energy management

Digital Twins for Production

Digital Twins for Production

RAPIDZ — Resource analysis and process integration through digital twins
Christian Salzig ORCID Icon, Julia Burr ORCID Icon, Sophie Hertzog
In today’s manufacturing industry, digital twins are a key enabler for optimizing production processes and efficient resource use. However, creating digital twins is often associated with high or difficult-to-estimate costs and typically requires unknown characteristic values, such as material parameters, making practical implementation challenging. With RAPIDZ, we present a tool for creating and using digital twins that overcomes these barriers through its modular structure. The virtual modeling of physical systems enables comprehensive analysis and real-time forecasting of material flows, energy consumption and machine performance. The use of RAPIDZ increases production line efficiency, enhances flexibility and response time, and enables proactive maintenance to minimize downtime.
Industry 4.0 Science | Volume 41 | Edition 3 | Pages 6-12 | DOI 10.30844/I4SE.25.3.6
Vom Energiedatenmanagement zum Digitalen Zwilling

Vom Energiedatenmanagement zum Digitalen Zwilling

Vereinfachte Modellierung eines Digitalen Zwillings mithilfe von Energiedaten
Alexander Blinn, Henrik te Heesen, Joachim Brinkmann, Julius Herzog
Bedingt durch globale Entwicklungen hinsichtlich der Preise und Versorgungssicherheit im Energiesektor stehen besonders energieintensive Unternehmen vor großen Herausforderungen. Zusätzlich fordern Kunden mehr Informationen über Energiekennzahlen und CO₂-Emissionen sowie ressourcenschonendere Prozesse. Mit einer energiedatenbasierten Simulationsmethode werden die Ressourceninformationen direkt aus dem Energiedatenmanagementsystem (EDMS) extrahiert und weiterverarbeitet. Hierbei werden sowohl aktuelle als auch stetig aktualisierte historische Daten verwendet, die automatisiert abgeglichen werden. Die digitale Abbildung der vorhandenen Prozesse ist lediglich auf Seiten der Energiedaten notwendig, ohne die technischen Prozesse in ihrer Gänze analysieren zu müssen. Mit dem so erstellten energetischen digitalen Schatten lassen sich Energiebedarfe für bevorstehende Produktionen und Produkte simulieren und können durch automatisierte Vorschläge in der Produktionsplanung positiv ...
Industrie 4.0 Management | Volume 39 | 2023 | Edition 5 | Pages 33-36 | DOI 10.30844/IM_23-5_33-36
The Dilemma of Compressed Air and Leaks

The Dilemma of Compressed Air and Leaks

Lisa Dawel, Alexandra Pehlken
Due to the sharp rise in energy prices, compressed air, or compressor performance and its power consumption, are once again in the foreground as part of energy management. Due to the fact, that compressed air often escapes via leaks and these are difficult to localize or measure, a niche topic is becoming very noteworthy again. Automated leak detection can determine the need for repairs and help increase energy efficiency. It is important that not only leaks are detected, but that the extent of the leaks can also be quantified. A cost-effective method of detecting leaks is energy monitoring of the air compressor. Continuous monitoring and evaluation of the energy data means that you can react quickly.
Industrie 4.0 Management | Volume 39 | 2023 | Edition 2 | Pages 33-35 | DOI 10.30844/IM_23-2_33-35
Electrical and Hydrogen Microgrid

Electrical and Hydrogen Microgrid

Energy Control of a Self-Sufficient Supply System Based on a Combined Electrical and Hydrogen Distribution Grid
David Salomon Stephan, Uwe Werner, Carsten Fichter
The main goal of assembling a self-sufficient microgrid is to integrate all technical equipment into an autonomous energy supply system as a virtual power plant (VPP). The system integration focuses on the power electronic devices and the combination of gas and electrical supply chains. The developed microgrid structure is fed from renewable energy systems (green hydrogen), the electrical grid and the H2 gas grid with a liquid or gaseous energy source. In comparison to an island grid, the microgrid can be operated in parallel mode with the common public grid. The associated challenges of transient energy flows and the holistic view of a regulated microgrid based on an electrical grid and an H2 gas network are part of this article.
Industrie 4.0 Management | Volume 38 | 2022 | Edition 1 | Pages 28-32
Decentral Control of Energy Flexibility in Production

