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Advancing the future of automation I Volume 3
Empowered by cutting- edge automation technology: the sustainable journey Connectivity – the backbone of sustainable automation How to use traceability 4.0 Solutions for improved product safety, compliance, and tracking How to optimize intra logistics to streamline and speed industry 4.0 supply chains
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Editor’s note The competitive edge in the
manufacturing landscape today is found through automation. Manufacturers have to navigate threats to their business every day. Whether those threats come from a global labor force shortage, geopolitical events, environmental impact, cost and availability of raw materials, or even supply chain limitations; manufacturers need every advantage to stay competitive in this turbulent world. Those who adopt strategies and processes to include automation applications as simple as asset monitoring systems to Digital Twin models can give themselves the ability to accurately and efficiently produce better products and get them in the hands of their consumers in a timely manner. For more information, please check out our website at www.digikey.com/automation.
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Moving into 2024 with tempered optimism
Empowered by cutting-edge automation technology: the sustainable journey Using electrification and automation to create more efficient and sustainable power grids – part one of two Using electrification and automation to create more efficient and sustainable power grids – part two of two How microgrids and DERs can maximize sustainability and resilience in industrial and commercial facilities
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Connectivity – the backbone of sustainable automation
Use IO-Link for increased flexibility, availability, and efficiency in industry 4.0 factories
How to use traceability 4.0 Solutions for improved product safety, compliance, and tracking How SCARA, six-axis, and cartesian pick-and- place robotics optimize and streamline electronics manufacturing processes How delta robotics optimize and streamline electronics manufacturing processes How to optimize intra logistics to streamline and speed industry 4.0 supply chains – part one of two How to optimize intra logistics to streamline and speed industry 4.0 supply chains – part two of two
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Moving into 2024 with tempered optimism By Eric J. Halvorson Segment
Marketing Manager II - Automation & Control
a large percentage of our total energy resources. Manufacturers are in a difficult but unique position that comes with a huge opportunity. Consumers now more than ever demand high quality, sustainable products manufactured through smart
and sustainable practices. As manufacturers look to be more competitive in getting goods in the hands of these consumers, environmental stewardship is more important than ever before. To add to the complexity, manufacturers continue to face a labor shortage epidemic. In order to meet the demands of the consumer, manufacturers need to be more nimble, more efficient in their processes, and constantly looking to improve. We see manufacturers doing this through the use of solar powered microgrids, carbon capture projects, asset monitoring, the use of AI and cloud computing, and many other technologies to meet net-zero goals.
with their assets in real time. If a motor is vibrating out of spec, they can address it immediately reducing downtimes, costly repairs, or replacements, and still maintain production levels. This also helps in reducing energy consumption greatly. The introduction of 5G has made asset monitoring even more achievable. By adding a wireless component with reliable, high speed, machine to machine communication, manufacturers can monitor every machine on the floor without the need to run more wire into sometimes very difficult to reach locations. The end result is the ability to take older factories and bring them into Industry 4.0.
Asset monitoring
Smart manufacturing
Introduction
Asset Monitoring is one of the easiest, effective ways to introduce automation on the factory floor. Manufacturers today, whether they are just beginning their journey into automation or have a state of the art, fully automated factory, need to maintain their equipment. This is by no means a new problem. Manufacturers need to protect their assets and minimize downtime. In the past, this meant scheduled maintenance plans that meant taking production lines offline to maintain compressors, tooling machines, motors, etc. Today, we can do it all from with the ease of a tablet. The integration of IIoT onto the factory floor has enabled manufacturers to communicate
Smart, sustainable manufacturing will continue to lead the conversation in industrial automation. When we look at the world’s total energy consumption, we see manufacturing representing
As we look back on 2023 in preparation for 2024, we can finally breathe a sigh of relief. 2022 and the first half of this year has been difficult for every point in the supply chain. We are now beginning to see an easing of normal stated factory lead times. Inventory across the channel is increasing and finally coming back into a state of normalcy. Over the past year and a half, it wasn’t uncommon to hear lead times on drives, PLCs, HMIs, and other advanced products to be well over 52 weeks. As a result, we’re looking with a degree of optimism in 2024 for industrial automation across the industry. To that point, here are some trends I see continuing into 2024.
