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Enabling an Intelligent Planet
Segmented Business Units Powered by
Global Trusted Brand
The Global Leader of Embedded &
Automation Solutions for iWorld System
Integrations
Industrial Automation
Business Group
Intelligent Services & Applied Computing
Business Group
Embedded Design-In Services
Business Group
Design & Manufacturing Services
Business Group
2010 Consolidated Sales : US$696M
研華公司企業簡介
企業使命 : 智能地球的推手
智能工廠與各項設備自動化的挑戰
• 能夠對設備的能源耗用進行透明的描述
• 進而提出對設備能源耗用的最佳化
• 速度與精度的要求以提升產量與產質
• 生產線製程管理的信息化, 網路化, 圖像化
及遠端監控與維護
• 生產機器設備的視覺檢測功能需求
• 製造技術智能化的趨勢
• 無線技術發展,物聯網概念, etc.
Energy Management The two most important levers to reduce energy costs
Total costs
Energy consumption
En
erg
y r
ate
s
Reduce energy consumption
Identify losses
Identify inactive reserves
Motivation initiatives
for power saving
Utilization optimization
Reduction in pause times
Optimizing procurement
Short-time contracts (e. g. per year)
Modification of the rate system
(e. g. time-varying rate system; time-of-use
rate)
Counteract increasing energy procurement
costs
Internal energy generation
targets here: • offers transparency on energy data • show optimization and cost reduction potentials
primarily offers energy planning and -procurement, bilancing (also CO2) and ad-hoc calculations of key parameters (KPI).
Energy Management Crucial questions by the plant operator
Energy quantity? Energy flows?
Transparent depiction of the TOP consumers
Costs? Per consumer? Per batch?
Optimal procurement / energy planning / demand profiles?
Reduction of the energy demand and the costs?
Gas
Water
Electricity
Heat
Where are potential savings?
Where and how can I purchase energy at the lowest price?
What are my energy unit costs? Energy costs per consumer?
What energy type is required and in what quantity?
What consumers require the most energy?
Detailed information mostly not available today!
Energy Management International standard ISO50001
Adjustment &
control
Management
Review
Energy Policy
Planning
Implementation
and operation
ISO 15001: Continous improvement process
Correction and
prevention
DIN EN 16001
Monitoring &
measuring Internal Audit
Begins at Top-Management
Strategy, energy policy,
sustainability
Budget, targets
Controlling
Efficiency-Projects
Is an ongoing task to improve
efficiency
Process, employee, quality control
Technical and legal aspects
Is more than just a technical system!
Energy-Management …
Energy Management is more than just a technical system!
Services for
optimization along the
whole energy value
chain, from the
production of energy up
to the consumer.
Energy Services
Technical system for the
col-lection, analysis,
documen-tation and
visualization of energy data
as well as regu-lation and
controlling of energy
consumption in plants and
buildings.
Energy Management System
Energy efficiency means
re-ducing energy
consumption without
having to reduce the use
of energy consuming
plants and equipment.
Energy Efficiency
EM enables companies to determine, improve and analyze systematically and
continuously their energy consumption. Within this optimization process
economic as well as technical and legal aspects have to be considered.
Definition Energy Management
The Comprehensive Approach Energy Management as 3rd Pillar
Operations Maintenance Energy Management
Continuous Performance Monitoring
Compare: setpoint / actual (Learn modus)
maintenance based on the actual condition
Coherent Automation
in Factory Automation
in Process Automation in Infrastructure
Automation
Energy Circle:
Identify
Evaluate
Realize
New
Energy Management Integrated system solution
Operation (FA) Maintenance / Diagnose Energy Management
Factory Automation Process Automation Storages etc.
Seamless integrated system
Operation (PA)
The Energy Management Storyline fitting the complete Energy Management process
Three steps to Energy Efficiency
Accompanied Consulting
Energy Monitoring System
Measurement, display energy flow
Cost center allocation, energy costs per production unit
SIMATIC WinCC & SIMATIC powerrate & Sentron PAC
Energy Management System
Cost Transparency, Monitoring & Reporting
Show reserve of energy (oversizing)
Interfacing SIMATIC IT (MES)
Products, Systems and Solutions
Drive Systems
Peak Load management with SIMATIC powerrate
Energy Planning and Procurement
Preparation / Consulting
Energy Check / Analysis
Energy Optimization Services
Documentation and action plan
Continuous Process
Energy Management EM Functionalities related to system
Reporting
Planning
Procurement
Visualization
Archiving
Load Mgt.
