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 Multiregional brain on a chip
16.01.2017 | Harvard John A. Paulson School of Engineering and Applied Sciences

nachricht Researchers develop environmentally friendly soy air filter
16.01.2017 | 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: Designing Architecture with Solar Building Envelopes

Among the general public, solar thermal energy is currently associated with dark blue, rectangular collectors on building roofs. Technologies are needed for aesthetically high quality architecture which offer the architect more room for manoeuvre when it comes to low- and plus-energy buildings. With the “ArKol” project, researchers at Fraunhofer ISE together with partners are currently developing two façade collectors for solar thermal energy generation, which permit a high degree of design flexibility: a strip collector for opaque façade sections and a solar thermal blind for transparent sections. The current state of the two developments will be presented at the BAU 2017 trade fair.

As part of the “ArKol – development of architecturally highly integrated façade collectors with heat pipes” project, Fraunhofer ISE together with its partners...

Im Focus: How to inflate a hardened concrete shell with a weight of 80 t

At TU Wien, an alternative for resource intensive formwork for the construction of concrete domes was developed. It is now used in a test dome for the Austrian Federal Railways Infrastructure (ÖBB Infrastruktur).

Concrete shells are efficient structures, but not very resource efficient. The formwork for the construction of concrete domes alone requires a high amount of...

Im Focus: Bacterial Pac Man molecule snaps at sugar

Many pathogens use certain sugar compounds from their host to help conceal themselves against the immune system. Scientists at the University of Bonn have now, in cooperation with researchers at the University of York in the United Kingdom, analyzed the dynamics of a bacterial molecule that is involved in this process. They demonstrate that the protein grabs onto the sugar molecule with a Pac Man-like chewing motion and holds it until it can be used. Their results could help design therapeutics that could make the protein poorer at grabbing and holding and hence compromise the pathogen in the host. The study has now been published in “Biophysical Journal”.

The cells of the mouth, nose and intestinal mucosa produce large quantities of a chemical called sialic acid. Many bacteria possess a special transport system...

Im Focus: Newly proposed reference datasets improve weather satellite data quality

UMD, NOAA collaboration demonstrates suitability of in-orbit datasets for weather satellite calibration

"Traffic and weather, together on the hour!" blasts your local radio station, while your smartphone knows the weather halfway across the world. A network of...

Im Focus: Repairing defects in fiber-reinforced plastics more efficiently

Fiber-reinforced plastics (FRP) are frequently used in the aeronautic and automobile industry. However, the repair of workpieces made of these composite materials is often less profitable than exchanging the part. In order to increase the lifetime of FRP parts and to make them more eco-efficient, the Laser Zentrum Hannover e.V. (LZH) and the Apodius GmbH want to combine a new measuring device for fiber layer orientation with an innovative laser-based repair process.

Defects in FRP pieces may be production or operation-related. Whether or not repair is cost-effective depends on the geometry of the defective area, the tools...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

Event News

12V, 48V, high-voltage – trends in E/E automotive architecture

10.01.2017 | Event News

2nd Conference on Non-Textual Information on 10 and 11 May 2017 in Hannover

09.01.2017 | Event News

Nothing will happen without batteries making it happen!

05.01.2017 | Event News

 
Latest News

Multiregional brain on a chip

16.01.2017 | Power and Electrical Engineering

New technology enables 5-D imaging in live animals, humans

16.01.2017 | Information Technology

Researchers develop environmentally friendly soy air filter

16.01.2017 | Power and Electrical Engineering

VideoLinks
B2B-VideoLinks
More VideoLinks >>>