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I was able to witness how an electrician utilized AR to diagnose a problem in a cabinet and make the repair. The AR provided the electrician a step-by-step process and enabled them to get the cabinet back up and running in a very short amount of time. It was quite impressive. Immersive technology is also being used in other ways. Virtual Reality (VR) can be utilized for training employees in factory operations and maintenance skills. This helps to reduce time to competency and transfer a high level of skill, factory knowledge, and situational awareness. Reshoring Manufacturing Manufacturers continue to look to be more competitive while controlling quality and creating more sustainable processes. As a result, there is a trend in manufacturing reshoring to North America and Europe. The threat of intellectual property theft, geopolitical threats, and environmental destruction are also considerations for the move. To be competitive, manufacturers look to automation as a means to meet demand. The US recently passed the CHIPS Act. This is a long-term project to bring back semiconductor manufacturing and research to the US as means to protect national security and make the US more competitive in this space. But semiconductors
aren’t the only industry making the change. We see a shift in everything from pharmaceuticals to household appliances. This means more higher quality jobs in higher cost labor markets. To achieve a balance, automated processes are implemented to ensure production quotas are met while maintaining a higher quality product. Conclusion 2022 and 2023 have been difficult years. We see economic pressures such as high inflation, high energy prices, and a tattered supply chain. Looking ahead into 2024, there appears to be a light at the end of the tunnel as we move toward normalcy once again. Industrial
automation is a rapidly evolving field that leverages various technologies to improve the efficiency, productivity, and quality of industrial processes. To recap, we will see continued efforts to move toward smart manufacturing, Increased adoption IoT enabled Asset Monitoring technologies, the use of AI in Digital Twin, Robotics, Immersive Technologies, and a concerted effort to reshore manufacturing. These trends indicate that industrial automation will continue to grow and innovate in 2024, driven by the convergence of IoT, edge computing, AI, ML, and 5G. These technologies will enable industrial companies to achieve higher levels of performance, efficiency, and competitiveness in the global market.
Artificial Intelligence (AI) The introduction of AI has really taken the entire world by storm. It’s all around us. It has now made its way into industrial automation. We are seeing it being utilized to program PLCs, Robotics, making accurate forecasts on production scheduling, and much more. Over the past couple of years, we have been seeing Digital Twin becoming more and more utilized across factory floors. Digital Twin gives the manufacturer the ability to accurately view their entire floor in a simulated environment. This provided the manufacturer to see how changes in programming, would affect real world production. This reduces design cycle time, testing, and improves outcome. Adding AI can enhance the accuracy and realism of digital twins by using computer vision, machine learning, and deep learning to analyze data from sensors, cameras, and other sources. AI can also generate realistic 3D models of physical objects and environments using generative adversarial networks (GANs) and other techniques. AI can enable digital twins to run simulations and scenarios to optimize performance, efficiency, and sustainability. AI can also help digital twins to learn from their own experiences and adapt to changing conditions. AI can also provide insights and recommendations based on the data and outcomes of the simulations.
pallets or removing trash. Cobots have been around for some time now. These are Robots designed to work in the presence of their human counterparts. They handle menial and even dangerous tasks to free up the human to work on more complicated tasks. Cobots are designed with an array of sensors to detect the presence of obstacles or workers. Utilizing laser scanners, the Cobot will reduce speed by predetermined zones to ensure the worker’s safety.
Robotics The next trend we will continue to see in 2024 and beyond are robotics. AMRs (Autonomous Mobile Robots), Cobots (Collaborative Robots), and AGVs (Automated Guided Vehicles) will all continue to grow in popularity. AMRs provide the ability to work around tight spaces where toxic chemicals, heavy machinery in manufacturing environments. Utilizing sensors, AI, and machine vision, the AMR s capable of navigating its surroundings accurately and completely independent of human control. AGVs are a fantastic solution for material handling in warehouses and distribution facilities. They move on pre-programmed paths through software programming and the use of sensors such as LiDAR. AGVs are designed to handle tasks such as moving
Immersive Technology
Another trend that is growing in popularity is Immersive Technology in industrial automation. The use of Augmented Reality (AR) to help workers throughout the manufacturing process and even in the MRO space. I personally attended an expo last year where
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Figure 1: Capturing and analyzing the condition data of machines holds potential for more sustainable processes. (Image source: Banner Engineering)
Optimize for sustainability Automation technology offers a range of approaches that system integrators in mechanical and plant engineering, as well as manufacturing companies, can utilize to leverage the optimization of their infrastructure, plants, and processes in terms of sustainability. The comprehensive use of sensors and their integration into the Industrial Internet of Things (IIoT) opens up a wide range of possibilities here by means of continuously monitoring energy consumption, environmental parameters, or inventories. With the help of connected sensors, manufacturing companies can, for example, track the transport of goods in real time, monitor filling levels or record condition data of machines and tools in production lines (Figure 1).
Agency, the manufacturing industry accounts for more than a quarter of the energy consumption; its share of electricity demand is also comparable. Production and processing of chemicals and metals are the leading sectors. These and many other manufacturing industries, including electrical and mechanical engineering as well as food production, are driven by the progress made in factory and process automation. In addition to optimizing productivity and costs, the focus is shifting more and more to parameters that result in improved sustainability of products and processes: In the context of digitalization and through the concept of Industry 4.0, they are increasingly targeting energy efficiency, the economic use of resources, waste avoidance, and the smallest possible carbon footprint.
