A Tool for Semi-Automated Extraction of Cotton Gin Energy Consumption from Power Data

The gin stand power is measurable using common tools; however, such tools typically do not detect active ginning. Detecting active ginning is important when trying to separate out the energy going to the moving parts of the gin stand (i.e., the baseline energy) versus the active energy doing work to remove the cotton fibers from the seed. Studies have shown that the gin stand is the second largest consumer of electricity in the ginning operation, while electricity accounts for nearly 17% of the average expense per bale. If active energy differences exist between cotton cultivars, there may be room to optimize and lower these expenses. The goal of the current work is to provide a method (and software tool) to analyze typical power logger data, and extract periods of active ginning, along with the energy consumed and ginning times, in a semi-automated way. The new method presented allows multiple periods of active ginning in a single file, and can separate the total energy into the active and baseline components. Other metrics of interest that the software calculates include the ginning time, and average power. Software validation using a simulated test signal showed that a 2%-or-lower error is possible with a noisy signal.