Intelligent Lighting Solutions for Industrial Plants

I.Overview

 Illumination power consumption is the most fundamental electricity usage in industrial production. The quality of the lighting system is directly related to the production safety, labor productivity, product quality, and even labor protection in industrial production. At the same time, the lighting control in factories is related to production costs and production efficiency. An excellent lighting system can not only provide lighting control but also minimize electricity costs to the greatest extent.
  In traditional lighting-controlled factories, the energy-saving measures are basically limited to using energy-saving lamps or electrodeless lamps. Various problems often arise, such as insufficient illuminance range and the inability of lamps to automatically determine whether to turn on or off based on the environment. The old intelligent lighting systems also have problems such as a small control range, fixed selectable modes, few controllable lamp types, low compatibility with third-party devices, and system crashes directly affecting the normal use of lighting. This not only fails to reflect the benefits of energy conservation but also increases maintenance costs and goes against the customers’ lighting needs, affecting production efficiency!

II. Demand Analysis

2.1 Characteristics of Industrial Plants

Industrial plants generally have high building structures and large spans. The installation height of lamps is high, the lighting space is large, and there are many lamp circuits. The workshop is a high-demand area for lighting in the factory, and it is an important part for normal production in the workshop. Unmanned intelligent control needs to be achieved at different times. If ordinary lighting control methods are used, the cost and construction difficulty will increase significantly. Intelligent lighting can reasonably control different areas and time periods, and cooperate with illuminance and infrared sensors to make full use of natural light, achieving unmanned intelligent control and reducing costs, rationally using electricity, and achieving energy conservation and emission reduction.

2.2 Components of Intelligent Lighting Control System

– Intelligent control system input devices (monitoring computer, intelligent control panel, touch screen, illuminance sensor, infrared sensor)
– Network communication system (switch, intelligent lighting bus, PC server, gateway)
– Intelligent control output devices (switch control module, dimming control module)

2.3 Intelligent Lighting Control Methods

– Scene control
  In the workshop, the lighting area can be controlled through the scene control panel according to the pre-set scenes. It can be defined as on, off, or delayed, such as automatically turning off after a certain time after turning on.
– Timed control
  The lighting can be turned on and off according to the normal working hours, so that the lights can be turned on and off at fixed times.
– Infrared motion and illuminance sensor control
  The lighting in the workshop can be automatically controlled by infrared motion sensors, and the lights can be turned on and off in response to the illuminance detected by illuminance sensors. At the same time, the working state can be changed through the central monitoring computer according to actual needs.
– Local panel control
  Each lighting area can not only be automatically controlled (timed or by computer), but also provide local control to facilitate manual control of the lights when special situations occur.
– Centralized switch control
  Through the monitoring software with graphical display on the central monitoring computer, a simple and clear graphical interface is provided for the end user, making it easy for non-professionals to control the on and off of each light or each group of lights.
– Interconnection with other systems
  Through interfaces, it can be interconnected with other systems (such as fire protection and security systems), and the entire lighting system can be controlled for each lighting control point according to specific needs.
– Remote control
  According to needs, the working status of the entire lighting system can be remotely monitored through the Internet or mobile phones.

III. Design Principles

3.1 Advancedness and Applicability

While the technical performance and quality indicators of the system reach the leading level in China, it ensures that the installation, debugging, software programming and operation of the system are simple and easy to master, and have the characteristics suitable for this project. The intelligent control system network technology adapts to the requirements of the times. At the same time, the system can be used for various management levels. The configuration of our system functions is based on providing users with comfort, safety, convenience and speed, and the operation is simple and easy to learn.

3.2 Economy and Practicality

This system fully considers the actual needs of users and the trend of information technology development. According to the user’s on-site environment, a system configuration plan suitable for the on-site situation and meeting the user’s needs is designed. Through strict and organic combination, the best performance-price ratio is achieved to save the user’s engineering investment. At the same time, it ensures the implementation of system functions and achieves the purpose of economy and practicality.