The demand for energy, the use of raw materials, and – particularly in metropolitan areas – the size of the land required are the most critical factors of industrial production. On the one hand, they determine the economic efficiency of factories and plants; on the other, they are crucial for sustainable operation. In many regions of the world, enormous efforts are being made towards limiting the use of conventional fossil fuels and replacing them with renewable alternatives. The successes to date are considerable thanks to the commitment of politics, industry, and the private sector. In Germany, for example, which aims to evolve renewables into the prevailing energy source within the framework of its energy revolution, their share of total energy consumption reached a value just above 48 percent last year. According to the Federal Network
Empowered by cutting-edge automation technology: the sustainable journey
Connected sensors, robotics, adaptive drives – advanced automation concepts are key to energy-saving and resource-efficient production. To system integrators and plant operators, they provide a powerful lever for optimizing their infrastructure and processes in terms of sustainability.
By Dr. Matthias Laasch, laasch:tec technology editorial consulting
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An excellent example of sensor product families that holistically support the IIoT approach to production is the Snap Signal portfolio from US supplier Banner Engineering. In general, the users’ challenge is to first identify relevant data and, in the next step, to extract it from existing equipment. If the need is identified to integrate additional sensor technology for measuring further variables, such as vibration and temperature at a drive, this should not require any changes to the existing control architecture. It is also important to standardize communication and convert all sensor and control data to a common protocol. For this purpose, the Snap Signal product line (Figure 2) offers smart sensors, signal converters, controllers, signal adapters, and wireless communication modules, as well as wired connectivity technology that enables automation engineers to plug-and- play to resolve these tasks.
The processing and analysis of such sensor data – performed either centralized in a cloud or directly in the field – then allows conclusions to be drawn regarding error and optimization potential in the processes or the need for maintenance. In this way, energy losses can be reduced and the use of resources minimized. On the other hand, predictive maintenance makes it possible to plan service work in advance and thus reduce downtime, which in turn helps avoid additional expenditure on energy and materials.
a system, which significantly reduces power consumption, particularly in variable-load applications. Regenerative drives can further reduce consumption by capturing and reusing braking energy. They are becoming increasingly important in the course of modularization and flexibilization of production plants, which is considered one of the core components of Industry 4.0. In the concept of the modular factory, automated guided vehicles (AGVs) and mobile assistance robots take on supporting functions, for example in handling and assembly. Low weight and recuperation are essential features here because they not only ensure economical energy use and a small eco- footprint, but also a long range for AGVs and cobots. French manufacturer Schneider Electric is addressing this market segment of highly efficient drive technology with its compact VFD Altivar ATV320. It is suitable for controlling three-phase synchronous and asynchronous motors in the power segment from 0.18 to 15 kW at variable speeds. According to the supplier, it combines integrated safety with numerous ready-to-use functions designed to support application efficiency. These include low-speed torque and speed accuracy, high dynamic response featuring flux vector control without a sensor, and an extended frequency range for high-speed motors. The
ATV320 (Figure 3) is particularly notable for its improved resistance to polluted atmospheres typical to many industrial processes, and meets IP20 as well as IP6x protection degree specifications. The VFD is designed to be fully integrated into different system architectures. It is equipped with RJ45 connectors for integrated Modbus and CANopen connectivity. Other communication options include Ethernet IP and Modbus TCP, Profinet, EtherCAT, DeviceNet, and PowerLink.
Figure 3: Altivar ATV 320 VFD for controlling three-phase synchronous and asynchronous motors at variable speed. (Image source: Schneider Electric)
Smarter control
Energy-saving drive technology
In the quest for a more sustainable use of energy and industrial resources, optimizing control technology is an inevitable part of the equation. When it comes to collecting, processing, and analyzing production data in automated plants, state-of-the-art edge controllers play a key role today. Compact, scalable and connected via Industrial Ethernet, these devices can be used to implement both cloud-based and local solutions. Dedicated functions for diagnostics and energy management help automation engineers analyze manufacturing processes, identify bottlenecks, and initiate optimization measures based on industrial controllers such as the Simatic S7-1200. Advanced control algorithms as well as integrated communication and safety functions make a decisive contribution to precise process execution.
With regard to the energy demand of production plants, for example, drive technology plays a major role. Efficient drive systems equipped with advanced variable frequency drives (VFDs), for example, are able to precisely match motor speeds to the true demand of
Figure 2: Supporting the IIoT approach to production: smart sensors, converters, and controllers from the Snap Signal family. (Image source: Banner Engineering)
Figure 4: Efficient process execution based on manufacturing data analysis using the Siemens Basic Controller, both cloud and local solutions can be implemented. (Image source: Siemens)
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and-place, packaging, and commissioning. The robot
The concepts of the digital twin and the digital shadow are promising approaches
Summary
Automation holds major advantages for process and production engineering in terms of productivity and costs. It is thus a crucial economic factor. Beyond this, however, advanced automation concepts and products are also key to improving the sustainability of industrial processes. From predictive maintenance to the modular factory and human-robot collaboration – this article, along with selected examples, gives an impression of the manifold possibilities.
