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Energy in Factory Automation and the Role of Industrial Networks

September 10, 2014

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Discussion Agenda

Cost of EnergyThe Role of Industrial NetworksEnergy Usage Reporting StandardizationControlling UsageSmart Grid Connection CIP Energy OverviewApplications

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Cost of EnergyKnowing when and where energy is used is importantAccording to the DoE and eia the industrial sector uses about 1/3 of the energy in the US.

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Cost of EnergyStudies suggest that 15-30% may be saved overall

Profinet International Study– Measurements were taken in an automotive

assembly plant to determine the amount of energy that could be saved during downtime.

– It suggested that up to 60% of the total energy used during production may be consumed during downtime.

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Cost of Energy

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Cost of EnergyMost of the electrical energy consumed is for electrical motors– As of 2012 only 28% of low voltage motors are

classified as high-efficiency.– By 2017 high-efficiency low voltage motors should

account for 62%. – 96% of the total cost of ownership for a motor is

the electrical energy usage, leaving 2% for the purchase cost and 2% for maintenance.

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The Role of Industrial NetworksAspects of energy management– Monitoring energy usage.– Controlling the amount of power a machine may

use at any given time.– Powering down when the machine is not active.

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The Role of Industrial NetworksMany of the industrial protocols have support for energy:– PROFINET has a profile for energy monitoring and

power control.– EtherNet/IP has objects for monitoring and power

control (production and idle states).– Sercos III has a profile for monitoring and power

control.

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Energy Usage Reporting Standardization

Common reporting unit: kWh.– Report the total energy consumption within the

plant in kWh.– Many energy types: steam, chilled water,

natural gas, oil, etc. may be reported in kWh.– Allows reporting of the total energy usage

within the machine regardless of energy sources (cost per widget).

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Two approaches– Power down unused devices and machines.– Run the device at a lower power level during

production.• Running the device or machine at a lower

power level may not save overall energy cost per widget, but would reduce the energy usage for a given period of time, for example at peak demand.

Controlling Usage

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Powering down devices should ideally be done during breaks– E.g. lunch, weekends, scheduled and

unscheduled maintenance.– Machine is idling.

Factors to consider– How much time is required to bring back up

the device after shutting down.– The energy used to shut down and start up, is

it less than remaining powered up?

Controlling Usage

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Running at a lower power level during production– May be applied as an attempt to keep peak

energy consumption below a certain point for a specific pay period (due to overage penalties).

– External environment factors ( transformer problems, overloaded grid, etc.).

– Power source changes (coal, wind, solar, etc.).

Controlling Usage

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Connection solutions could come in the form of gateways– Provide translation between Industrial

Networks and Smart Grid Networks (e.g. IEC 61850).

– The approach allows for a firewall between the utilities provider and the factory floor.

Smart Grid Connection

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CIP Energy Overview

Connections

Objects architecture

Message Router0x02

Identity0x01TCP/IP Interface

0xF5

Ethernet Link0xF6

Assembly0x04

ConnectionManager

0x06

Assembly0x04

Assembly0x04

Non-ElectricalEnergyObject

Electrical EnergyObject

Base EnergyObject

IO EM

Assembly0x04

Unconnected Msg Connected MsgEtherNet/IP

ParametersObjects

ParametersObjects

ParametersObjects

Power Management

Object

EnergyCurtailment

Object

Application Objects

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Monitoring concepts: Base Energy, Electrical and Non-Electrical objects

CIP Energy Overview

Base Energy Object

Electrical Energy Object

Non-Electrical Energy Object

(0 .. 1)

Associated Base Energy Object Path

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Base Energy Object normalizes all data to kWh’s and/or kW’s

• Range: 999 terawatts hours to watts hours, 15 digits of accuracy.

• kW’s are reported as a 32 bit real. Electrical Object has specific electrical attributes for example

• Reactive Power, total and per line.• Active Power, total and per line. • Phase / Line Frequency.• Current Average, line to line and line to neutral.• Voltage Average, line to line and line to neutral.• Etc.

CIP Energy Overview

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Non-Electrical Object may be used for any energy type– For example:

• Natural Gas, Compressed Air, Fuel Oil, Tallow.• Provision for custom energy types.

– Reports energy in native units, translated to kWh’s via the Base Energy Object.

– Attributes are provided for conversion math.• E.g. 1 kWh = ((1 Gallon of Diesel * 383)/10).

CIP Energy Overview

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Base Object may have a number of types

CIP Energy Overview

Energy Source

Power monitor Line or department

Energy measured

Overload relay Motor amps (measured)

Energy derived

Voltage (assumed)

Generic deviceEnergy proxy

Software application

Energy aggregated

Parent/child relationship Specified using EPATHs

Controller or Translator

Power supply 300W

Energy fixed

Infeed VFD

Heating element

Machine controller to line

controller

Power supply

Non-CIP servo

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Power Management Object– The purpose of this object is to bring the

machine/device to a lower power state (non operational).

– Time based, the longer the pause time the higher potential energy savings.

– May support many levels of pause depending on the device.

– The possible states are Owned, Paused, Sleeping and Resuming.

CIP Energy Overview

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– Power Management Object States• Owned indicates that this device may be controlled by a power

management client.• Paused indicates the device is in a lower power state.• Sleep indicates the device is fully powered off with exception of the MAC

layer (waiting for Wake on LAN).• Resuming indicates the device is powering back up after being in a low

power state.

CIP Energy Overview

Requested Pause or Sleep Time

Resume Time

Wake from Sleep Time

Minimum Pause or Sleep Time

Time to achieve low power level

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Power Curtailment Object– This object is power based, requests are given

in the amount of power required to be consumed.

– Lowers power consumption during production, likely by lowering the production output (lower part count).

– The object manages this by holding configuration sets for different power levels of run time modes e.g. 70%, 50%, 30% of full scale power usage.

CIP Energy Overview

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Example Cell – The following Cell is an example of how Industrial networks can be utilized in

the context of Energy. – The sample is only showing electrical energy but could easily be applied to

other energy types.

1. Robot Controller2. Robot Controller 3. Glue Gun4. Drive Control 5. I/O Block

Applications

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Applications

Energy Tool

CIP Client

[15kWh]

Line PLC

Energy Object ServerEnergy Aggregator

[7kWh] Robot Controller (1)

Inst 1 [2kWh]Inst 2 [1kWh]

Robot Controller (2)

Inst 1 [5kWh]Inst 2 [2.5kWh]

End of ArmTools

[0.5kWh]

End of ArmTools

Glue Gun (3)

[1kWh]

IO blockProxied

Inst 1 [1kWh]Inst 2 [1kWh]

Proxied IO Lift motor

(5)

Proxied IO Lift motor

(5)

Drive Controller(4)

[100kWh]

Ethernet/IP

Ethernet/IP

DeviceNet

DeviceNet

Line PLC

Energy Object ServerEnergy Arregatitor

[8kWh]

Energy Monitoring Flow

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– Understand how much energy is consumed to build products at the Cell level.

– Compare baseline with current data for preventive maintenance.

– Schedule jobs in different cells to keep the peak energy consumption down and lower overall cost.

– Use data to set up power curtailment programs, allowing for demand response capable production lines.

Conclusion What can we do with this info?

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Questions?

Thank You

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