3.3 Reliability and Safety

In the design, the principle of high starting point, high quality and high reliability is followed. After a system failure or accident causes the system to crash, it can ensure the accuracy, integrity and consistency of the data, and has the function of rapid recovery. At the same time, the system has a complete set of management strategies to ensure the safe operation of the system.

3.4 Openness and Standardization

Open and standardized technology enables air conditioning, ventilation and lighting equipment in buildings to be easily integrated into one platform. This will greatly reduce personnel training and equipment maintenance costs, improve energy utilization, and provide value-added services by collecting and sharing a large amount of real-time equipment operation and capital consumption data. The open system uses standardized protocols such as TCP/IP and LonWorks, which are compatible with almost all systems on the market and can be integrated into the same network architecture. Therefore, engineers can customize solutions based on actual conditions. Our system is not limited to the technology of one supplier, giving you more choices.

3.5 Expandability

The system design takes into account the future development of technology and usage needs, and has the possibility of update, expansion and upgrade. It can also expand system functions according to the actual requirements of future project engineering. At the same time, redundancy is left in the scheme design to meet the future development needs of users.

3.6 Pursuing the Optimal System Equipment Configuration

Under the condition of meeting the user’s requirements for functions, quality, performance, price and service, we pursue the optimal system equipment configuration to minimize the user’s system cost.

IV. System Scheme Design

4.1 Workshop

– Induction control: Install illuminance sensors to automatically turn on and adjust the brightness of the lights according to the outdoor light source illuminance.
  – Time control: Automatically turn on or off the lights according to different times, such as: during working hours, the TJSMC intelligent lighting control system will provide sufficient illuminance for the workshop; after work, the system will automatically turn off some lights or dim the brightness. If someone works overtime, it will be changed to manual control to avoid energy waste.
  – Multi-point control: Due to the large area of the factory workshop, multi-point control of the same area lights is required to facilitate the daily use of personnel. All lighting circuits in the area are connected to the control system, and control panels can be placed at each entrance to achieve this.

4.2 Warehouse

– Induction control: Install illuminance sensors and human body sensors. When someone enters the warehouse, the TJSMC intelligent lighting control system will automatically adjust the light to the preset brightness according to the outdoor light source illuminance measured by the illuminance sensor. This can effectively avoid energy waste.
  – Security control: The TJSMC intelligent lighting control system can be linked to the alarm system. Install gas sensors in the warehouse. When flammable gas is detected, the exhaust fan will be automatically turned on, and the alarm device will be activated if necessary. Install human body sensors and smoke sensors. When someone intrudes into the room or a fire occurs during non-working hours, the alarm device will be activated immediately to prevent unnecessary harm.
Temperature and humidity control: Install temperature and humidity sensors in the room. When the set temperature and humidity values are exceeded, the system will automatically alarm so that the staff can handle it in time and avoid unnecessary losses.

4.3 Open-plan Office Area

– Zoning Control: Due to the large office space for employees, the entire employee office area can be divided into several independent lighting zones. Scene control switches can be used to turn on the lighting in the corresponding areas as needed.
  – Multi-point Control: With multiple entrances and exits, multi-point control within the office area is achieved for convenient operation. At each entrance and exit, all the lights in the entire office area can be turned on and off, allowing for convenient control of the lights in the office area from nearby locations as needed.
 

 – Time Control: Lighting can be controlled based on time. For example, the lights can automatically turn off at 8 p.m. on regular days. If someone is working overtime, the system can be switched.

4.4 Executive Office

– Scene Control: Multiple adjustable light sources are used. Different lighting scenes can be created by presetting different combinations of brightness and darkness through the system, maintaining a consistently soft and elegant lighting environment in the office (such as office, meeting, and relaxation scenes). Touch screens or mobile phones can be used for control, and the desired lighting scene can be called by simply pressing a scene button.
  – Curtain Control: Curtains can be automatically opened or closed based on different scene requirements.
  – Temperature Control: Temperature and humidity sensors are installed, and the system will automatically adjust the air conditioning temperature based on preset values, maintaining the most comfortable and energy-efficient indoor temperature in the office.