occupies a footprint of 208 mm x 208 mm, weighs approximately 54 kg, is IP56/67 and ESD-protected (Electrostatic Discharge), as well as suitable for floor, ceiling, wall, and angle mounting. Digital models, materials, and more Beyond the approaches shown here, engineers can leverage further optimization potential by applying sustainable materials, circular economy techniques and the latest developments in the field of digitalization. The aim of circular economy is to avoid waste and residual materials and to recycle and reuse as many raw materials, components, and packaging materials as possible. Its principles can make a decisive contribution to automated plants operating more sustainably.
towards identifying optimization potential without testing on real machines or plants with a high expenditure of resources. Thanks to the comprehensive digital representation of real products, plants or processes - and of their life cycles - maintenance measures can be initiated or correlations established between development, production and all other stages of the value chain. Engineers can thus simulate the behavior, functionality and quality of real objects or processes in detail - and improve their sustainability, for example by eliminating the need for physical prototypes.
Figure 5: KR Agilus in a project at the University of Reutlingen/Germany. Here, students work with industry partners on developing sustainable alternatives to disposable plastic cutlery. (Image source: KUKA Deutschland)
Efficient by precision Small, agile and extremely versatile, with their compact,
highly efficient processes thanks to their very precise and repetitive accurate motion control. For example, they are ideal for minimizing the need for rework in machining processes as well as the level of rejects. The use of such compact and variable assistants also makes sense for small and medium-sized companies as the manufacturer documents in various success stories [4]. These include a university project in which students at the University of Reutlingen/ Germany are researching reusable alternatives to disposable plastic cutlery. They are supported by German injection molding expert
Gindele as well as by KUKA and their system partner Robomotion. All handling around injection molding is covered by a highly flexible robotic cell, the core of which is an Agilus compact robot equipped with a 3D-printed gripper. According to the data sheet, the KUKA Agilus KR6 R900-2 six-axis robot features a maximum reach of 901 mm and a payload of 6.7 kg and it achieves a pose repeatability of ±0.02 mm in accordance with ISO 9283. Possible usage ranges from handling in conjunction with other machines, through test and measurement technology, and the application of adhesives or sealants, to assembly, pick-
lightweight design and intelligent control technology, robots have a significant impact on the sustainable use of production resources. The robust and highly adaptable devices of German manufacturer KUKA's Agilus family are an outstanding example of this (Figure 5). They come with an integrated energy supply and in several variants, some are offered as cleanroom robots, others for hygiene-critical applications or potentially explosive environments. Designed for human-robot collaboration, the robots enable
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Replacing traditional power grid energy sources with sustainable, green ones is called electrification. In this article, Part 1 of 2, some of the challenges associated with electrification are discussed along with how automation can aid in its efficiency and sustainability. Part 2 of this series will discuss leadership in energy and environmental design (LEED) and zero energy building (ZEB) certifications and how they can reduce carbon emissions and improve sustainability.
Electrification is the replacement of systems that use fossil fuels like oil, coal, and natural gas for electricity generation with photovoltaics (PVs) and other green technologies and replacing internal combustion engine (ICE) vehicles with electric vehicles (EVs). Electrified systems, plus the use of automation that ties them all together and supports smart grids and microgrids, are important factors moving society toward a more sustainable and greener future. Today’s electric grid was not designed to charge large numbers of EVs, and smart grids and microgrids are expected to be critical technologies needed to support the widespread replacement of ICE vehicles with EVs. In California, the governor recently issued an Executive Order requiring that by 2035 all new car and passenger light truck sales be zero-emission vehicles (EVs). Developers of smart grids and microgrids must meet a daunting array of international standards to tackle these sorts of mandates.
For example, the IEEE has over 100 standards approved or in development relevant to smart grids, including the more than 20 IEEE standards named in the National Institute of Science and Technology (NIST) Framework and Roadmap for Smart Grid Interoperability. In addition to IEEE standards, microgrids are governed by the IEC 62898 microgrid series and other standards. This article is the first of two parts. It looks at challenges related to implementing electrification, integrating distributed energy resources (DERs), the similarities and differences between smart grids and microgrids, and how automation enhances their efficiency and sustainability, including supporting the universal adoption of EVs. It begins by digging into what DERs are and where they fit in and closes by looking at how the emergence of utility microgrids is blurring the distinction between microgrids and smart grids. Whatever the implementation, DigiKey
supplies a wide array of industrial automation products that support electrification and DER integration. The second article examines how electrification and automation can be used in green buildings to achieve Leadership in Energy and Environmental Design (LEED) and Zero Energy Building (ZEB) certifications. What’s a DER? The North American Electric Reliability Corporation (NERC) definition is: “a Distributed Energy Resource (DER) is any resource on the distribution system that produces electricity and is not otherwise included in the formal NERC definition of the Bulk Electric System.” The term distribution system in North America refers to electric lines carrying 34.5 kilovolts (kV) or less that typically run from substations to end users. The bulk power system (BPS) includes the lines coming into the substation that often carry 100+ kV over long
Using electrification and automation to create more efficient and sustainable power grids – part one of two
By Jeff Shepard Contributed By DigiKey's North American Editors
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elements support faster and more effective responses to power disturbances and enable balancing and securing the grid, especially during peak demand periods and with variable RE availability. Smart grid technologies also support the coordination and integration of microgrids with the distribution system and BPS. Conversely, a microgrid is designed to accommodate electrification technologies like RE sources, BESS, and EVs. Microgrids and smart grids require automated controls, including a distributed energy resource management (DERM) system.
