ABERLE PMS-EProcess Management System – Energy Efficiency

www.aberle-automation.com

Energy-Efficient WarehousingSignificant Energy Savings without Loss of Power

Optimization

With this approach, the increase of energy efficiency is achieved not only by structural or device-related methods of optimization. At the core of this unique system is PMS-E in the form of an intelligent control technology which embraces all logistics processes as regards efficiency while optimizing, controlling and documenting them in terms of reduced energy consumption.

The result: less consumption for the same performance.

PMS-EAdvantages in every respect

• Measurable increase in efficiency and cost savings

• Can be retrofitted to any existing system• Optional expansion possibilities for drive

mechanisms and building services engineering• PMS-E documentation enables

a choice of cheaper electricity rates• Low investment with fast payback• Certification with the energy control center

according to DIN EN ISO 50001

Logistics centers usually have a daily operating timetable with corresponding power peaks in capacity utilization. In practice, analysis shows that the intralogistics, consisting of a variety of components (materials handling systems, storage and retrieval systems, etc.), keep a high degree of readiness outside these peak times and thus consumes energy.

The outstanding performance of the PMS-E system solution lies in its ability to provide energy savings in highly automated logistics centers with a complex storage and control technology. The performance capability, response time and reliability of operation are maintained at 100 % without restriction.

2 Advantages in every respect Aberle PMS-E

Energy Savings

without Loss of Power

less means more

Added Value by Energy-Efficient WarehousingEnergy-Optimized Plant Control –Increase Efficiency and Reduce Energy Consumption

With PMS-E our customers can save energy from:

• Materials handling technology

• Lighting• Standby times• Building services

(heating, ventilation, air conditioning)

• Media supply

… and maintain at the same time the performance of their systems:

• Logistics• Assured

production• Benchmarking• Installation of

CIP processes

Additionally, we make further potentials available for our customers:

• Cost saving• Energy saving• CO2 reduction• Create scope for

investment• Support for corporate

philosophies

less means more

5Aberle PMS-E Added Value by Energy-Efficient Warehousing

Significant Energy Savings without Loss of Performance

Concentration of reasonable operating timesPMS-E takes into account all data relating to the flow of goods. It draws on all information regard-ing goods orders, shipping dates and delivery times and in response to the placement of goods works out the most effective order picking times (e. g.: reduced energy tariffs in night-time opera-tion). By merging picking processes to their most sensible period of time in relation to the overall utilization, additional operating times are cre ated in which the power supply to storage technology (otherwise made available for continuous opera-tion) can be reduced and in some cases can even be switched off.

Automation of all processes and consumptionsPMS-E coordinates and automates all optimized warehouse operations and the provision/shut-down of the entire intralogistics. This way it allows energy savings of 25 – 40 %! In addition, PMS-E offers the possibility of integrating the building services engineering as well as the warehouse logistics and of controlling all power consumers in accordance with the same parameters of sensible deployment.

6 Significant Energy Savings without Loss of Performance Aberle PMS-E

BCDEF

A

G

Distribution of Energy Costs of a Logistics Facility

Lighting

Conveyor technique, storage and picking

Ventilation and heating systems

50 %

15 %

35 %

Total Cost of the Logistics Facility

25 % Intralogistics

8 Intelligent Control and Coordination Aberle PMS-E

Benefits• Automatic adjustment of speed and accelera-

tion of active components (e. g.: storage and retrieval machines and lifting units) in line with planned requirements

• Rearrangement performed at night with re-duced power consumption at cheaper night-time electricity rates

• Standby (sleep) mode for equipment• Power-saving circuits throughout the plant• Energy recovery for SRM (optionally available)• Delayed start of SRM and single axles prevent

load peaks• Efficient and energy-efficient storage strategies

that are adapted to the operator model (e. g.: ad hoc, production supply, batch, …)

• Integration of the whole building services man-agement as an option, for example to control lighting, heating, ventilation, compressed air in demand-oriented fashion

Measurable effects• Reduces load on all the mechanical

drive components• Less wear• Lower noise level• Reduced energy demand• Higher system performance

Advantages• Reduction of consumption• Increase of machine efficiency• Improvement of overall efficiency• Reduction of costs

Intelligent Control and CoordinationDocumentation for cheaper tariffsIn addition to reducing power consumption, PMS-E automates the documentation of the resulting peak loads for companies. The reduction of the periods of peak loads and the correspon-ding system documentation contributes to an optimized tariff situation and cumulates cost reduction (as a result of the volume of energy savings) with the cost reduction due to more advantageous bases for tariff calculation.

