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Optimized Energy Efficiency with Tecnomatix Energy-related simulation and evaluation with Plant Simulation 11
Energy prices Germany Electric power prices in Eurocent per kWh Source Eurostat Austria Sweden Spain *3 in 10 years World prices for energy, 1991-2010 2000 = 100 http://en.wikipedia.org/wiki/Energy_economics UK
Plant Simulation with energy simulation • Energy simulation is a core function of Plant Simulation version 11. • The same energy dialog is available in the Plant Simulation building blocks
License • The Plant Simulation Energy Simulation is available in all license configurations • Professional, Standard • Application, Runtime, Viewer • Education, Student • without additional licenses or fee.
Setup • Using energy simulation in Plant Simulation is very easy. • Set energy simulation to active. • Insert the power input for Working, Setup, Operational etc. in kW. • You can (but do not have to) define times to change from one energy state to the next energy state.
Energy States Working: A part is on the machine and it's being worked on Operational: All Engines are running, but the machine is not working – e.g. because it‘s empty Standby: Electronic is ready but main engines are switched off;e.g. Standby is a result of the pausing time Failed: Correlates with the failure status of the resource Off: Lowest status of energy consumption Setting up: Correlates with the setup behavior of the resource.
Transition times • Change energy level: • Transition times are defined between: • Off, Operational and Standby • Working, Setup and Failed are statuses resulting from the material flow.
State transition • The energy simulation feature in Plant Simulation is simple and easy to use. The behavior for pausing times and unplanned times in the shift model are already predefined and can be selected from a pull-down menu.
State transition • „Why switch machines to Standby or completely Off?” • Most modern machines allow users to easily switch off the main engine and go into a predefined standby or off mode. • This feature is seldom used as many companies do not know the savings potential. • The state transition used in the class element of a machine enables users to calculate the result with one click. • In the example shown here, changing the machine status during breaks and during nonproductive night time to Standby saves 6% and to Off saves 12% of the total energy consumption!
Don‘t be afraid… … to lower production to save energy by turning off machines. Modern control units(e.g. Siemens S7 300 /400 using the PROFIenergy Protocol) • Enable users to program a „wake up time“ • The machine changes to the previous status before the break or to Standby when the Off shift time is over • This action is predefined in Plant Simulation with the „Power up early“ function
Simtalk • The energy simulation feature can be addressed using Simtalk. • To get an overview, mark the relevant resource and press „F8“ to visualize all attributes. • To restrict the table only to the energy-relevant attributes, click on the „power flash“
Working with energy simulation To change a machine’s status to „Off“ when the machine in front is empty: • Change the EnergyTargetState to „Off“ • Plant Simulation automatically uses the defined time to turn the machine off • Vice Versa • To start the machine early enough to assure it‘s operational when a part enters, set EnergyTargetStatus to „Operational“
Charts The Plant Simulation Statistic Wizard • Is predefined for Energy analysis • Sorting e.g. by „Operational” points out which resource has a high potential to save energy without reducing productivity by changing the state actively to „Standby”
Energy Analyzer As a new function in Tecnomatix Plant Simulation version 11, we are proud to announce the Energy Analyzer, patent pending; U.S. Patent App’l Pub. No. 2013/001863.
The unique Energy Analyzer • Plant Simulation version 11 offers a unique Energy Analyzer • We are proud to announce the Energy Analyzer, patent pending; U.S. Patent App’l Pub. No. 2013/001863.
Plotter • Visualize peak energy consumers
Save Energy Built-in conveyor lines function
Save energy • Built-in method to save energy on accumulating conveyors. • If the conveyor is accumulating, and all parts have accumulated and no new part enters, the conveyor stops to save energy (and reduce belt friction). • In this small example the energy consumption is reduced from 72kWh to 25.6kWh • 64% energy savings with one click!
Summary • Energy consumption will be a major differentiator for or against a line builder • Plant Simulation version 11 offers an OTS toolset to • Model • Analyze • Optimize • Manage energy consumption in complex dynamic production environments