Decentral Control of Energy Flexibility in Production

Alexander Sauer, Sebastian Weckmann
An increasingly fluctuating energy production and therefore fluctuating energy prices are new challenges for sustainable and cost-effective manufacturing. Due to a growing volatility in the energy supply, industrial consumers are increasingly involved in the balance of the energy system. The goal is to consume energy only when it is cheap and reduce the power consumption during periods of high energy prices. This leads to a conflict between the flexible use of energy and the production output which has to be balanced. While Smart Grids solutions for regional and higher structured energy networks balance supply and demand, solutions for the industrial environment are still missing. In this article, the current research on the development of a decentralized control solution for industrial energy system is presented.
Industrie 4.0 Management | Volume 33 | 2017 | Edition 1 | Pages 47-51
Holistic Implementation of Industry 4.0 to Enhancing Energy Transparency

Holistic Implementation of Industry 4.0 to Enhancing Energy Transparency

Vorstellung einer praxisorientierten Einführungsstrategie
Sebastian Schenk, Tobias Heinen
Due to a lack of energy consumption transparency, manufacturing companies are struggling to identify the energetic cost drivers within a factory. Energy transparency can be reached through the aid of suitable measuring technologies. However, the gained transparency must be used intelligently to obtain economic benefits. One possible solution is the use of modern information technologies that are provided by the Industry 4.0. Maximum synergies can only be achieved through a holistic implementation of Industry 4.0, by taking the business model, the operational processes, the technology and the employees into account. A corresponding strategy for the implementation of Industry 4.0 in the context of energy transparency is introduced in this article.
Industrie 4.0 Management | Volume 33 | 2017 | Edition 1 | Pages 15-18
Consolidation of Emission Indicators

Consolidation of Emission Indicators

Determination of Greenhouse Gas Efficiency of Diversified Logistic Service Providers
Wolf Lampe
Range and individualisation of diversified logistic services vary substantially. A unique indicator for specific CO2-emission is not a viable option. The author proposes to aggregate individual CO2-efficiency trends of sub-entities by adding all singular tendencies during a reporting period weighted against the overall CO2-emission of the reporting entity or group of entities. The result is a weighted average tendency giving a viable indication of the specific CO2-emission trends of a logistics service provider.
Industrie 4.0 Management | Volume 33 | 2017 | Edition 1 | Pages 7-10
Energy Costs and Energy Management

Energy Costs and Energy Management

A Study on the Importance of Energy in Manufacturing Companies
Tobias Rackow, Tallal Javied, Jörg Franke, Sebastian Schießl, Peter Schuderer
Energy management systems provide a framework for the transparent display of energy consumptions, aiming for an increase of energy efficiency. At the same time, a certified energy management system is condition for the reimbursement of electricity taxes and the exemption of the EEG (Renewables Energy ACT) apportionment. Even though energy management systems lead evidently to a reduction of energy consumptions, only little companies have implemented such a system. The study presented in this paper gives an insight into the status of the cost factor energy and respective management systems in German SMEs (manufacturing industry). Moreover, the main pillars of energy management systems and their benefits are outlined.
Industrie Management | Volume 31 | 2015 | Edition 3 | Pages 49-52
Energy Data Capturing Systems: Economic Valuation and Decision Support

Energy Data Capturing Systems: Economic Valuation and Decision Support

Wirtschaftliche Bewertung und Entscheidungsunterstützung
Egon Müller, Markus Buschmann, Kai-Uwe Wonneberger
The lack of information concerning energy flows can be seen as a significant barrier to increase energy efficiency in an industry. The extension of energy measurement systems often fails due to the difficult appraisal of expected reflux. The suggested model presents a way to overcome this barrier by forecasting potentials and including soft facts into the appraisal as well. Learning effects objectify the presented model through time and make it more stable. As a result an expected net present value can be calculated and used to estimate the benefit of installing a measurement device into a given technical system.
Industrie Management | Volume 27 | 2011 | Edition 6 | Pages 33-37
Energy Management in Production

Energy Management in Production

Approaches for Monitoring and Controlling Energy Efficiency
Katharina Bunse, Matthias Vodicka, Paul Schönsleben
Current political developments regarding the withdrawal from nuclear energy will probably result in an additional increase in energy costs over the next few years. This increases the relevance of reducing energy consumption in production for industrial enterprises. Thus, in addition to quality, cost, delivery reliability and flexibility, energy efficiency is integrated as an additional performance criterion in the decisions of production managers. An important instrument to increase energy efficiency in production processes is the implementation of energy management. This paper presents the advantages of an integrated energy management and outlines the main tasks and methods. IT solutions are presented that assist companies in configuring and controlling production processes to become more energy efficient.
Industrie Management | Volume 27 | 2011 | Edition 6 | Pages 53-56