Advantages• No additional mechanical technology• Direct reduction of energy costs• Short-term return on investment

(about 2 years)• Use of tax benefits by applying PMS-E• Energy savings of 25 – 40 %• Reduction of CO2 emissions in

power generation• ases the load on the electricity grid

Basic FunctioningControl of all intralogistics components• Storage and retrieval machines (SRM)• Materials handling technology• Lifting devices• Shuttles• Transfer elements• Picking robots• Forklifts including charging equipment• Stretchers• Strapping machines

OptionalIntegration of the entire building services technology• Heating, ventilation• Compressed air supply• Lighting, etc.• Water supply and disposal• Metrology / Wastewater technology• Locks and door operation

Integration of additional energy-saving components• SRM with energy recovery• LED lighting• Shuttle conveyors• Run-on-demand for conveyors

Aberle PMS-E A Complete System with Option for Additional Potential

10 Functionalities Aberle PMS-E

Material Flow Computer

Intralogistics (conveyor technique, ...)

Building Services Engineering Production

Robots

Storage and Retrieval Systems, ...

ERP System (SAP, ...)

Report Functions

User Interface

Energy Control Center

Energy control center The energy control center is where all information about energy consumption, orders, progress status and movements converge. All the informa-tion is used to control the flow of men, goods and buildings.

The task of the energy control center is to com-pute the most advantageous mix of available technology, the installed building and existing orders and then to pass on the processes as a reference variable to distribution centers (goods, men, technology, and energy).

The Control Center for Holistic Energy ManagementEfficiency and Potential Energy Savings become Controllable

Systematic, sustainable efficiency improvement:• Detecting peak loads and lowering the price by

deliberately capping peaks in a selective manner• Transparency and conscious use of energy by cost

center assignment of energy cost leads to savings• Avoiding the “watering can effect”: Investments in

saving are input where they provide the greatest yield

• Establishment of a learning curve as well as monitoring and evaluation of the points where consumption takes place lead to new savings measures – CIP in matters of energy

• Obtaining information for predictive maintenance

13Aberle PMS-E The control center for holistic energy management

Process analysisUsing smart energy meters for process analysis, initially the actual consumption, hours and operat-ing conditions, the distribution over time and the underlying priorities for the system components are recorded. Using the PMS-E software module, the data is then analyzed and represented in graph form.

Component optimizationThe data from the process analysis forms the basis for the optimization of components. As a result of the actual data made available on each machine, its exact energy consumption can be measured and reported transparently. In this way, in the second step of the process management, for example, the identified set load profiles, energy consumption and process efficiency can be seen in relation to each other – and by using so-called load management, alternatives can be considered.

Systematic IntroductionPMS-E Energy Process Management with Customer-Specific Adaptation

Consumption-optimized operationThe third level of optimization, consumption-op-timized operation with continuous controlling, is performed by PMS-E in conjunction with a Warehouse Management System such as Aberle PMS-W and plant control systems. It aims for optimal process control taking account of time and energy requirements as well as optional restrictions. The basic idea: To cope with the required volume, in general systems do not need to perform to its full potential all the time.

By means of intelligent distribution of order loads, ecologically more sensible however slightly longer, movement and lifting times below the machinery‘s capacity limits can be almost completely offset when applied over the entire working day. In this way, it becomes possible to operate machinery in an energy-efficient manner using ecological crite-ria without loss of logistic performance.

14 Customer-specific adaptation Aberle PMS-E

Success Stories

Mercedes-Benz

Highly flexible supply of truck production parts without using forklifts – with this objective, the Mer-cedes-Benz plant in Wörth set up its first automated small parts warehouse (miniload AS/RS). The IT basis for the new, highly flexible logistics is Aberle Process Management System (PMS). For process control in the fully automatic, 12-lane miniload AS/RS on a floor space of 10,000 m2 with about 189,000 container storing positions and an attached rack storage, Aberle GmbH installed the application software, including all necessary interfaces to the higher-level ERP system (by SAP) as well as the material-flow control system under the control of the PMS. The PMS manages the product range and loading equipment, controls the storage and picking processes, supports the scheduling of employees and ensures the seamless traceability of products. Special feature: In addition to the PMS-V visualization system, the PMS in Wörth also has the PMS-E module installed. Thus, the Process Management System ensures not only transparency of stocks and processes, but is also designed for maximum energy efficiency in the system control. With considerable consequences for consumption and cost structures.

J. Schmalz GmbH

The J. Schmalz GmbH company, a world leader in innovative vacuum technology, has built its new pro-duction and logistics centre in Glatten near Freudenstadt covering a total of 13,770 m2. The solution for warehouse, shipping, and production supply includes a miniload AS/RS, a manually operated high-bay pallet warehouse and a sophisticated picking strategy for customer deliveries and for supplying its own production.

Overall, the J. Schmalz company was able to reduce energy consumption by around 40 % over compa-rable systems through the consistent use of PMS-E in the production supply in the miniload AS/RS, in the manual pallet storage and in order picking.

Aberle GmbHDaimlerstraße 4074211 Leingarten · GermanyPhone +49 7131 9059-0Fax +49 7131 9059-59www.aberle-automation.cominfo@aberle-automation.com

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