30% energy saving potential: White Paper

"Potential of PROFIenergy” - white paper describes how to save 30% energy in production applications

A new white paper from PI (PROFIBUS & PROFINET International) concerning PROFIenergy describes the results of measurements in real-world applications and highlights the potential benefits for manufacturers, OEMs, and – in particular – plant operators. The data acquired confirm that the use of PROFIenergy in the studied production applications enables energy savings of 30 %.

The well-founded statements regarding the potential for energy savings are based on targeted measurements at various points in the energy distribution and at defined time intervals as a function of the plant status. The potential for energy savings – and thus cost savings – can be determined directly based on the duration of pauses and the energy consumption by loads that are not switched off.

The new white paper also describes the operating principle behind the PROFINET profile developed specially for energy-saving automation systems along with possible applications and optimum use of this profile. Target markets include production lines used for discrete production that feature high-performance machines, such as robots and laser-based components. In addition to the obvious cost savings, PROFIenergy provides competitive advantages to users, for example, in the form of longer machine life due to fewer operating hours. Not the least of the advantages is the environmental benefit resulting from the improved CO2 balance.

Significent potential savings..

Study confirms significant potential savings through PROFIenergy

A study by the Institute for Automation & Industrial IT, (Koeln University of Applied Sciences, D), confirms potential savings of 50% or more during idle phases as a result of PROFIenergy. Up to now hardly any empirical values and only limited comprehensive data were available on the relationship between energy consumption and operating modes, especially with regard to idle times. Measurements taken as part of the study were intended to provide clarity and actual figures.

Initial analyses and measurements were completed on production lines at the Daimler factory in Sindelfingen and the Volkswagen Commercial Vehicles factory in Hannover. The behavior of the overall plant and its components were analysed with respect to load curve, load distribution, and pause durations, among other things. In addition, the influence of operating modes on energy consumption was analyzed, and pauses were analyzed with respect to frequency and duration. In addition to planned pauses and idle times, unplanned pauses were also recorded and their relevance determined. With up to 15 different measuring points, it was possible to record typical load curves in the plant from the main incoming supply to individual consumers and to determine characteristic values.

Specific examples taken from the measured results indicate the energy savings potential realized by using PROFIenergy. In some production areas, the potential savings were in excess of 50%. During the analysis it became clear that unplanned pauses, amounting to about 60%, can also be utilized, because even short pauses of 3 to 5 minutes are relevant for use of PROFIenergy. These pauses represent significant savings potential that can be exploited with clever use of PROFIenergy to signficantly reduce energy consumption.

The first PROFIenergy pilot applications are currently undergoing testing at multiple user sites.

Support for green initiative

HMS supports the “green automation initiative” of the automobile manufacturers with the release of an embedded Anybus-CompactCom PROFIenergy communication module.

HMS Industrial Networks has released an embedded Profinet communication module with integrated PROFIenergy profile server. With this new release HMS supports the efforts of the AIDA group of automobile manufacturers (Audi, BMW, Daimler, Porsche and Volkswagen) to reduce the energy consumption of manufacturing plants. The new module provides manufactures of automation devices with a fast and easy way to integrate energy control functionality, according to the PROFIenergy standard, into their devices. Thanks to the standardized PROFIenergy commands, a central controller can switch complex automation systems consisting of automation devices from various manufactures easily and safely into standby mode during production breaks and standstill times. This safe up to 40% of the electrical energy needed for the production process and helps to reduce the CO2 emission.

The PROFIenergy server is implemented in the firmware of the Anybus-CompactCom Profinet IO communication module. The module acts as Profinet IO device according to conformance class B in the Profinet network and is equipped with a fast 2-port switch which allows Profinet installations in line topology without the need for expensive external switches. The integrated profile server handles the PROFIenergy commands and parameters according to use cases 1 – 3 and provides a standardized hardware and software interface towards the electronics of the automation device. This minimizes the development efforts needed inside the automation device to fully comply with the PROFIenergy standard.

By choosing to integrate support for the new PROFIenergy CompactCom module, customers will automatically get access to all major industrial networks, since it is part of the Anybus-CompactCom family of interchangeable plug-in communication modules - the world’s most flexible and cost-efficient solution for connecting devices to all major fieldbus and Industrial Ethernet networks including Profibus, DeviceNet, CC-Link, CANopen, Profinet, EtherCAT, Modbus-TCP and Sercos III. CompactCom modules are used as communication interfaces of intelligent automation devices such as drives, HMIs, robots, inverters, instruments, and scales.

The Anybus-CompactCom modules come in a slim housing about the size of a compact flash card. The core of the module is HMS´s NP30 network microprocessor with its integrated fast Ethernet controller and RAM and Flash memories for the EtherNet/IP device software stack. The onboard 2-port switch provides two 100 Mbit/s full duplex Ethernet interfaces with RJ45 connectors.