Compressing
Data Aquisition
Communication
Energy Management System
– Easy integration in any control system environment via
standard interface or Ethernet (Modbus TCP / OPC)
– Full integration of energy management systems, e. g.
Seamless system integration
System integration as a standard
Integration Example
Connection of Power Meter through filed
bus to reduced the cable cost
Connection of the control to the
operation and monitoring level via
Ethernet
Energy curves provide transparency
Load curves Benefit
Identification of Deviations that could be
challenged Optimization potentials,
e. g. domestic production of high loads Peak loads Energy consumption
outside of production times Create “energy
awareness”
Performance diagram
Load curve
04 11 18 25 30 01
Month (=720h)
March 2011
Reports for energy transparency
Cost center reporting Benefit
Well arranged representation of cost centers and
energy costs
Comparability of different consumers or consumer
groups, e. g. production lines
Graphical representation of energy data and costs
MS Excel based, adaptable report templates
Transparent consumer
costs
Identification of
optimization levers
between different
consumers and groups
Controlling of
optimization progress
and measures
Adaptable to own
requirements
cost center report cost center report
Load management
Load management „cuts off“ the peaks Benefit
Avoids peak loads by automated switching off and on consumers, typically in attendant facilities
Processing of additional user defined conditions possible (AND combination)
Integrated warning and alarm messages Max./Min. on and off times configurable Consumers to be switched off and their capacity can be
configured, consumer groups and rotating consumers
Avoids peak loads and ensures compliance to contracts Reduction of the
load limit Reduction of energy costs Equal use of
consumers
Leistungsdiagramm 11.04.2007
0
500
1000
1500
2000
2500
3000
00:0
0
00:4
5
01:3
0
02:1
5
03:0
0
03:4
5
04:3
0
05:1
5
06:0
0
06:4
5
07:3
0
08:1
5
09:0
0
09:4
5
10:3
0
11:1
5
12:0
0
12:4
5
13:3
0
14:1
5
15:0
0
15:4
5
16:3
0
17:1
5
18:0
0
18:4
5
19:3
0
20:1
5
21:0
0
21:4
5
22:3
0
23:1
5
t
kW
15„ Periode
trend analysis
consumer
Energy Management overview
Emission Energy balancing
Energy billing
Batch related balancing
Energy planning
€ / $
CO2 kWh kWh
kWh/kW
Energy and material balance – KPI calculation
Calculation Level III
Excel Calculations pre-defined
in the report template
Result presentation
Calculation Level II
Calculation Level I
Database based calculations
(supported by pre-defined objects)
Date Management
Powerful Online Calculation Core
Interface Management
Energy planning
Basic load profile
Scaling up/down
+/- n % +
External effects
+/- n MW +
Production planning
Units/time +
Production planning
On/off +
Ge
ne
ral fo
rec
as
t
Emission monitoring CO2
Emission =
Material usage × emission factor × oxidation
factor
Fuel
Raw material
Emission
Products
Production
process
Measuring Standard factors
Yes to energy management - but sustainable!
