workshop is the most representative. It has the characteristics of large area, high ceiling, many function rooms, different cleanliness levels, and many lighting application scenarios.

Take the filling unit of a joint workshop of a liquid milk factory in Yili as an example, the construction area of ??a single filling room is about 900m2, and the ceiling height is 9-10m, as shown in Figure 1. The equipment, pipes and bridges of different heights are arranged in the room. In order to use natural light as much as possible and save energy consumption, natural lighting is set on the side walls and top. The operation status of the equipment is roughly divided into operation, stop, cleaning and maintenance. Considering the expansion factors of the factory, it is generally necessary to set up reserved spaces in different process sections of the pretreatment unit. These spaces are not equipped with equipment in the early stage of the factory operation. The factory runs continuously for 7×24 hours.

Based on the above characteristics, our traditional loop control, schedule control, personnel presence control, illuminance control, and automatic combined manual control scheme no longer meet the actual use requirements, nor can we achieve the most ideal energy-saving effect. This poses a challenge to the scheme design. How to use limited investment to meet the needs of use and achieve at least 10% energy saving is a problem we solve in the scheme design stage.

2 Design principles

We used to deal with as an example, the equipment area is designed according to 200Lux illuminance, and more than 130 120W LED lamps are selected. In order to ensure uniform illuminance and cover the top of equipment, pipe racks and bridges, and to meet the maintenance requirements, the lamps are uniformly distributed, and part of the working surface is partially illuminated. However, in the actual use process, we found that during the daily production operation, some lamps do not need to be lit, or do not need to operate at maximum brightness. This causes a waste of energy and a reduction in the life of the lamp, and the illumination cannot be constant. If it is solved through management means, then the staff needs to frequently switch on and off the lamps and lanterns.

In order to solve the actual problems, we take energy saving, illuminance and humanization as design principles.

3 Software and hardware design

We must clarify the following key points when designing the plan:

(1) Single lamp can be controlled;

(2) Dimmable;

(3) With centralized management function;

(4) Dimmable according to regional illumination;

(5) Flexible control strategy and manual control function;

(6) Any lamp can be freely combined, and lamps can be grouped quickly with the adjustment of equipment layout and adjustment between functions.

Set up a lighting server in the central control room to upload the data of the building automatic control system to the centralized lighting management platform. The upper management software platform supports both C/S (Client-Server) and B/S (Brower-Server) architecture, which can be accessed through a browser or installing a client.

DALI lamps, sensors and light control panels are connected in series or free topology in hand. The DALI bus uses RVSP2×1.5, the longest distance does not exceed 300m, and is finally connected to the DALI lighting controller. The controller is connected to the factory control special network through the Ethernet line and is managed by the central control room. The touch screen is directly connected to the control network via an Ethernet cable.

DALI intelligent lighting can realize the dimming of each lamp, at the same time can realize the control of lamps in any combination area, and the circuit can be freely combined in the later period without changing the on-site hardware. Upwards, you can directly access the upper-level monitoring network or a third-party platform through OPC, BACnet/IP, LON-IP852 and other network protocols to achieve integration. Using this method can make the lighting control architecture more concise, and the digital signal is not easily interfered. The DALI signal is not polarized, and it can be co-managed with strong electricity, and the construction and wiring are more convenient.

According to the comparison data, it can be seen that the total annual electricity consumption when not using smart lighting is 1,937,624 kWh (kW·h), and the total electricity cost is 1,646,981RMB; and the total annual electricity consumption after using the DALI intelligent lighting system It is 1,114,134 kWh (kW·h), and the total electricity cost is 947,014 RMB. By comparison, we can save 826,490 kWh (kW·h) of electricity annually, save 699,967 RMB in electricity costs, and achieve an energy saving rate of 40%. The energy saving effect is remarkable.

In addition to the significant energy-saving effect, we can also realize the operation time recording of the lamp, the calculation of the theoretical power consumption of the lamp, the preventive maintenance of the lamp, the fault alarm and other functions through the recording, analysis and alarm functions of the system platform software, which provides great management convenience. Due to the single lamp dimming mode, the measured lamps do not need to operate at 100% illumination, which indirectly improves the life of the lamps and prolongs the replacement period of the lamps and saves a certain maintenance cost for the factory. In the future, with the adjustment of the production line, we can quickly complete the deployment of lamps through software grouping.

Applying DALI digital dimming technology in industrial plants to realize lighting control automation and intelligent operation. Through energy-saving optimization control measures such as customized schedule control, mode control, induction control, and illumination control, good energy-saving benefits have been achieved, and it has a high promotion value for the design and implementation of intelligent lighting in other plants.

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