4.5 Canteen

– Sensor Control: Illuminance sensors are installed to automatically turn on and adjust the brightness of the canteen lights based on the outdoor light intensity, avoiding energy waste.
  – Time Control: Different lighting scenes are preset according to the factory’s work schedule (such as “dining” scene, “normal” scene, “cleaning” scene, etc.), and the system will automatically switch scenes at different times.
  – Manual Control: Intelligent panels are installed in the canteen for manual control in special circumstances.

4.6 Dormitory

– Sensor Control: Illuminance sensors are installed to automatically turn on and adjust the brightness of the dormitory lights based on the outdoor light intensity, avoiding energy waste.
  – Combination of Automatic Control and Manual Control: During working hours, the system will automatically turn off the dormitory lights to prevent energy waste due to employees forgetting to turn off the lights. If necessary, the lights can be manually turned on.

4.7 Bicycle Shed and Underground Garage

– Sensor Control: Motion sensors and illuminance sensors are installed to achieve the function of lights turning on when someone enters and turning off with a delay when they leave, in case of insufficient brightness.

4.8 Bathrooms, Public Corridors and Staircases

– Sensor Control: Human body sensors and illuminance sensors are installed to achieve the function of lights turning on when people approach and turning off with a delay when people leave in low light conditions.
  – Manual Control: Manual control panels are provided at each entrance and exit to manually control the local lighting fixtures as needed.

4.9 Square

– Scene Control: Pre-set scenes can be switched to change different scenarios, such as “Festival” scene, “Performance” scene, and “Ordinary” scene.
  – Time Control: Some lights can be turned off at scheduled times. For example, at midnight when it’s quiet, the system will automatically turn off some lights.

V. Superiority of Intelligent Lighting

5.1 Realization of Intelligent Lighting Control

After adopting an intelligent lighting control system, the lighting system can operate in a fully automatic state. The system will switch between several basic working states as pre-set and automatically transition between various working states according to the pre-set time. Additionally, a manual control panel can be used to meticulously pre-set lighting scenes based on different times of the day and different purposes. When in use, only the pre-set optimal lighting scene needs to be called up, creating a novel visual effect and allowing for the adjustment of the illuminance in each area as desired.

5.2 Significant Energy-Saving Effects

Apart from providing a comfortable environment for personnel, energy conservation and reduction of operating costs are another important concern for factory owners. The intelligent lighting control system can achieve energy savings by rationally managing the illuminance settings for different dates and times based on the operational status of each functional area. It ensures that lights are turned off when not needed and that in most cases, not all lights in many areas need to be fully on or at maximum brightness. The system can provide the most comfortable lighting with the most economical energy consumption. It guarantees that lights are only turned on when necessary or reach the required brightness, significantly reducing the energy consumption of office buildings.

5.3 Extended Lamp Life

The fatal cause of lamp damage is excessive voltage. The higher the working voltage of a lamp, the shorter its lifespan. Conversely, a lower working voltage leads to a longer lifespan. Therefore, appropriately reducing the working voltage of lamps is an effective way to extend their lifespan. The intelligent lighting control system can successfully suppress grid impulse voltages and surge voltages, preventing lamps from premature damage due to these reasons. It can also artificially set voltage limits through the system to increase lamp lifespan. The system employs soft start and soft shut-off technologies, avoiding thermal shock to the filament and further extending the lifespan of lamps. The intelligent lighting control system can successfully extend the lifespan of lamps by 2 to 4 times. This not only saves a large number of lamps but also significantly reduces the workload of lamp replacement, effectively lowering the operating costs of the lighting system.

5.4 Comprehensive Control

The intelligent lighting system can be monitored through the intelligent lighting monitoring server in the central control room. For example, it can provide information on the current working status of each lighting circuit, set and modify scenes, and control the entire system and issue fault reports in case of emergencies. It can also be connected to other control systems within the factory, such as the security system or fire protection system, through gateway interfaces and serial interfaces. In case of an emergency, all circuits can be forcibly turned on.

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