non-dispatchable and not directly controllable by the utility. The centralized, automated control enabled by smart grid technology is needed to compensate for the fact that the RE sources used for electrification and EV charging are not as predictable as conventional utility grid elements. Smart grid and microgrid controllers need information from various sensors to monitor connected resources in real time. With the advent of EVs and EVSE, the controllers are also used to help manage power demands of charging, and they can use vehicle- to-grid (V2G) communication to coordinate the connection of EVs to the grid or a microgrid to provide incremental energy storage capacity.
In addition to monitoring the status of connected resources, controllers for grid-connected microgrids must also monitor the status of the local utility grid. Switchgear is an essential component of smart grids and microgrids and must respond in milliseconds to ensure robust operation. Switchgear sizes vary from a few kilowatts (kW) for small microgrids to multiple Megawatts (MW) for large microgrids and the utility grid. The switchgear and controller can be in the same cabinet for small microgrids, reducing costs and speeding installation. Smart grid and microgrid DERMs include intelligent metering of energy production and energy consumption that is used by cloud- based analytics to maximize the
Figure 1: DERs exist in the distribution system (blue); other renewable energy resources are in the bulk power system (green). (Image source: NERC)
Smart grids, microgrids, and electrification A microgrid is a DER, but not all DERs are microgrids. From the perspective of the BPS, the terms microgrid and DER refer to types of power generation or storage resources. The term smart grid refers to the communication and control technologies used by the BPS to ensure resilient and efficient operation. Another differentiating factor is that microgrids include generating and storage resources plus loads. A smart grid is comprised primarily of generation resources, with some storage but no loads. The smart grid can communicate with loads, but they are separate from the grid. Electrification affects microgrids, the BPS, and smart grids in
different ways. In the BPS, electrification is being added to an existing grid and, if not properly managed, can have
distances, connecting large-scale bulk electricity generation facilities with interconnection resources and substations (Figure 1). DERs are any non-bulk system resource, including generation units like wind turbines and photovoltaic installations, energy storage units, most battery energy storage systems (BESS), EV battery chargers — also called electric vehicle service equipment (EVSE)— and microgrids. DERs exist behind the utility meter as well as directly on the distribution system. Behind the meter, DER sources include photovoltaic arrays, BESS, grid-connected EVs, and standby backup power sources like large diesel generator installations at data centers and other locations. A microgrid is a particular type of DER.
DERMs are a must
DERMs and automation are defined and implemented differently in smart grids and microgrids. Smart grids include diverse generation sources and electricity users spread over a wide area with a centralized control center for grid management (Figure 2). Grid management is the key concept for smart grid control in the BPS. Existing BPSs were designed and built before there was a need to support electrification, and they can experience unreliable operation as dispatchable (controllable) fossil-fuel-powered generation is increasingly replaced by unpredictable (and therefore less controllable) RE sources. In addition, charging large numbers of EVs will be mostly
unintended negative operational consequences. That’s where smart grid technology comes in. Two-way communications and control are the primary differentiator of smart grids. Those control systems include sensors to monitor the stability of the grid and advanced meters to monitor electricity demand. They also use a variety of controllable power switching and power quality devices to manage electricity flows. The sensors are critical to enable greater penetration of renewable energy (RE) sources and electrification into the BPS and ensure grid stability. In addition, the sensors and control
Figure 2: A smart grid relies on automated controllers and DERMs for real-time grid management. (Image source: ETAP)
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economic benefits of DERs and support high levels of resilience. The exact architectures of DERMs can vary for different varieties of microgrids.
They must be completely self- sufficient. Networked or nested microgrids are networks of several individual DERs or microgrids connected to a common utility distribution system. They are usually controlled by a centralized supervisory system that balances the needs of the microgrid operation with support for the wider utility grid. The controller often assigns a hierarchy of importance to the microgrids and DERs to ensure that the most critical elements are protected. Applications for networked microgrids include community
microgrids, smart cities, and the emerging category of utility microgrids. Networked microgrids are a subcategory of grid-connected microgrids. All grid-connected microgrids are physically connected to the distribution grid, and they have a switching device at the point of common coupling (PCC) where the connection to the distribution grid occurs. During normal operation, a grid-connected microgrid is connected to the distribution grid. It can provide services to the grid, such as frequency and voltage regulation,
real and reactive power support, and demand response to mitigate capacity imitations. The microgrid is not connected to the utility distribution grid in an islanded operation. Islanding can occur because of a disruption in the distribution grid or for other needs like maintenance. When transiting from islanded to grid-connected operation, these microgrids need to sense the frequency of the distribution and synchronize operation before reconnecting. There are numerous microgrid applications, including campuses, hospitals and medical centers, commercial installations, communities, and industrial facilities. The newest application category is utility microgrids (Figure 3). Blurring the line Utility microgrids that blur the line between smart grids and microgrids are being deployed. In the process, the definition of a DER changes from a distributed energy resource to a dedicated energy resource. Utility microgrids are designed to reduce power outages due to extreme weather events, wildfires, and other unforeseen challenges. With existing grid architectures, large sections of the grid are de-energized for safety during extreme events.
