demand-side energy management systems for manufacturing · adiwa - work package a4 objective and...

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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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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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

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