Intelligent lighting is in line with current national policies and the actual needs of enterprises
The demand for intelligent lighting control in industrial production
Green energy conservation - With the country's carbon neutrality policies and the demand for green environmental protection and energy conservation, factories, as major industrial electricity consumers, have made energy conservation and emission reduction an important evaluation indicator in their operational management. Whether it comes to air conditioning or lighting, clear energy consumption monitoring and management are required.
Stable system - With the progress of productivity and the upgrading and transformation of enterprise production, there is also a need to upgrade the production lighting environment, such as meeting the requirement for standard illuminance.
Operational and maintenance costs - Reducing the time spent on lamp inspection and maintenance can bring lower labor costs to enterprises, thereby truly increasing their profits.
Lighting control - The panel supports scene control, group control and dimming functions.
Commercial confidentiality and security - According to the needs of different enterprises, it can not only achieve intelligent upgrading, but also meet high-level confidentiality and security standards.
Construction difficulty
We need a system that allows us to control lights through circuit grouping. It should be able to measure the current illuminance, adjust the light brightness to ensure that the current brightness reaches the standard, and at the same time, statistically analyze energy consumption so that we can timely understand and adjust the lighting configuration.
Project background
The multi-circuit grouping control and dimming of lighting can effectively help factories improve energy efficiency.
The integrated factory is divided into multiple factory areas, where thousands of high-power ceiling lights are installed. The products manufactured in the factory attach great importance to the brightness of the lights, so the brightness for employees' work needs to be designed in a standardized manner. With the continuous improvement of LED technology and control technology, our team is also researching new control solutions to improve lighting in large spaces such as factories, simplify maintenance, and reduce costs.
According to the production needs of different factory areas, grouping and scenario-based adjustments can be made, and the panel can be used for convenient operation.
However, in order to meet customers' needs for commercial confidentiality, the factory imposes restrictions on devices connecting to the Internet. Therefore, it is necessary for the control system to be deployed locally, and the local devices and systems should be capable of being maintained, monitored, and updated.
The challenges encountered
Construction area
As an extra-large high-bay production workshop with an area of 20,000 square meters and 1,000 working condition lamps installed, it poses great difficulties in construction and commissioning.
Stability
For the lighting control in factories, stability is of paramount importance. Any control failure can lead to huge losses in factory production. Therefore, Fenglian must come up with a better control solution to guarantee "zero" accidents in factory lighting.
Bringness smart control
Factories require standard light illuminance, meaning that the light illuminance in every workshop must meet a uniform standard. To achieve this, intelligent dimming via a control panel or backend system is necessary, which can adjust for factors such as light depreciation of lamps and changes in ambient brightness.
Operation and Maintenance
Factories attach great importance to commercial confidentiality and security. All data must be stored locally and must not be connected to the Internet, which poses significant challenges to the control of smart devices and OTA upgrades.
Devices install
Gateway
Based on the area, the number of lamps, and considering the equipment environment of the factory area, our engineers have selected Zigbee technology. Each gateway can cover an area of 300 square meters and support more than 50 end nodes, while achieving stable control effects.
1-10V Wireless Bridge box
First, we conducted a one-month test on the relevant industrial and mining lamps and intelligent controls. Meanwhile, we actively gathered insights from factory employees, administrators, and equipment maintenance personnel to understand the factory's specific needs and areas for improvement. We evaluated the quality of the lamps' light output, dimming capability, and ease of use, and ultimately chose our 1-10V controller paired with Philips LED driver modules.
Light Sensor
To meet the requirement for illuminance, we used Fenglian's light sensors and conducted on-site detection of the factory environment. We designed installations of illuminance sensors at multiple locations to achieve the best results in detecting light conditions that align with human visual perception. The data is then wirelessly transmitted to the gateway, which in turn dims or turns off the lights to maintain the standard ambient light level.
In response to the customer's confidentiality system, we have designed a local deployment solution using our BEELOCAL system, which enables intelligent control, smart large-screen displays, energy consumption analysis, and web-based operation and maintenance management locally. Through the system, the service life of lamps can be monitored, and replacement lamps can be prepared before significant light depreciation occurs, thereby reducing maintenance time. Meanwhile, with the authorization of the owner, it facilitates OTA upgrade management.
Beesmart Six Key Control Panel
By using the upgraded "Little Black Box", real-time monitoring of lighting energy consumption is achieved. Lamps can be assigned to smart lighting scene groups, supporting pre-set control schedules and scene-based controls to achieve energy-saving effects. For example, non-operating workshops can be dimmed or turned off, and only the corresponding lamps in infrequently used areas need to be turned on, instead of having all lamps on.
The data from energy consumption analysis helps save energy and improve the comfort of workers' working environment. It is estimated that through reasonable planning, grouped lighting control, dimming, and scene schedule management, under the premise of ensuring adequate lighting in the employees' production environment, electricity consumption can be reduced by 32% annually (estimated based on simulated usage scenarios). Dimming lights and grouped switching can save the factory 20% of costs, including lamp wear and tear as well as man-hours for manual maintenance.
Lighting Control
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