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Energy management according to Industry 4.0 principles

06.09.2021

Optimizing energy consumption is always an effective method of reducing costs. The efficiency of which is greatly enhanced by the use of Industry 4.0 technologies.

Information systems that combine manufacturing assets, controls, and analytics into a single ecosystem enable enterprises to track, measure and visualize energy use in real time.

By analyzing the data obtained, you can find the optimal balance between performance, energy consumption and equipment wear. Also, based on the analysis, a corporate policy is developed that ensures the efficient use of resources.

In light of global initiatives to reduce the role of natural resources in industry, the relevance of energy management systems is only increasing. This is also evidenced by the numbers. According to forecasts, the global EMS market may reach $ 62.3 billion by 2023.

Energy Management 4.0

With the help of IT solutions, it is possible to create maximum value from the minimum amount of resources.

These Industry 4.0 principles also apply to energy management:

– reducing consumption where appropriate;

– creation of added value and economic value;

– increasing the overall performance of the equipment;

– availability, stability and quality of supply;

– reduction in the volume of maintenance;

– extension of service life and reduction of risks for key assets of the enterprise.

The implementation of such a strategy requires the coordination of many business processes. We will have to create a multi-level monitoring system that will collect and process data on assets, operations, supply and consumption flows.

Each level of such an intelligent system will open access to tools for influencing the energy efficiency of production. To ensure that EMS works effectively, it is necessary to take into account the interests of individual lines of business, corporate units and even external stakeholders. At the same time, it is critically important to maintain a centralized approach to optimizing energy management, avoiding a shift in focus to solving local problems.

Energy efficiency in practice

In theory, the process of creating and maintaining effective energy management measures seems complex. In reality, digital transformation has provided access to a host of energy management software tools.

Let’s consider some areas of application of Industry 4.0 technologies.

The Industrial Internet of Things is the foundation for building an energy management system. The Industrial Internet of Things (IoT) connects all the smart objects involved in the production chain. Data from sensors, meters and planners form a coherent picture. You see the consideration of real energy costs and the role of energy in the cost of production, the vulnerability of production and directions for optimization.

Big Data is a tool for interpreting streaming data into useful information. Powerful analytics tools help you make informed, cost-effective decisions faster. Given the growing number of data sources, such technologies will become indispensable in energy management.

Augmented Reality is a promising method for modeling and visualization. Today, augmented reality is increasingly being used to create open energy management systems for industrial environments. The technology provides opportunities for demonstrating large amounts of data in real time and remotely attracting experts to solve problems in the service sector.

Blockchain is a tool for increasing the traceability and reliability of data storage. The technology allows for the creation of an immutable history of energy transactions, provides unprecedented accuracy and reliability of cost analysis. Blockchain is already being used in industry to organize diversified supplies of renewable electricity without the involvement of intermediaries.
Each technology can be critical in organizing energy management in an enterprise, saving resources and increasing production profitability. The main thing is to avoid mistakes when implementing EMS.

Challenges, problems and solutions

More and more variables are added to the original energy efficiency formula. The situation is complicated by the growing role of decentralized solutions in industry, for example, the use of autonomous power generation facilities. This increases the requirements for the manufacturability of software solutions and the level of training of operators.

To avoid widening the gap between the skill level of the staff and the functionality of the EMS, balanced and flexible systems should be chosen.

With SmartEAM solutions, you get a versatile, easy-to-use and powerful tool for energy management. Our EMS provides real mechanisms for influencing equipment performance, helping to identify and eliminate sources of waste of resources.

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