Machine automation is a key opportunity for achieving energy efficiency and improved machine performance. Many of today’s control devices offer new capabilities through programming and ready-to-use embedded features. New algorithms, for example, have already proven themselves and can be found in controller and device application libraries.

Schneider Electric believes using active energy management through automation realised up to 37% in energy savings on an automotive production line. The savings were achievd through the proper management of the control systems when machines are operating, idle and stopped.

Predictive control finds new energy savings

In an HVAC application for example, integrating an advanced predictive control loop algorithm can deliver more than 10% of additional energy savings when compared to PID regulation. See chart.

Monitoring operating modes and status through automation

End-users do not always use the full capacity of their machines and equipment, depending on their production objectives. Some key areas are frequently stopped intentionally to activate only the needed resources. These techniques can be efficiently applied in conveying, such as becoming active only when the load arrives rather than running continuously.

Stopping, idling, or on-hold functions are deactivating the actuators and should be integrated in the programming to generate further energy efficiency for the benefit of end users. Studies have demonstrated that machines are rarely in production 100% of the time, and it is estimated that consumption could be reduced by nearly 37% if machines were properly managed during these idle periods, for example, by simply powering them off.

Safe stopping and restarting conditions should also be considered as a source of energy efficiency, such as avoiding keeping the control system and communications bus under power when switching off the machine. This is possible when parameters are saved upon stopping and re-enabled upon restarting under the previous state. Sometimes the solution is not completely obvious, such as for constraints on safety or quick restarting of the line; end users preferably choose to maintain the control system under power.

Some optimization and benefit can be reached as well in managing the starting of machines. By using sequential starting you can minimize the starting current and avoid maximum demand peaks that generate penalties by some power utilities.

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