以能源使用績效為導向

的智慧工廠

吳仲祥

系統工程部

柏眾網控股份有限公司

研華集團

內容大綱

工業電價調漲源起

智能工廠節能管理的挑戰

智能工廠節能管理未來趨勢

智能工廠節能新時代的願景

- 智能感知

- 資訊傳遞

- 雲端運算

- 先進製程管理

Enabling an Intelligent Planet

Segmented Business Units Powered by

Global Trusted Brand

The Global Leader of Embedded &

Automation Solutions for iWorld System

Integrations

Industrial Automation

Business Group

Intelligent Services & Applied Computing

Business Group

Embedded Design-In Services

Business Group

Design & Manufacturing Services

Business Group

2010 Consolidated Sales : US$696M

研華公司企業簡介

企業使命 : 智能地球的推手

中國人工工資不斷高漲

價調漲出爐工業電漲23-27％ 工業電價調漲 23 ~ 27 %

智能工廠與各項設備自動化的挑戰

• 能夠對設備的能源耗用進行透明的描述

• 進而提出對設備能源耗用的最佳化

• 速度與精度的要求以提升產量與產質

• 生產線製程管理的信息化, 網路化, 圖像化

及遠端監控與維護

• 生產機器設備的視覺檢測功能需求

• 製造技術智能化的趨勢

• 無線技術發展,物聯網概念, etc.

Energy Management The two most important levers to reduce energy costs

Total costs

Energy consumption

En

erg

y r

ate

s

Reduce energy consumption

Identify losses

Identify inactive reserves

Motivation initiatives

for power saving

Utilization optimization

Reduction in pause times

Optimizing procurement

Short-time contracts (e. g. per year)

Modification of the rate system

(e. g. time-varying rate system; time-of-use

rate)

Counteract increasing energy procurement

costs

Internal energy generation

targets here: • offers transparency on energy data • show optimization and cost reduction potentials

primarily offers energy planning and -procurement, bilancing (also CO2) and ad-hoc calculations of key parameters (KPI).

Energy Management Crucial questions by the plant operator

Energy quantity? Energy flows?

Transparent depiction of the TOP consumers

Costs? Per consumer? Per batch?

Optimal procurement / energy planning / demand profiles?

Reduction of the energy demand and the costs?

Gas

Water

Electricity

Heat

Where are potential savings?

Where and how can I purchase energy at the lowest price?

What are my energy unit costs? Energy costs per consumer?

What energy type is required and in what quantity?

What consumers require the most energy?

Detailed information mostly not available today!

Energy Management International standard ISO50001

Adjustment &

control

Management

Review

Energy Policy

Planning

Implementation

and operation

ISO 15001: Continous improvement process

Correction and

prevention

DIN EN 16001

Monitoring &

measuring Internal Audit

Begins at Top-Management

Strategy, energy policy,

sustainability

Budget, targets

Controlling

Efficiency-Projects

Is an ongoing task to improve

efficiency

Process, employee, quality control

Technical and legal aspects

Is more than just a technical system!

Energy-Management …

Energy Management is more than just a technical system!

Services for

optimization along the

whole energy value

chain, from the

production of energy up

to the consumer.

Energy Services

Technical system for the

col-lection, analysis,

documen-tation and

visualization of energy data

as well as regu-lation and

controlling of energy

consumption in plants and

buildings.

Energy Management System

Energy efficiency means

re-ducing energy

consumption without

having to reduce the use

of energy consuming

plants and equipment.

Energy Efficiency

EM enables companies to determine, improve and analyze systematically and

continuously their energy consumption. Within this optimization process

economic as well as technical and legal aspects have to be considered.

Definition Energy Management

The Comprehensive Approach Energy Management as 3rd Pillar

Operations Maintenance Energy Management

Continuous Performance Monitoring

Compare: setpoint / actual (Learn modus)

maintenance based on the actual condition

Coherent Automation

in Factory Automation

in Process Automation in Infrastructure

Automation

Energy Circle:

Identify

Evaluate

Realize

New

Energy Management Integrated system solution

Operation (FA) Maintenance / Diagnose Energy Management

Factory Automation Process Automation Storages etc.

Seamless integrated system

Operation (PA)

The Energy Management Storyline fitting the complete Energy Management process

Three steps to Energy Efficiency

Accompanied Consulting

Energy Monitoring System

Measurement, display energy flow

Cost center allocation, energy costs per production unit

SIMATIC WinCC & SIMATIC powerrate & Sentron PAC

Energy Management System

Cost Transparency, Monitoring & Reporting

Show reserve of energy (oversizing)

Interfacing SIMATIC IT (MES)

Products, Systems and Solutions

Drive Systems

Peak Load management with SIMATIC powerrate

Energy Planning and Procurement

Preparation / Consulting

Energy Check / Analysis

Energy Optimization Services

Documentation and action plan

Continuous Process

Energy Management EM Functionalities related to system

Reporting

Planning

Procurement

Visualization

Archiving

Load Mgt.

