demand-side energy management systems for manufacturing · adiwa - work package a4 objective and...
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SYSTEMATIC THOUGHT LEADERSHIP FOR INNOVATIVE BUSINESS
Demand-side Energy Management Systems for Manufacturing Informatik 2010, Leipzig
SAP Research Center Dresden Dr. Michael Ameling September 28th, 2010
Agenda
1. Introduction
2. Scenario
3. Concept
4. Prototype
5. Conclusion
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Section One Introduction
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Introduction Sustainability
Sustainability Economic View Ecologic View Social View
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Introduction Energy Monitoring & Management
Energy Water Air Gas Electricity Steam
Goals Benchmarking of energy consumption Reducing energy consumption Reducing energy loss (distribution) Avoiding energy peaks (in demand) Energy availability (resource) planning Increasing efficiency
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Energy Production
Energy Storage
Energy Distribution
Energy Consumption
Utilities Supported by
AMI, Smart Grid
private & industrial
consumer
“You can´t manage what you don´t measure”
key challenge: intermittency of RES [8]
Production Paradigm Change & Role of ICT
Efficiency Nowadays Maximum gain from minimum capital
maximum gain from minimal resources
Savings Industrial production savings potential: 25 - 30% [1] Energy savings potential (by 2020): 25% (95 Mtoe) [2] Industry ≅ 30% of Europe’s primary energy consumption
Savings of up to 65% reasonably expected [2]
ICT Role ICT reducing carbon emission (by 2010) potential: up to 970 million tons (global)
Improved motor systems, industrial process optimization [3] ICT-optimized logistics (e.g.: optimized transport routes, networks, inventory reduction) [3]
Reduction in transport emission: up to 16% reduction in storage emissions globally: 27%
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Energy Consumption and Savings Potential Examples in Manufacturing
Electricity Consumption & Production Europe’s share of global primary energy consumption: 18% (10,900 Mtoe4) in 2006 Doubling of world electricity production: 16.4 TWh (2004) to 30.1 TWh (2030) [4]
equals annual increase of 2.4 %. Electricity Usage Electricity in Germany: 15% (528 TWh) of primary energy [5]
Industry share: 47% (2/3 electrical drives, 1/3 heating and lighting Compressed Air Compressed air: 10% of industrial energy consumption (> 80 TWh/year) [6]
321,000 compressors (10 -300 kW) installed in Europe [5]
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Optimization Strategy Saving Process Optimization 25 - 30%
Optimized Logistic 16%
Integrated Process Chains 30%
Development of New Products 10 - 40%
Intelligent Motor Drives 20 - 40%
Alignment with Best Performers 15%
Strategies and Potential for Manufacturing:
Section Two Scenario
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ADiWa - Work Package A4 Objective and Application Scenario
Overall Objective ADiWa From Internet of Things towards intelligent business processes
Usage of all IoT information relevant to a process Flexible formation and dynamic adjustment of processes in companies
Overall Objective ADiWa WP A4 Lean and green production and logistics
Provide a concept for reaching sustainability Transparency in production and logistics Efficient energy management
Application Scenarios Manufacturing in the SAP Research Future Factory
Demand-side energy management Dynamic routing
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Production of different kind of fridge magnets Several logos Several insertions (thermometer, sharpener) Any combination with different production plan
Resources Workers CNC Mills Drills Assembly workplaces Quality check workplaces
Energy Resource Units in hour
SAP Future Factory Manufacturing Scenario Manufacturing of Fridge Magnets
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SAP Future Factory Energy Consumption at Process Level
Provisioning Drilling Milling Assembling Packaging
0,327 kW/h
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Management
Prozesse
Weather Data Stock Market (e.g.: EEX1)
ADiWa - Work Package A4 Use Case Demand-Side Energy Management
Fossil Power
Green Power
Drilling Milling Assembling
Drilling Milling Assembling
Day related Year related
1EEX – European Energy Exchange
Order DA Order CA
Order B
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Section Three Concept
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Architecture Overview
Device Abstraction Layer
Persistency Layer
Logic & Analytic Layer
Presentation Layer
Hardware
Process Modeling Tool
Energy Management System
Smart Meter
Smart Meter
Smart Meter
Stock Market
Weather Forecast
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Process Execution Engine
CEP Engine
Analysis
Database
ME
S (P
roduction P
lanning) E
RP (O
rder Planning)
Event Bus
IO-Adapter IO-Adapter R R
Section Four Prototypes
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SAP Research Future Factory Visit Us!
