energy simulation of compressed air systems …€¦ · 17/06/2015 · tecnomatix plant simulation...
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Tecnomatix Plant Simulation Worldwide User Conference 2015
Siemens Industry Software
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inpro
D. Wolff (inpro), J. Nagel (Volkswagen)
June 17th, 2015
Energy Simulation of Compressed Air Systemsusing Tecnomatix Plant Simulation
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Air
0,78
0,21
0,01nitrogenoxygenother
Tecnomatix Plant Simulation Worldwide User Conference 2015
Siemens Industry Software
Volkswagen Group AcademyUmbrella organization of all academies for all brands and locations of VOLKSWAGEN AGwith the goal of uniform standards of quality and competences all over the world.
AutoUni – Institute for Production, Logistics & Components
3PMX-1 / K-SE-61Stand: 15.05.2015
Volkswagen Group
Knowledge transferKnowledge exchangeKnowledge generation
CommitteeDepartments
Universities, technicalcolleges and research
establishments
AutoUniInnovative knowledge partner, which combines science and practice to provide futureknowlegde in coorporation with worldwide renowned universities.
• Qualification on academic level• Networking of the participants across all brands• Impulses of science
Institute for Production,Logistics & Components
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Innovationsgesellschaft für fortgeschritteneProduktionssysteme in der Fahrzeugindustrie
• Founded: 1983
• Location: Berlin
• ~100 Engineers & Developers
• 3.000 m2 Laboratory
• Development Center
inpro
Tecnomatix Plant Simulation Worldwide User Conference 2015
Siemens Industry Software
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Production Systems and Information Processes
Competences• Virtual commissioning
• Data structures forthe digital factory
• Knowledge management
• Human-machine interface
• Development of CAE tools
• Energy Optimized Planning
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Motivation
Complexity of modern production systems incurs the use of digitalplanning tools, supporting integrated energy management.
Cost pressure and political decisions require energy consumptiontransparency and continuous efficiency improvement
in production systems.
Tecnomatix Plant Simulation Worldwide User Conference 2015
Siemens Industry Software
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Energy Use in Car Manufacturing
For comprehensive energeticevaluation, system boundaryshould include peripherics.
In machining, compressed air andcooling lubricant systems aremajor energy consumers.
Existing Potentials• Air generation (speed controlled
pumps)
• System dimension
• Intelligent compressor control(switch-on/switch-off)
generationgeneration processingprocessing distributiondistribution
simulative approach
Bubbles: potential savings estimateBubbles: potential savings estimate
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1 Greenfield• Dimensioning of CA storage/compressor train
• Screw compressors consume ca. 1/3 of nominal powerduring full load when idle. The use of „intelligent“compound controls aims at reducing these idle times:efficient operation mode for generator
2 Brownfield• Planning of standby intervals for applications
through creation of manufacturing batches:efficient operation mode for application
Simulation Use Cases
Tecnomatix Plant Simulation Worldwide User Conference 2015
Siemens Industry Software
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Functional Chain:
CA supply is a typical system of 2nd periphery and its consumptionis directly linked to the production program.
Compressed Air Systems (CAS)
generationgeneration processingprocessing applicationapplicationdistributiondistribution
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Compressor Types
Piston Compressor
Screw Type Compressor
Turbo Compressor
flow rate[m3/h]pr
essu
re[b
ar]
Tecnomatix Plant Simulation Worldwide User Conference 2015
Siemens Industry Software
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Compressor Operating Strategies
partial load
compressorstrategy
internal superiorfocus
cascadepressurecorridor
frequencycontrol
speedcontrol
delayedidling
control
idlingcontrol
inter-mittentcontrol
full load
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Compressor Operating Strategies
partial load
compressorstrategy
internal superiorfocus
cascadepressurecorridor
frequencycontrol
speedcontrol
delayedidling
control
idlingcontrol
inter-mittentcontrol
full load
Tecnomatix Plant Simulation Worldwide User Conference 2015
Siemens Industry Software
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Sensor or pressure switch puts compressor into „full load“ or „stop“;depending on net pressure
• best energy balance, for system with big storage
Simulation Strategy: Intermittent Control
pressure gradient
pow
erin
take
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Compressor Operating Strategies
partial load
compressorstrategy
internal superiorfocus
cascadepressurecorridor
frequencycontrol
speedcontrol
delayedidling
control
idlingcontrol
inter-mittentcontrol
full load
Tecnomatix Plant Simulation Worldwide User Conference 2015
Siemens Industry Software
1515© INPRO, Germany Streng Confidential – für internen Gebrauch 1515© INPRO, Germany Streng Confidential – für internen Gebrauch 1515© inpro 2015 Plant Simulation Worldwide User Conference June 15 - 17, 2015 – Stuttgart, Germany
Sensor or pressure switch puts compressor into „full load“ or „idle“;depending on net pressure. „Idle“ consumes minimum energy withoutproducing air.
• Reduction of power-on-phase reduces switching cycles wear & tear on drive
Simulation Strategy: Idling Control
pressure gradient
pow
erin
take
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Compressor Operating Strategies
partial load
compressorstrategy
internal superiorfocus
cascadepressurecorridor
frequencycontrol
speedcontrol
delayedidling
control
idlingcontrol
inter-mittentcontrol
full load
Tecnomatix Plant Simulation Worldwide User Conference 2015
Siemens Industry Software
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Sensor or pressure switch puts compressor into „full load“, „idle“ or„stop“; switching the latter two based on a defined delay time
• Hybrid solution
Simulation Strategy: Delayed Idling Control
pressure gradient
pow
erin
take
tv: delay time
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Pilot Case „Component Manufacturing“
Tecnomatix Plant Simulation Worldwide User Conference 2015
Siemens Industry Software
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generationgeneration processingprocessing applicationapplicationdistributiondistribution
CA Generation and Storage
Compressor/Container Consumer
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CA Consumers
Compressor/Container
generationgeneration processingprocessing applicationapplicationdistributiondistribution
Consumer
Tecnomatix Plant Simulation Worldwide User Conference 2015
Siemens Industry Software
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Model
statesensor
currentconsumption
rate
CA container(pipe system and
storage)
CA consumer(machine)
CA generator(compressor)
parametrization & visualization
uptimelogger
specificconsumption
logger
consumptionlogger
currentpressure
leak rate
consumptionparameters
compressorcontrol
allocationmapping
switchingcycle
logger
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Simulation
Tecnomatix Plant Simulation Worldwide User Conference 2015
Siemens Industry Software
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Seamless Digital Energy OptimizationPlanning
Operation
Knowledge
Commissioning
Simulate & OptimizeEnergy Use
Plan EnergyEfficiency
Analyze energyconsumption
Energy OptimizingControl Systems
Energy standards
Prepare EnergyOriented Automation
Pic central: Siemens AG
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inproSteinplatz 210623 Berlin
P. 0049 30 39997-0F. 0049 30 39997-117M. [email protected]
www.inpro.de
Thank you for your kind attention.