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In today’s world energy cost big dollars for manufactures and the fact is most plants don’t know where there energy is being used. To help with this problem the Industrial Network communities are providing common interfaces to gather and control energy in the industrial space. This presentation will focus on aspects of Energy where it relates to Industrial Automation and some of the challenges we face. We will also cover upcoming initiative for interfacing to the smart grid for demand response request.
Citation preview
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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 Energy
The Role of Industrial Networks
Energy Usage Reporting Standardization
Controlling Usage
Smart Grid Connection
CIP Energy Overview
Applications
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Cost of EnergyKnowing when and where energy is used is important
According to the DoE and eia the industrial sector uses about 1/3 of the energy in the US.
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Cost of Energy
Studies 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 Energy
Most 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 Networks
Aspects 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 Networks
Many 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 monitorLine or
department
Energy measured
Overload relayMotor 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 Controller
2. Robot Controller
3. Glue Gun
4. Drive Control
5. I/O Block
Applications
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5
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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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