Sustainable energy data management in several
steps Creation
transparency
Costs-by-cause-based
accounting
Process
optimization
Operation
optimization
Installing measuring
points
Represnting the
energy flow
Identifying
potentials uses
Visualizing
Documenting
+
Continuos improvement Process
+ =
Allocating
energy costs
to cost centers
Energy cost per
production unit
Energy flow per
production unit
Automatic load
management
Identify power
dristribution
reserves
Data exchange
with process
control
systems
Optimizing
energy
procurement
Optimizing
energy costs
Phase 1 Phase 2 Phase 3 Phase 4
智能工廠未來趨勢 - 從替代體力到替代腦力的設備自動化
智能
製造
智能感知
先進製造技
術與管理 資訊傳遞
能源耗用
Sensor
Application Communication
Management
VFD Inverter
Internet/Intranet/Ethernet
Advantech Energy Management Solution Architecture
Remote
WebAccess
IE Client
WebAccess
MMI/ SCADA
Backup
WebAccess
HMI/ SCADA
Primary
Measurement meter –
power/ Heat/ Gas meter
BEMG-4110/
4220
(Concentrator)
Energy (能源管理)
BAS-3500 DDC
Controller
BACNet
MS/TP
Building Management (空調及機電自動化)
BAS-3000
Remote IO
• BEMS
- Energy Analysis
- Energy Reports
- Cost Analysis
- Cost Report
Advantech
BEMS (SQL/
Access Database)
Modbus
RTU
BAS-3000
BACNet IO
BACNet IP Modbus TCP
3rd party
DDC
Modbus
TCP
BAS-3000
BACNet IO
BACNet
MS/TP
Modbus TCP
General Certification Vertical Designs
Ha
rdw
are
So
ftw
are
Solu
tio
ns
Automation Devices & Computing Application Specialized Products
Fully Integrated Solutions
Internet of Things (IoT) Products
Green Energy Water/ Environment Factory Automation BA/BEMS Production Automation
研華工業自動化事業群產品及解決方案
研華在智能製造設備自動化的願景 與合作伙伴共同成為智能製造的推手
並且作為設備自動化解決方案的提供者
MES in the Factory/ Plant Cloud
Embedded Platform(IPC / Board)
With SUSIAccess HMI
PC-Based
Machine
CNC
Machine PLC-based
Machine
Real-Time
Ethernet
control
Sensor
Motion Control
(VB / C++ ..) CNC control
(CNC logic)
PAC control
(Soft-logic )
雲端運算
/
先進製程管理
資訊傳遞
智能感知
智能感知 智能製造設備自動化-智能感知
RS-485
I/O Device
IEC-61499 I/O Device
Ethernet
I/O Device
Motion Device
WSN
I/O Device
Video Device
BACNet Device
Integrated I/O Controller
PAC
Device server
Fieldbus Master
DDC
Controller
Motion
Controller
Wi-Fi PoE Switch
USB
Device
Managed Switch
Profinet EtherCAT Modbus/
TCP ModBus/RTU
Internet Internet
AMONET
IEC-61499
ProfiBus Ethernet/IP PowerLink
IEC-611131
I/O Card
Motion
Card
PAC I/O Device
Serial Comm.Card
Unmanaged Switch
Data Gateway
Embedded Automation Computer
3G/GPRS
資訊傳遞
OP
C-U
A
Smart device
ADAM
device
PoE
device
Ethernet device
Motion device
Wireless device
WSN device
Video device
PLC device
BA device
Controller+I/O
PAC
Device server
Fieldbus master
DDC
Controller
Gateway
Motion
Controller
3G,WIFI
WiMAX PoE Switch
USB
device
M. Switch
Switch
IEC-61499
UNO
智能製造設備自動化-資訊傳遞
廠務 (水/電/氣供應端)
設備1 設備 2 設備 3 設備 4
高單價component 管理 幫浦 /馬達 …等
幫浦 or 馬達訊號
設備訊號
廠務訊號
先進製程控制 系統資料庫 資料庫用途:
主要依照資訊的歷史來做為未來“預測性”判斷的指標
先進製程管理 智能製造設備自動化-先進製程管理
先進製程管理
目的:
• 提高生產設備投資報酬率
• 穩定工廠生產的產品品質及良率
• 即時有效通報及監控生產機台的製程狀況
• 提升工程師監控設備機台的效率
• 提供“充足的”機台製程資訊,進而改進生產品質
• 加強競爭力
相關市場研究開發 : • APC (Advance Process Control)
• TPM (Total Predictive Maintenance)
• iMCMs (intelligent Machine Condition Monitoring system)
智能製造設備自動化-先進製程管理
研華產品用於先進製程資料的收集 Operator Station
• SCADA/HMI function
• Video Surveillance
- Video Recording/Playback
- Camera remote PTZ control
- Video Motion Detection
先進製程 Database
APC Smart TPM iMCMs
WebAccess Graphic Display
資料蒐集器 資料蒐集器 資料蒐集器
Meter … Sensor…
Sensor…
Serial
Meter … 電力Source
ADAM-3112/3114 AC 比壓器/比流器 Module
Ethernet I/O ADAM-5000/TCP
Ethernet I/O ADAM-6000
Serial Device Server
Sync