Microgrid varieties
Microgrids can be classified by their applications and architecture. The three microgrid architectures are remote, networked, and grid- connected. Remote microgrids are in places like islands or remote mining and agricultural operations. They are also called off-grid microgrids and are physically separated from any utility BPS.
An important and unfortunate impact of those unscheduled and extensive power outages is to discourage the use of EVs. Utility microgrids are seen as a key to widespread EV adoption. Utility microgrids are being proposed and deployed across the U.S. For example, Southern California Edison (SCE) has proposed the development of Public Safety Power Shutoff Microgrids to help maintain electricity availability as widely as possible during wildfires. Other utilities refer to the new grid architecture as community microgrids (Figure 4). The islanding capability of utility microgrids is key to improving electricity availability on a more granular level than is currently possible. It’s expected to be deployed in a wide range of microgrid sizes, from complete residential communities to public Figure 4: Utility microgrids can include a wide range of assets spread over relatively wide geographic areas and blur the line between traditional microgrids and smart grids. (Image source: Edison International)
places, including schools and other strategic locations like fire stations, medical centers, and evacuation centers. EVSE installations are a crucial part of the designs of most of these community microgrids. As envisioned, the EVSE will support the grid connection of EVs as additional sources of backup power as well as for EV charging. Conclusion Electrification is necessary to ensure more sustainable power grids and drive reductions in CO2 emissions. Many electrification technologies like PV energy and EVs are not as predictable as the traditional resources they are replacing. That means electrification must be supported with advanced sensor networks and automated control systems in smart grids and microgrids.
Figure 3: Microgrids are often categorized by their application. (Image source: Siemens)
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Replacing traditional power grid energy sources with sustainable, green ones is called electrification. In Part 1 of this series, some of the challenges associated with electrification were discussed along with how automation can aid in its efficiency and sustainability. This article, Part 2 of 2, will discuss leadership in energy and environmental design (LEED) and zero energy building (ZEB) certifications and how they can reduce carbon emissions and improve sustainability.
Leadership in energy and environmental design (LEED) and zero energy building (ZEB) certifications represent significant efforts supporting society's desire to reduce carbon emissions and improve sustainability. Achieving LEED and ZEB certifications requires a holistic approach that combines electrification that replaces fossil fuels-based energy systems with green alternatives like photovoltaics (PV) and electric vehicles (EVs) with advanced automation and control systems.
The LEED program from the U.S. Green Building Council (USGBC) includes decarbonizing existing buildings and new construction. ZEB efforts are coordinated by the Energy Efficiency and Renewable Energy (EERE) office of the US Department of Energy. Achievement of LEED and ZEB certifications requires architects and contractors to take new approaches to how buildings are designed, built, and operated. Compared with ZEB, which focuses solely on energy consumption,
LEED is a more expansive concept that addresses carbon, energy, water, waste, transportation, materials, health, and indoor environmental quality. This second of a two-article series on electrification and sustainability begins by looking at the LEED and ZEB certification levels and what it takes to get those certifications for commercial and industrial buildings, including a comparison of several definitions of a ZEB. It then details an example of how Phoenix Contact used automation
and on-site PV electricity generation to achieve LEED
Using electrification and automation to create more efficient and sustainable power grids – part two of two
Silver and ZEB certification for a 70,000-square-foot addition on its main campus, including how some of the company's own products contributed to the success of the project (Figure 1). It closes with a glance at how LEED buildings can contribute to the United Nations' Sustainable Development Goals.
