The efficient treatment of energy is of great importance to manufacturing companies. To be able to optimise the energy consumption of production facilities, all relevant consumption data must be recorded and analysed. In the ESIMA (energy-autonomous sensors and interaction with mobile users) research project, Festo, together with partners from industry and science, has devised an energy management concept based on easy-to-install sensors. Along with the development of energy-autonomous sensors, a key component of the project was visualisation, which gives plant operators a differentiated overview of their own processes, thereby contributing to the development of Industry 4.0 factories.
Energy consumption, for example for individual workpieces, can be calculated using this coordinated concept that extends from simple installation of the sensors, data acquisition and transmission by radio, to visualisation. A decisive advantage is that the sensors can easily be installed in existing production facilities. All relevant consumption data is recorded during the production process, including electrical energy consumption (current, voltage, power) and consumption of compressed air (pressure, flow). The wireless sensor systems can also register relevant ambient parameters such as temperature, humidity and CO2 content. The measurement data can then be pre-processed and transmitted by radio to a base station.
Compressed air sensor with data transmission by radio
In the course of the project, Festo developed a compressed air sensor that simultaneously measures air pressure and flow and transmits this data by radio to a base-station. An integrated turbine generator unit, operated by means of a small amount of the compressed air, provides the electrical energy required for the components.
A frequency agile access process ensures the reliability of the wireless data transmission: the system repeatedly changes the transmission and reception frequencies to prevent collision with other radio systems such as an already existing WLAN. The findings from the ESIMA project are also incorporated into the development of the ‘wireless’ IO-Link.
Visualisation on mobile devices
The acquired data is visualised using an Internet application developed in the project and can be viewed on mobile devices such as smartphones or tablet PCs. The presentation of the data can be adapted to the user’s requirements. A machine operator, for instance, can examine sensor readings and machinery conditions, whereas a team leader would be more interested in energy consumption and production statistics.
Energy data management for Industry 4.0
“The findings from ESIMA show us how energy data can be recorded much more economically and flexibly”, said Bernd Kärcher, project manager of ESIMA at Festo. “The acquisition of data, their transmission by radio and their visualisation on mobile terminals in a web application make for efficient energy management in the context of Industry 4.0.”
Along with optimised energy consumption, customers also benefit when it comes to servicing. Since the sensors automatically register even the smallest deviations from normal values, repairs can be carried out to prevent expensive downtimes in production.
Project partners from industry and science included VARTA Microbattery, the Hahn-Schickard Society, EnOcean, the Electrical Measuring Technology department of Helmut Schmidt University, C4C Engineering and the Institute of Machine Tools and Production Technology of TU Braunschweig.
This co-operative project was subsidised by the German Federal Ministry of Education and Research as part of the research programme in the field of ‘Energy-autonomous mobility – reliable energy-autonomous systems for mobile people.’
For more information contact Kershia Beharie, Festo, 086 003 3786, [email protected], www.festo.co.za
| Email: | [email protected] |
| www: | www.festo.co.za |
| Articles: | More information and articles about Festo South Africa |
© Technews Publishing (Pty) Ltd | All Rights Reserved
printer friendly version