Compressing

Data Aquisition

Communication

Energy Management System

– Easy integration in any control system environment via

standard interface or Ethernet (Modbus TCP / OPC)

– Full integration of energy management systems, e. g.

Seamless system integration

System integration as a standard

Integration Example

Connection of Power Meter through filed

bus to reduced the cable cost

Connection of the control to the

operation and monitoring level via

Ethernet

Energy curves provide transparency

Load curves Benefit

Identification of Deviations that could be

challenged Optimization potentials,

e. g. domestic production of high loads Peak loads Energy consumption

outside of production times Create “energy

awareness”

Performance diagram

Load curve

04 11 18 25 30 01

Month (=720h)

March 2011

Reports for energy transparency

Cost center reporting Benefit

Well arranged representation of cost centers and

energy costs

Comparability of different consumers or consumer

groups, e. g. production lines

Graphical representation of energy data and costs

MS Excel based, adaptable report templates

Transparent consumer

costs

Identification of

optimization levers

between different

consumers and groups

Controlling of

optimization progress

and measures

Adaptable to own

requirements

cost center report cost center report

Load management

Load management „cuts off“ the peaks Benefit

Avoids peak loads by automated switching off and on consumers, typically in attendant facilities

Processing of additional user defined conditions possible (AND combination)

Integrated warning and alarm messages Max./Min. on and off times configurable Consumers to be switched off and their capacity can be

configured, consumer groups and rotating consumers

Avoids peak loads and ensures compliance to contracts Reduction of the

load limit Reduction of energy costs Equal use of

consumers

Leistungsdiagramm 11.04.2007

0

500

1000

1500

2000

2500

3000

00:0

0

00:4

5

01:3

0

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5

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03:4

5

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0

05:1

5

06:0

0

06:4

5

07:3

0

08:1

5

09:0

0

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5

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0

11:1

5

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0

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5

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0

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5

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0

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5

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0

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5

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0

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5

19:3

0

20:1

5

21:0

0

21:4

5

22:3

0

23:1

5

t

kW

15„ Periode

trend analysis

consumer

Energy Management overview

Emission Energy balancing

Energy billing

Batch related balancing

Energy planning

€ / $

CO2 kWh kWh

kWh/kW

Energy and material balance – KPI calculation

Calculation Level III

Excel Calculations pre-defined

in the report template

Result presentation

Calculation Level II

Calculation Level I

Database based calculations

(supported by pre-defined objects)

Date Management

Powerful Online Calculation Core

Interface Management

Energy invoicing

Result – Energy invoicing after costs-by-cause-

principle

Energy planning

Basic load profile

Scaling up/down

+/- n % +

External effects

+/- n MW +

Production planning

Units/time +

Production planning

On/off +

Ge

ne

ral fo

rec

as

t

Emission monitoring CO2

Emission =

Material usage × emission factor × oxidation

factor

Fuel

Raw material

Emission

Products

Production

process

Measuring Standard factors

Yes to energy management - but sustainable!

Sustainable energy data management in several

steps Creation

transparency

Costs-by-cause-based

accounting

Process

optimization

Operation

optimization

Installing measuring

points

Represnting the

energy flow

Identifying

potentials uses

Visualizing

Documenting

+

Continuos improvement Process

+ =

Allocating

energy costs

to cost centers

Energy cost per

production unit

Energy flow per

production unit

Automatic load

management

Identify power

dristribution

reserves

Data exchange

with process

control

systems

Optimizing

energy

procurement

Optimizing

energy costs

Phase 1 Phase 2 Phase 3 Phase 4

智能工廠未來趨勢 - 從替代體力到替代腦力的設備自動化

智能

製造

智能感知

先進製造技

術與管理 資訊傳遞

能源耗用

Sensor

Application Communication

Management

VFD Inverter

Internet/Intranet/Ethernet

Advantech Energy Management Solution Architecture

Remote

WebAccess

IE Client

WebAccess

MMI/ SCADA

Backup

WebAccess

HMI/ SCADA

Primary

Measurement meter –

power/ Heat/ Gas meter

BEMG-4110/

4220

(Concentrator)

Energy (能源管理)

BAS-3500 DDC

Controller

BACNet

MS/TP

Building Management (空調及機電自動化)