By Jeff Shepard Contributed By DigiKey's North American Editors
Figure 1: Rooftop PV generation was a key factor enabling this Phoenix Contact facility to achieve LEED Silver and ZEB certifications. (Image source: Phoenix Contact)
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and other energy-consuming building systems. Embodied
generation and externally generated (sourced) energy. On-site fossil fuel combustion is not prohibited. The total energy consumption must consist of on-site or externally generated renewable energy or carbon offsets. ILFI Zero Energy Certification is the most restrictive standard. It requires on-site renewable sources to supply 100% of the building's energy needs. No combustion is allowed, and certification is based on actual performance; modeling is not allowed. Zero Code specifically targets new commercial, institutional, and mid-to high-rise residential buildings. It defines a zero-carbon building as one that uses no on-site fossil fuels and produces on-site or procures enough of carbon-free renewable energy or carbon credits to meet building operational energy needs. Zero Code also requires that buildings meet the ASHRAE Standard 90.1-2019 for building efficiency. Zero Code allows the substitution of other energy efficiency standards if they result in equal or greater energy efficiency. LEEDing by example Phoenix Contact recently installed a 961-kilowatt (kW) PV system on the roof of the logistics center on the company's main US campus. The system generates enough power to satisfy about 30% of the facility's energy needs, or the
equivalent energy consumption of about 160 homes per year. The building earned LEED Silver and Zero Energy certifications. The on-site, natural gas-fired 1 MW microturbine cogeneration system was integrated with the PV system. The central energy control system monitors the PV plant's output and the building's energy consumption in real time. The microturbine generator is used when overall energy demand exceeds the PV system's output. There are times when the PV system and the microturbine are used together to provide electricity to the grid through net metering, generating income for the company. The system was designed to reduce natural gas consumption during daylight hours and run the microturbine generator mostly at night, maximizing overall energy efficiency and minimizing overall CO2 generation. On some days, it's possible to reduce natural gas consumption to almost zero. Some statistics of the PV system include: n 2,185 solar panels n 1,214,235 kWh generated annually n 1,939,279 pounds of CO 2 footprint reduction Continuous monitoring and control of individual PV system segments in large installations like this one is necessary to achieve maximum efficiency and availability of power production.
LEED is holistic LEED is a comprehensive system that factors in all elements needed to create high-performance buildings. LEED certifications are based on credits or points awarded to a project using detailed performance criteria. The performance categories and their relative importance (from most- to least important) are 1 : n Reduce contribution to global climate change. n Enhance individual human health. n Protect and restore water resources. n Protect and enhance biodiversity and ecosystem services. n Promote sustainable and regenerative material cycles. n Enhance community quality of life. The most essential criteria, reducing contribution to global climate change, accounts for 35% of all points. The levels of LEED certifications include Certified (40- 49 points), Silver (50-59 points), Gold (60-79 points), and Platinum (80+ points). In the newest version of LEED, v4.1, most points are related to operational and embodied carbon. Operational carbon is the carbon dioxide (CO 2 ) emissions generated by heating, ventilation and air conditioning (HVAC), lighting,
Defining zero
Automation needs actionable information Effective automation and control for electrification systems like PV installations requires extensive and actionable information. Real- time monitoring of each string of PV panels maximizes production and supports preventative maintenance. If a string goes down unexpectedly, it could lose thousands of kW of power with corresponding monetary losses. The 961 kW PV system at Phoenix Contact's main US campus includes twelve inverters with six strings of PV panels feeding each inverter, and it incorporates several of the company's products, starting with second-generation EMpro energy meters like the panel mount 2908286. These meters are designed to measure and transmit key energy parameters to cloud- based platforms that support remote monitoring of all the system elements. EMpro energy meters are available for various power system designs, including one-, two- and three-phase installations and configurations. The system monitors numerous system elements and operational conditions in real-time, including: n Inverters are individually monitored for DC input power, AC output power, active and reactive power, faults, and operational status.
Zero energy seems like a straightforward concept, but it has several definitions. The three most cited are the LEED Zero Energy program, International Living Future Institute (ILFI) Zero Energy, and the Zero Code Renewable Energy Procurement Framework (Zero Code) — an initiative of the Architecture 2030 organization that has been adopted as a California building energy standard. There are significant differences in how "zero" is defined. To achieve LEED Zero Energy certification, a building must have an energy balance of zero for 12 months, including on-site
carbon are emissions associated with the production of building materials and building construction processes throughout the whole lifecycle of a building. LEED certification is important for the creation of a greener society. Buildings account for 39% of global CO 2 emissions, with 28% from building operations and 11% from embodied emissions (Figure 2). Since the buildings sector is the most significant contributor to global CO 2 emissions, special programs have also been developed to encourage the development of zero energy buildings.
Other 9%
Building Operations 28%
Industry 30%
Building Materials and Construction 11%
Transportation 22%
Figure 2: Building operations plus materials and construction are major contributors to global CO 2 production. (Image source: new buildings institute)
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Using Electrification and Automation
Goal 17: Strengthen the means of implementation and revitalize the Global Partnership for Sustainable Development Corporate strategies can also contribute to a more sustainable society. For example, Phoenix Contact's gaining LEED Silver and Zero Energy certifications for its logistics center for the Americas was one part of the company's initial goal to achieve carbon neutrality at all of its worldwide locations. The company's next target is to create an entirely climate-neutral value-added chain before 2030. Conclusion The building sector is the most significant contributor to global CO 2 production. LEED and ZEB certifications are important
tools for measuring the success of using electrification and automation to create more efficient and sustainable buildings. As shown, large-scale PV generation installations integrated with on- site cogeneration capacity can contribute to a greener society. LEED-certified buildings also support achievement of the UN's seventeen SDGs and the goal of eliminating global poverty by 2030. References: 1 LEED rating system, Green Building Council 2 Sustainable Development Goals, United Nations
n Each PV string is monitored for current and voltage output. That data is evaluated to determine string health and possible maintenance needs. n Panel temperatures are monitored with numerous sensors spread throughout the installation.
