1. Report on New Automation Technologies Incorporating Humanlike Abilities, with Results of Testing on a Photoelectric Sensor Production Line
Core Technology Department, Technology Development Headquarters,
Azbil Corporation
Yutaka Harada
We have developed an active compliance device which mimics some of the abilities of the human hand, and a servo vision system which mimics some of the abilities of the human eye. These technologies were tested as part of automated equipment on the production line of the HP7 photoelectric sensor. In comparison to conventional equipment, the automated equipment was more effective in terms of quality, cost, and delivery. Making these technologies more humanlike may assist in goals such as the recovery of domestic production in Japan and the automation of overseas production. This paper describes the technologies and the results of testing.
2. A Photoelectric Sensor with Automatic Sensitivity Adjustment
Recent social and economic changes have caused customers of photoelectric sensors to redouble their efforts to make their equipment and facilities more cost competitive and to improve the quality of their products. To assist in these goals, Azbil Corporation has developed a general-purpose photoelectric sensor which has the most commonly used sensor shape; is easy to install and adjust without specialized training, while retaining reliability for worry-free use; has a long service life; is energy-efficient; and is equipped with automatic sensitivity adjustment.
3. A Data Collection and Management System for Trends in Energy Demand
We have developed a centralized system to better understand trends in energy demand by major gas consumers. The system can collect and manage data on gas demand through wireless communication or other means. This paper reports on battery-driven technology that is easy to install and manage, making small-scale automatic meter reading possible.
4. An Intelligent Emergency Shutdown System in Case of Earthquake
With earthquakes occurring more frequently in recent years, business continuity planning (BCP) has gained momentum in the manufacturing industry. The challenge for BCP in improving earthquake response measures is to suspend and restore manufacturing equipment operation quickly and safely, in order to ensure the safety of human life, the environment, and the equipment. Against the background of this challenge, a system for detecting an earthquake and suspending the operation of manufacturing equipment was a desideratum. This paper reports the development of the “Intelligent Earthquake Emergency Shutdown System” by our company as a BCP solution. It also reports on the performance of an intelligent earthquake sensor used by Tokyo Gas Co., Ltd., during the Great East Japan Earthquake.
5. New Trends in Batch Process Control
Development of a Model-Based B2B (Batch to Batch) Control for Precise Reaction Temperature Control
Through activity in the field to resolve actual process control problems, Azbil Corporation has developed a model-based batch-to-batch (B2B) control system for industrial batch polymerization processes. In order to precisely control the reaction temperature, several methods based on a rigorous polymerization process model were used at each design stage of the B2B control system. For example, adaptive adjustment of the model according to actual batch operation results is one of the most important features of the design. The B2B control system consists of gain-scheduled I-PD/II2-PD (I-PD with double integral) control, feed-forward compensation, and the B2B model modification mentioned above. In actual batch operations, B2B control provides superior control performance compared to conventional control systems. We are currently working to apply this methodology to a wider variety of systems, and to commercialize a toolbox for B2B control system design.
6. Construction of a Desiccant System Simulator
Building Systems Company,
Azbil Corporation
Yasuhito Oomagari, Suguru Ito
Waseda University
Seiichi Yamaguchi, Kiyoshi Saito
Desiccant air conditioners are often installed in manufacturing plants where a low dew point is required. They are designed to deal with high humidity load in the summer, and in many plants they are operated at full capacity continuously even during the winter. This often results in wasted energy consumption due to excessive dehumidification. Therefore, we can expect energy savings by introducing a control system to eliminate excessive dehumidification. However, introducing appropriate control is difficult because the behavior of a system is complicated. In this study, we constructed and evaluated a simulator to understand the dynamic behavior and energy characteristics of the system. We found that we can operate a system in a dynamically stable and energy-saving dehumidification mode-by controlling the regeneration air flow rate and the rotor rotary speed.
7. Diagnostic Techniques for Cavitation in Building Air-Conditioning System Control Valves
Valve Production Development Department,
Azbil Corporation
Ryosuke Kinoshita, Shinichi Tsunoda
When cavitation occurs in control valves installed in hot or cold water pipes in air-conditioning systems, noise and vibration caused by the generation and collapse of air bubbles may negatively affect living areas. If control valves are continuously used in this condition, serious malfunction, such as external leaking, may occur due to cavitation erosion. Hence, it is desirable to diagnose cavitation in control valves while the air-conditioning system is in operation. This paper describes our diagnostic technique for cavitation, which focuses on the characteristics of cavitation within control valves in order to supply the valves with a cavitation diagnostic function.
8. Development of Cloud Services for Electric Power & Energy Savings
Building Systems Company,
Azbil Corporation
Takashi Koyanagi, Koji Higashijima, Hiroshi Onodera
Core Technology Department, Technology Development Headquarters,
Azbil Corporation
Tomohiro Konda, Tasuku Imanishi
A controller with advanced algorithms, such as an energy-saving control for a building air conditioning system, has conventionally been expensive, resulting in doubts about the return on investment, and installation that has been limited mainly to large buildings. We therefore developed cloud-based services which connect remote servers with client buildings and factories using dedicated communication lines. High-level algorithms on the servers are used to achieve energy savings, etc., at the buildings from the remote location. With this service, we can provide many buildings with systems and functions that were previously difficult to install, such as a variable water temperature (VWT) system with a learning function, and power-prediction functions.
9. Visualizing the Energy Performance of an Air Handling Unit Using a Control Valve That Measures and Controls Flow Rate
Building Systems Company,
Azbil Corporation
Keita Satou, Ryouta Dazai
Valve Production Development Department,
Azbil Corporation
Motohiro Furuya, Ryosuke Kinoshita
In order to achieve energy savings in a building, it is necessary to understand the energy performance of the air handling unit, to identify a system that will improve energy performance, and to provide specific countermeasures. By including a function for measuring the flow rate in the control valve installed in each air handling unit, we have made it possible to gain a detailed understanding of the energy use of the air handling unit at a lower cost and with less construction work. Moreover, we have worked out the logic for using obtainable energy data to extract areas where measures are needed to improve the air handling unit’s energy performance. Verification was carried out in Building 100 of our Fujisawa Technical Center, and effectiveness was confirmed.
10. Control Logic That Maintains a Difference in Water Temperature between Fan Coil Unit Inflow and Outflow While Keeping Living Areas Comfortable
Building Systems Company,
Azbil Corporation
Takahiro Kido, Junpei Tahara, Naomichi Oki
This paper reports our development of fan coil unit (FCU) control logic that maintains a water temperature difference between FCU inflow and outflow while ensuring comfort in the residential area. In the actual application of conventional FCUs, it is understood that the temperature difference that was anticipated at the design stage will not always be maintained. Failure to maintain the difference causes too much water to flow through the FCU and causes inefficient operation of the heat source, resulting in energy loss from the entire air handling system. The logic reported in this paper resolves this problem and maintains indoor comfort at the same time.
11. Seeking Dependable, Safe, and Comfortable Living: Technical Integration Trials in the azbil House
Business Development Department, Home Comfort Headquarters,
Azbil Corporation
Masayuki Iwata
The azbil House, a laboratory for air-conditioned comfortable living, has opened as the flagship research and publicity facility of the azbil Group’s Life Automation business, and as an expression of the Group’s philosophy of seeking safety, comfort and fulfillment in people’s lives, and contributing to global environmental preservation. We describe the aims of this facility and the synergy therein of the technology and services of each business entity in the azbil Group.