BAS-3000

Remote IO

• BEMS

- Energy Analysis

- Energy Reports

- Cost Analysis

- Cost Report

Advantech

BEMS (SQL/

Access Database)

Modbus

RTU

BAS-3000

BACNet IO

BACNet IP Modbus TCP

3rd party

DDC

Modbus

TCP

BAS-3000

BACNet IO

BACNet

MS/TP

Modbus TCP

General Certification Vertical Designs

Ha

rdw

are

So

ftw

are

Solu

tio

ns

Automation Devices & Computing Application Specialized Products

Fully Integrated Solutions

Internet of Things (IoT) Products

Green Energy Water/ Environment Factory Automation BA/BEMS Production Automation

研華工業自動化事業群產品及解決方案

Intelligent Automation, Seamless Integration 研華工業自動化事業群

研華在智能製造設備自動化的願景 與合作伙伴共同成為智能製造的推手

並且作為設備自動化解決方案的提供者

MES in the Factory/ Plant Cloud

Embedded Platform(IPC / Board)

With SUSIAccess HMI

PC-Based

Machine

CNC

Machine PLC-based

Machine

Real-Time

Ethernet

control

Sensor

Motion Control

(VB / C++ ..) CNC control

(CNC logic)

PAC control

(Soft-logic )

雲端運算

/

先進製程管理

資訊傳遞

智能感知

智能感知 智能製造設備自動化-智能感知

RS-485

I/O Device

IEC-61499 I/O Device

Ethernet

I/O Device

Motion Device

WSN

I/O Device

Video Device

BACNet Device

Integrated I/O Controller

PAC

Device server

Fieldbus Master

DDC

Controller

Motion

Controller

Wi-Fi PoE Switch

USB

Device

Managed Switch

Profinet EtherCAT Modbus/

TCP ModBus/RTU

Internet Internet

AMONET

IEC-61499

ProfiBus Ethernet/IP PowerLink

IEC-611131

I/O Card

Motion

Card

PAC I/O Device

Serial Comm.Card

Unmanaged Switch

Data Gateway

Embedded Automation Computer

3G/GPRS

資訊傳遞

OP

C-U

A

Smart device

ADAM

device

PoE

device

Ethernet device

Motion device

Wireless device

WSN device

Video device

PLC device

BA device

Controller+I/O

PAC

Device server

Fieldbus master

DDC

Controller

Gateway

Motion

Controller

3G,WIFI

WiMAX PoE Switch

USB

device

M. Switch

Switch

IEC-61499

UNO

智能製造設備自動化-資訊傳遞

DATA TSUNAMI

雲端運算 智能製造設備自動化-雲端運算

廠務 (水/電/氣供應端)

設備1 設備 2 設備 3 設備 4

高單價component 管理 幫浦 /馬達 …等

幫浦 or 馬達訊號

設備訊號

廠務訊號

先進製程控制 系統資料庫 資料庫用途:

主要依照資訊的歷史來做為未來“預測性”判斷的指標

先進製程管理 智能製造設備自動化-先進製程管理

先進製程管理

目的:

• 提高生產設備投資報酬率

• 穩定工廠生產的產品品質及良率

• 即時有效通報及監控生產機台的製程狀況

• 提升工程師監控設備機台的效率

• 提供“充足的”機台製程資訊，進而改進生產品質

• 加強競爭力

相關市場研究開發 : • APC (Advance Process Control)

• TPM (Total Predictive Maintenance)

• iMCMs (intelligent Machine Condition Monitoring system)

智能製造設備自動化-先進製程管理

研華產品用於先進製程資料的收集 Operator Station

• SCADA/HMI function

• Video Surveillance

- Video Recording/Playback

- Camera remote PTZ control

- Video Motion Detection

先進製程 Database

APC Smart TPM iMCMs

WebAccess Graphic Display

資料蒐集器 資料蒐集器 資料蒐集器

Meter … Sensor…

Sensor…

Serial

Meter … 電力Source

ADAM-3112/3114 AC 比壓器/比流器 Module

Ethernet I/O ADAM-5000/TCP

Ethernet I/O ADAM-6000

Serial Device Server

Sync

設備監控

系統回復

遠端控制

2

1

3

SUSIAccess 軟體打造IPC無限遠端監控功能

整合機台/系統，進行設備監控/遠端控制/系統回復

研華產品用於資料傳遞的應用

研華產品用於智能製造的解決方案

研華自動化團隊 自許成為您在 智能製造下一波趨勢 的最佳合作伙伴!

研華股份有限公司

企業使命 : 智能地球的推手