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Future Factory Energy Meter Distribution in Production Line
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Prototype Energy Monitoring Dashboard
Device Abstraction Layer
Persistency Layer
Logic & Analytic Layer
Presentation Layer
Hardware
SAP TREX
ABAP/ Java + TREX Analytics
Xcelsius BOBJ Explorer Silverlight
MDI
PLOGGS NZR SEM easyMeter E+H Mitsubishi
Additional Gateway
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Prototype - Energy Monitoring Dashboard Energy Consumption per Asset
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Prototype - Energy Monitoring Dashboard Cumulated View of Assets
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Literature (selection)
[1] SEMI S23-0705: Guide for Conservation of Energy, Utilities and Materials Used by Semiconductor Manufacturing Equipment, 2005
[2] Twenty Solutions for Growth and Investment to 2020 and Beyond, 2008
[3] Garczynska, M., CECIMO: Energy Efficiency in Manufacturing: The Role of ICT, 14 July 2008
[4] Miller, G., Infineon Technologies AG: Infineon Power Products Help Improve Energy Efficiency in Many Application Fields; Pophal, C., Infineon Technologies AG: Energy Efficiency in Semiconductor Manufacturing at Infineon Technologies
[5] ZVEI, Energiesparen mit elektrischen Antrieben, 2006
[6] Bredau, J., Festo: Email to Frank-Lothar Krause, Erastos Filos, Matthias Putz and Reimund Neugebauer, 21 July 2008
[7] ICT and Energy Efficiency The Case for Manufacturing, European Commission Information Society and Media, 2009
[8] Sumic, Zarko: Hype Cycle for Smart Grid Technologies, Gartner, 2010
[9] European Commission, Factories of the Future PPP, Strategic Multi-Annual Roadmap, 2010
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Thank you!
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Grid
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Secondary color palette 100%
Primary color palette 100%
Definition and Halftone Values of Colors
RGB 68/105/125
RGB 96/127/143
RGB 125/150/164
RGB 152/173/183
RGB 180/195/203
RGB 4/53/123 RGB 240/171/0 RGB 102/102/102 RGB 153/153/153 RGB 204/204/204
RGB 21/101/112
RGB 98/146/147
RGB 127/166/167
RGB 154/185/185
RGB 181/204/204
RGB 85/118/48
RGB 110/138/79
RGB 136/160/111
RGB 162/180/141
RGB 187/200/172
RGB 119/74/57
RGB 140/101/87
RGB 161/129/118
RGB 181/156/147
RGB 201/183/176
RGB 100/68/89
RGB 123/96/114
RGB 147/125/139
RGB 170/152/164
RGB 193/180/189
RGB 73/108/96
RGB 101/129/120
RGB 129/152/144
RGB 156/174/168
RGB 183/196/191
RGB 129/110/44
RGB 148/132/75
RGB 167/154/108
RGB 186/176/139
RGB 205/197/171
RGB 132/76/84
RGB 150/103/110
RGB 169/130/136
RGB 188/157/162
RGB 206/183/187
85%
70%
55%
40%
RGB 158/48/57 Tertiary color palette 100%
85%
70%
55%
40%
SAP Blue SAP Gold SAP Dark Gray SAP Gray SAP Light Gray
Dove Petrol Violet/Mauve Warm Red Warm Green
Cool Green Ocher Warning Red Cool Red