In today’s world energy cost big dollars for manufactures and the fact is most plants don’t know where there energy is being used. To help with this problem the Industrial Network communities are providing common interfaces to gather and control energy in the industrial space. This presentation will focus on aspects of Energy where it relates to Industrial Automation and some of the challenges we face. We will also cover upcoming initiative for interfacing to the smart grid for demand response request.

1. September 10, 2014
1

2. Cost of Energy
The Role of Industrial Networks
Energy Usage Reporting Standardization
Controlling Usage
Smart Grid Connection
CIP Energy Overview
Applications
2

3. Knowing when and where energy is used is
important
According to the DoE and eia the industrial sector
uses about 1/3 of the energy in the US.
3

4. Studies suggest that 15-30% may be saved
overall
Profinet International Study
– Measurements were taken in an automotive
assembly plant to determine the amount of energy
that could be saved during downtime.
– It suggested that up to 60% of the total energy
used during production may be consumed during
downtime.
4

5. 5

6. Most of the electrical energy consumed is for
electrical motors
– As of 2012 only 28% of low voltage motors are
classified as high-efficiency.
– By 2017 high-efficiency low voltage motors should
account for 62%.
– 96% of the total cost of ownership for a motor is
the electrical energy usage, leaving 2% for the
purchase cost and 2% for maintenance.
6

7. Aspects of energy management
– Monitoring energy usage.
– Controlling the amount of power a machine may
use at any given time.
– Powering down when the machine is not active.
7

8. Many of the industrial protocols have
support for energy:
– PROFINET has a profile for energy monitoring and
power control.
– EtherNet/IP has objects for monitoring and power
control (production and idle states).
– Sercos III has a profile for monitoring and power
control.
8

9. Common reporting unit: kWh.
– Report the total energy consumption within
the plant in kWh.
– Many energy types: steam, chilled water,
natural gas, oil, etc. may be reported in kWh.
– Allows reporting of the total energy usage
within the machine regardless of energy
sources (cost per widget).
9

10. Two approaches
– Power down unused devices and machines.
– Run the device at a lower power level during
production.
•Running the device or machine at a lower
power level may not save overall energy
cost per widget, but would reduce the
energy usage for a given period of time, for
example at peak demand.
10

11. Powering down devices should ideally be
done during breaks
– E.g. lunch, weekends, scheduled and
unscheduled maintenance.
– Machine is idling.
Factors to consider
– How much time is required to bring back up
the device after shutting down.
– The energy used to shut down and start up, is
it less than remaining powered up?
11

12. Running at a lower power level during
production
– May be applied as an attempt to keep peak
energy consumption below a certain point for a
specific pay period (due to overage penalties).
– External environment factors ( transformer
problems, overloaded grid, etc.).
– Power source changes (coal, wind, solar, etc.).
12

13. Connection solutions could come in the
form of gateways
– Provide translation between Industrial
Networks and Smart Grid Networks (e.g. IEC
61850).
– The approach allows for a firewall between the
utilities provider and the factory floor.
13

14. 14
Assembly
0x04
Connections
Objects architecture
Identity
Energy
Curtailment
Object
TCP/IP Interface 0x01
Base Energy
Message Router
0x02
0xF5
Ethernet Link
0xF6
Assembly
0x04
Connection
Manager
0x06
Assembly
0x04
Non-Electrical
Energy
Object
Electrical
Energy
Object
Object
IO EM
EtherNet/IP Unconnected Msg Connected Msg
Parameters
Objects
Parameters
Objects
Parameters
Objects
Power
Management
Object
Application Objects

15. Monitoring concepts: Base Energy,
Electrical and Non-Electrical objects
15
Base Energy
Object
Electrical Energy
Object
Non-Electrical
Energy Object
(0 .. 1)
Associated
Base Energy
Object Path

16. Base Energy Object normalizes all data to
kWh’s and/or kW’s
• Range: 999 terawatts hours to watts hours, 15 digits of
accuracy.
• kW’s are reported as a 32 bit real.
Electrical Object has specific electrical
attributes for example
• Reactive Power, total and per line.
• Active Power, total and per line.
• Phase / Line Frequency.
• Current Average, line to line and line to neutral.
• Voltage Average, line to line and line to neutral.
• Etc.
16

17. Non-Electrical Object may be used for
any energy type
– For example:
• Natural Gas, Compressed Air, Fuel Oil, Tallow.
• Provision for custom energy types.
– Reports energy in native units, translated to
kWh’s via the Base Energy Object.
– Attributes are provided for conversion math.
• E.g. 1 kWh = ((1 Gallon of Diesel * 383)/10).
17

18. Base Object may have a number of
types
18
Energy
Source
Power
monitor
Line or
department
Energy measured
Overload relay
Motor amps
(measured)
Energy derived
Voltage
(assumed)
Non-CIP servo
Generic device
Energy proxy
Energy aggregated
Software
application
Controller or
Translator
Parent/child relationship
Specified using EPATHs
Power supply
300W
Energy fixed
Infeed VFD
Heating
element
Machine
controller to line
controller
Power supply

19. Power Management Object
– The purpose of this object is to bring the
machine/device to a lower power state (non
operational).
– Time based, the longer the pause time the
higher potential energy savings.
– May support many levels of pause depending
on the device.
– The possible states are Owned, Paused,
Sleeping and Resuming.
19

20. – Power Management Object States
• Owned indicates that this device may be controlled by a power
management client.
• Paused indicates the device is in a lower power state.
• Sleep indicates the device is fully powered off with exception of the MAC
layer (waiting for Wake on LAN).
• Resuming indicates the device is powering back up after being in a low
power state.
20
Requested Pause or Sleep Time
Resume Time
Wake from Sleep Time
Time to achieve
low power level
Minimum Pause or Sleep Time

21. Power Curtailment Object
– This object is power based, requests are given
in the amount of power required to be
consumed.
– Lowers power consumption during production,
likely by lowering the production output (lower
part count).
– The object manages this by holding
configuration sets for different power levels of
run time modes e.g. 70%, 50%, 30% of full
scale power usage.
21

22. Example Cell
– The following Cell is an example of how Industrial networks can be utilized
in the context of Energy.
– The sample is only showing electrical energy but could easily be applied to
other energy types.
1. Robot Controller
2. Robot Controller
3. Glue Gun
4. Drive Control
5. I/O Block
22
3
2
1
4
5

23. 23
Energy Monitoring Flow
Energy Tool
CIP Client
[15kWh]
Line PLC
Energy Object Server
Energy Aggregator
[7kWh] Robot Controller (1)
Inst 1 [2kWh]
Inst 2 [1kWh]
Robot Controller
(2)
Inst 1 [5kWh]
Inst 2 [2.5kWh]
End of Arm
Tools
Glue Gun (3)
[1kWh]
End of Arm
Tools
[0.5kWh]
IO block
Proxied
Inst 1 [1kWh]
Inst 2 [1kWh]
Proxied
IO Lift motor
(5)
Proxied
IO Lift motor
(5)
Drive Controller
(4)
[100kWh]
Ethernet/IP
Ethernet/IP
DeviceNet
DeviceNet
Line PLC
Energy Object Server
Energy Arregatitor
[8kWh]

24. – Understand how much energy is consumed to
build products at the Cell level.
– Compare baseline with current data for preventive
maintenance.
– Schedule jobs in different cells to keep the peak
energy consumption down and lower overall cost.
– Use data to set up power curtailment programs,
allowing for demand response capable production
lines.
24

25. 25

26. 26

27. 27