Resource-efficient operation of production systems based on an example from car body constructionEnergy PLC Case Study
The benefits of energy automation are reflected in reduced power consumption of machines and systems during breaks in production. The prerequisite for a solution to energy automation is the acquisition and analysis of the media and energy use of the components installed during the "production" and “production breaks". By appropriate deactivation of parts of the system, it is possible to reduce energy consumption during breaks without reducing productivity. This advanced function in system automation is implemented in the Energy PLC that was developed by Phoenix Contact.
The fundamental principles for developing the Energy PLC were compiled by the "Green Carbody Technologies innovation alliance that is sponsored by the German Federal Ministry for Education and Research as part of the "Researching for the production of tomorrow" concept.. This research project is supervised by Projektträger Karlsruhe (PTKA). In this case, it was possible to acquire detailed information on media and electrical energy from an active car body production line and form the basis for an innovative power management solution.
Analysis of the data acquired made it possible to identify recurring cycles. Furthermore,
Analysis of the measured data made it possible to describe the general state of systems and components and this served as the basis for development of the energy management system Phoenix Contact.
The Energy PLC represents the core of the configurable power management system . It receives information on planned production times and breaks from a higher-level control system via a standardized interface and then determines the optimum switching strategy based on the lengths of the planned breaks. The method of function and parameters of the installed system components are adjusted by control technology and switched to “Ready” or “Off” during those periods where production is at idle. The Energy PLC integrates all relevant infrastructures of both media supply in the production hall. This overall view can result in a reduction of energy use of up to 15%.