PROFIenergy

Pro Energy is a profile for the energy management in production. Profienergy relies on the communication protocol on PROFINET. It controls the power consumption of automation equipment in manufacturing (such as robotic assembly cells, laser cutting systems and subsystems such as painting ) via a PROFINET network. The control of energy consumption itself on open and standardized commands that are applied to planned and unplanned interruptions in production. With the use of Profienergy no external hardwired systems longer needed.

Background

The motivation for a standardized profile of energy efficiency comes from the Automation Initiative of German Automobile Manufacturers Association ( AIDA) from. The companies in the AIDA are Audi, BMW, Mercedes, Porsche and VW. The working group of PROFIBUS & PROFINET International ( PI) was founded to develop the new profile has the specification drawn up and published in late 2009. In the study group the ABB, AIT, Bosch, Danfoss, Hilscher, ifak, Lenze, Murr Electronics, Phoenix Contact, SEW Euro Drive, SCA Schucker, Rexroth, Siemens and WZL are active.

Description

Profienergy is an interplay of the three involved in a manufacturing process elements ahead:

• Control unit in an automation network (typically a PC, but also a monitoring system or energy management control system on the same network may be ),
• Communication network (PROFINET )
• Current load (may be a single apparatus or a part of the equipment, a cell, or even a larger subsystem may be ).

Which can be controlled by Profienergy switching mechanisms located within the energy consumer. It is therefore no further wiring needed. The control unit sends commands via PROFINET, which react with the energy consumer in production breaks. Breaks can be started at known times or arise as response to unforeseen events or breakdowns. Every consumer responds to the commands in a suitable way for him.

Provider companies decide on the best strategy for energy management by incorporating a software agent that is implemented in the device firmware. Any manufacturer can best judge how his device or subsystem can save energy and in which order the individual parts optimally and must be eliminated. For example, would have a production cell first a conveyor belt to slow before a robot can be driven into the energy- saving sleep mode. If the pause is long enough, the electronic control unit may be perhaps even completely removed from the system and the power consumption can be further reduced. Thus, it can be restarted if necessary but the conveyor belt must start again first. Sleep modes at several levels, are also possible.

Profienergy is also defined as a field device or system component, vendor-neutral returns information about the power requirement for the controller. This is essential so that even in mixed vendor installations optimum energy-saving scenarios can be realized by selectively turning on and off of loads. Here, a peak load management are applied and if necessary also consumers of energy other than electricity can be controlled.

Application

Profienergy uses the acyclic PROFINET communication and thus does not affect the coexisting cyclic communication of automation processes. The specified commands are based on the following applications:

• Short breaks ( up to an hour ) - In general, such breaks are planned - eg Lunch breaks - and the devices can be switched off routinely. Safety-related functions are handled according to safety regulations. When you turn, the system starts a device in a switch-on and checked that all devices run correctly. The manufacturing process is then resumed.
• Longer periods (several hours or days) - Here the situation is similar as above, except that additional devices are added to the standby or turned off completely, or deeper ' Sleep' modes are activated.
• Unplanned breaks (usually faults) - This situation is also similar, the user just do not know when and how long it will happen. First, the devices are driven in a 'Stop state in order to reduce energy consumption. Depending on how long the devices are useful if connected in more energy-saving states.
• Measurement and visualization of the load - data of the devices are collected, either directly ( through instruments ) or implicitly ( through knowledge of the electrical parameters ). Knowing when, where and how much energy is needed can lead to more effective energy strategies. The energy consumption of a machine can be visualized as a HMI and archived. This allows both semi-automatic (ie partially manual ) intervention in the processes and the control of other energy-intensive processes with non-electrical energy such as Pneumatic, hydraulic or steam systems via the network.

Implementation

Profienergy separates the control logic (typically a PLC) of the processes from the energy management system, so that if desired, a separate energy management controller may be used. This separation, both parts of the application program can be tested independently of each other and put into operation. Retrofitting Profienergy in devices and subsystems can be done via firmware updates.

Savings potential

The stipulated in Profienergy standard procedures and data structures allow different manufacturers equip their products with compatible functionalities. This approach encourages competition among providers enabling end users get a larger selection of products with optimized energy -saving features. The network infrastructure is already in place with PROFINET, as well as the control hardware. The savings will depend on the type of equipment. Switching Functions are integrated in the device. Thus it can be achieved despite the higher by integrating the Profienergy functionality upfront cost short-term return on investment. Peak load management can reduce cost disadvantages by exceeding contractual load.