Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

Real-time energy audit reduces power consumption

24.10.2013
Software that monitors industrial machine operations in real time can reduce the overall energy consumption of factories

Governments are pressuring industries to reduce energy consumption for both environmental and economic reasons. Optimizing factory processes and improving equipment can lower energy usage but this not only takes time and money, it also requires a vast amount of background operational knowledge.

Now, Oon Peen Gan and co-workers at A*STAR’s Singapore Institute of Manufacturing Technology, together with researchers at the National University of Singapore and The University of Texas, United States, have developed an approach to track the daily energy usage of individual machines. Their approach monitors the operational state of a machine in real time1.

“Our proposed idea improves energy efficiency through better sequence control of machines and operations,” notes Gan. “It can be as simple as switching off a light when not in use.”

To test their idea, Gan and his team identified the operational state of two individual industrial molding machines, based on their energy consumption. The researchers placed sensors inside the machines and fed the data from the sensors into a mathematical model called a finite-state machine (FSM), which is commonly used for analyzing manufacturing processes. Since a machine in the ‘start-up’ state has a different energy output to one in full production, the FSM could be used to produce power-consumption profiles of the machines.

The researchers then used a unique two-stage framework to help them analyze and classify the data. “During the first stage we cleaned the raw energy signals using a digital filter to produce a much smoother dataset with less noise,” explains Gan. “Secondly, we trained a pattern-recognition algorithm, or neural network, to classify the data into separate events. Each event represents a machine operation state.”

Using the model, Gan and co-workers determined the exact operational state of each molding machine in real time. Because the researchers could easily find abnormal energy patterns in the model output, the software tool may prove very useful for engineers looking for machine faults across the factory floor.

With the trained neural network in place, a software user can classify any machine’s operational state from its energy output without needing to know the machine type. Theoretically, the model could be used to monitor many different types of machines in any industry.

“We hope to incorporate our new model into existing software that is used by manufacturers to monitor their shop floors,” says Gan. “We aim to validate the model with experiments at a number of industrial companies in Singapore in the near future.”

The A*STAR-affiliated researchers contributing to this research are from the Singapore Institute of Manufacturing Technology

Journal information

Le, C. V., Pang, C. K., Gan, O. P., Chee, X. M., Zhang, D. H. et al. Classification of energy consumption patterns for energy audit and machine scheduling in industrial manufacturing systems. Transactions of the Institute of Measurement and Control 35, 583–592 (2013).

A*STAR Research | Research asia research news
Further information:
http://www.a-star.edu.sg
http://www.researchsea.com

More articles from Power and Electrical Engineering:

nachricht Hybrid storage with market potential: Battery production goes Industrie 4.0
01.03.2017 | Fraunhofer Institute for Applied Polymer Research IPA

nachricht WSU research advances energy savings for oil, gas industries
28.02.2017 | Washington State University

All articles from Power and Electrical Engineering >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: Researchers Imitate Molecular Crowding in Cells

Enzymes behave differently in a test tube compared with the molecular scrum of a living cell. Chemists from the University of Basel have now been able to simulate these confined natural conditions in artificial vesicles for the first time. As reported in the academic journal Small, the results are offering better insight into the development of nanoreactors and artificial organelles.

Enzymes behave differently in a test tube compared with the molecular scrum of a living cell. Chemists from the University of Basel have now been able to...

Im Focus: Safe glide at total engine failure with ELA-inside

On January 15, 2009, Chesley B. Sullenberger was celebrated world-wide: after the two engines had failed due to bird strike, he and his flight crew succeeded after a glide flight with an Airbus A320 in ditching on the Hudson River. All 155 people on board were saved.

On January 15, 2009, Chesley B. Sullenberger was celebrated world-wide: after the two engines had failed due to bird strike, he and his flight crew succeeded...

Im Focus: Breakthrough with a chain of gold atoms

In the field of nanoscience, an international team of physicists with participants from Konstanz has achieved a breakthrough in understanding heat transport

In the field of nanoscience, an international team of physicists with participants from Konstanz has achieved a breakthrough in understanding heat transport

Im Focus: DNA repair: a new letter in the cell alphabet

Results reveal how discoveries may be hidden in scientific “blind spots”

Cells need to repair damaged DNA in our genes to prevent the development of cancer and other diseases. Our cells therefore activate and send “repair-proteins”...

Im Focus: Dresdner scientists print tomorrow’s world

The Fraunhofer IWS Dresden and Technische Universität Dresden inaugurated their jointly operated Center for Additive Manufacturing Dresden (AMCD) with a festive ceremony on February 7, 2017. Scientists from various disciplines perform research on materials, additive manufacturing processes and innovative technologies, which build up components in a layer by layer process. This technology opens up new horizons for component design and combinations of functions. For example during fabrication, electrical conductors and sensors are already able to be additively manufactured into components. They provide information about stress conditions of a product during operation.

The 3D-printing technology, or additive manufacturing as it is often called, has long made the step out of scientific research laboratories into industrial...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

Event News

Booth and panel discussion – The Lindau Nobel Laureate Meetings at the AAAS 2017 Annual Meeting

13.02.2017 | Event News

Complex Loading versus Hidden Reserves

10.02.2017 | Event News

International Conference on Crystal Growth in Freiburg

09.02.2017 | Event News

 
Latest News

A better way to measure the stiffness of cancer cells

01.03.2017 | Health and Medicine

Exploring the mysteries of supercooled water

01.03.2017 | Physics and Astronomy

Research team of the HAW Hamburg reanimated ancestral microbe from the depth of the earth

01.03.2017 | Life Sciences

VideoLinks
B2B-VideoLinks
More VideoLinks >>>