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Energy monitoring

Situation

Monitoring and control mechanisms are two key components of any energy efficiency program. At present, most trades and machines are unregulated in terms of energy consumption optimization. Drives are usually only turned on and off and hardly walk in their optimal speed ranges, although they account for around 60% of energy consumption. According to ZVEI, there is a potential for energy savings through energy monitoring and control of over 30%.

Problem

Meanwhile system- and producer-dependant energy monitoring components are offered, but always include only a portion of the process and thus allow no process comprehensive energy monitoring and auditing. The data models of the individual components correspond to the respective manufacturer's standard and therefore are often not interoperable.

Objective

Consolidation of all energy consumption data in a vendor-independent data model and storage of data in a central database at the process control level, or in a separate IT system.
Correlation of energy data with time-synchronous process states of controls or units, to identify problem points in the current production and logistics process.
Provision of aggregated data to a superordinate IT system (ERP, BI, ...) via system interfaces or reporting of data for an independent energy audit, permit a detailed, targeted analysis of the energy consumption situation.

Base technology

Since 1997 Fränz & Jaeger uses the technology of decentralization and distribution of control and application functions by software agents (software services) throughout for its process automation projects. Meanwhile, this F & J concept was realized successfully and effectively with customers in networks of up to 450 control nodes with the integration of different types of mechanics.

We use a special runtime environment for the control node (IPC), that allows us to save all data and events continuously. This technology allows us not only to monitor mechanics and control, but also to measure the energy consumption. This assumes, however, a corresponding functionality in the mechanics and interfaces.

EnergyDataCollector ELOG

The F & J Energy Data Collector ELOG is a software agent, which is runing parallel to the existing functional modules (agents) in the control node (IPC) and receives energy consumption data cyclically and log it. The control node uses its own or accesses via bus systems special energy monitoring modules of the respective machine manufacturers.
The special challenge is that each manufacturer uses its own data model with diverse structures, data types, and energy levels. Therefore, always individual, customized collector agents are necessary. The manufacturer-specific data are stored up to date in a vendor independent format in the control node.
The F & J-concept includes a presentation interface, which provides the data from the energy database for an external SQL reporting tool, eg Chrystal Reports or the like.
The customer can create their own individual energy auditing reports on the basis of the reporting tool of their choice,  or have them created by F & J.

Export / interface

The F&J Energymonitor framework includes an agregator-agent which provides data for custom-specific processing. In the simplest case the energy data is provided as a CVS-File for further processing. However, there is also the possibility to form a custom extension to an interface to higher-level systems (ERP,BI, MSSQL .. ). 

Consultation

F & J supports its customers in the search for possible practical energy optimization potential and possible adaptation of the process and its parameters for further optimization of energy consumption.
The procedure begins with a survey of the existing system infrastructure and eventualy existing energy monitoring components. Then a custom neutral data model and the necessary data interfaces is defined.
Based on the definitions the central database can now be generated and may need implementation of new system interfaces.
The final step is the definition and implementation of reporting capabilities and the acquisition in higher level IT systems.