LEED and sustainable development The United Nations (UN) has identified 17 Sustainable Development Goals 2 (SDGs) intended to end global poverty by 2030. According to the USGBC, the electrification and automation inherent in LEED buildings can contribute toward meeting 11 of the 17 SDGs, including:
n Weather conditions like wind speed and direction,
temperature, relative humidity, and air pressure are collected. n Solar irradiance is measured with two pyranometers, one at a 10-degree angle matching the installed angle of the panels and one installed horizontally. n Soiling sensors measure the light loss caused by dust and dirt on the surface of the PV panels. n Cameras provide security monitoring of the system. The system also needs data loggers and interfaces. For example, the company's Radioline wireless modules, like the model 2901541, communicate wirelessly with PV module temperature and soiling sensors using the RS-485 protocol without cables. In other cases, power over Ethernet (PoE) is used to transmit power and data at the same time. Intrusion protection can be provided by FL mGuard 1000 Series Security Routers, like the model 1153079, that provide firewall security and user management.
Goal 3: Good health and well-being
Goal 6: Clean water and sanitation
Goal 7: Affordable and clean energy Goal 8: Promote sustained, inclusive, and sustainable economic growth, full and productive employment, and decent work for all Goal 9: Build resilient infrastructure, promote inclusive and sustainable industrialization, and foster innovation Goal 10: Reduce inequality within and among countries Goal 11: Sustainable cities and communities Goal 12: Responsible consumption and production
Figure 3: DIN-rail mount controller suitable for large-scale PV generation systems. (Image source: Phoenix Contact)
Tying it all together takes a controller like the DIN-rail mount model 1069208 from Phoenix Contact based on the company's PLCnext Technology (Figure 3). When paired with an input/ output (I/O) module like the model 2702783, the controller aggregates data from the sensor network and transmits it to a cloud service provider. In addition, an industrial PC runs Phoenix Contact's Solarworx software. The included software tools and libraries support communication protocols and standards the solar industry adopts. The system enables customized automation and visualization of PV system operation, and it's compatible with
third-party software packages that can analyze historical and real-time data for performance optimization. The libraries include functional blocks that meet the requirements
of IEC 61131 standard for programmable controllers.
Feed-in control is the final piece of the electrification puzzle for integrating distributed energy resources (DERs) like PV arrays with the power grid. PGS controllers from Phoenix Contact can monitor the voltage and reactive power levels at grid connection points and determine the required control values for the inverters to support feed- in management of power into medium- and high-voltage grids.
Goal 13: Climate action
Goal 15: Protect, restore, and promote sustainable use of terrestrial ecosystems, sustainably manage forests, combat desertification, and halt and reverse land degradation andbiodiversity loss
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How microgrids and DERs can maximize sustainability and resilience in industrial and commercial facilities
Distributed energy resources (DERs) like solar energy, wind energy, combined heat and power (CHP), battery energy storage systems (BESS), and even conventional generators can be significant contributors to improvements in sustainability and resilience in commercial and industrial facilities, especially when combined into a microgrid using an automated control system to intelligently coordinate and manage energy generation, flow, storage and consumption. To maximize microgrid environmental and economic benefits, the controller must balance the operation and integration of DERs in real time, manage smart loads like lighting, heating ventilation, and air conditioning (HVAC) systems, electric vehicle (EV) charging and information technology installations, use historic demand information to project future load profiles, provide safe and efficient connections to the utility grid and provide support for demand response functions with real-time energy pricing data. This article reviews the elements that comprise a microgrid, looks at microgrid architectures, presents an overview of IEEE 1547, which establishes requirements for interconnection of DERs, and IEEE 2030 that provides a comprehensive technical process
for describing the functions of a microgrid controller, then considers how microgrid controllers can enhance sustainability, resilience, and economic benefits, and closes with a brief overview of cyber security concerns for microgrids. What does it take to make a microgrid? Microgrids are diverse in their implementations and components. To discuss how microgrids and DERs can maximize sustainability and resilience, it’s best to start with a definition and a few examples of microgrid components and architectures. The U.S. Department of Energy (DOE) defines a microgrid as “a group of interconnected loads and distributed energy resources within clearly defined electrical boundaries that acts as a single controllable entity with respect to the grid. A microgrid can connect and disconnect from the grid to enable it to operate in grid- connected and island-mode.” 1 While the definition of a microgrid is straightforward, there’s a range of microgrid categories, operating modes, and possible subsystems to choose from when building a microgrid, and realizing a microgrid’s maximum sustainability and resilience involves numerous architectural and operational choices.
By Jeff Shepard Contributed By DigiKey's North American Editors
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