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Supporting mass customization, high quality, and sustainable operations in Industry 4.0 factories

take a systematic approach toward achieving continual improvement in energy management and energy performance

consumption 2. The current transformer transforms the energy

■ Currents ■ Voltages

■ Phase angles ■ Frequencies ■ Power factors ■ Power consumption ■ Minimum and maximum values ■ Operating hours ■ Energy/electrical work

Figure 4: Shown is a typical energy monitoring application that can be easily supported with an S7-1200 PLC. Image source: Siemens

consumption into a measurable quantity for the energy meter module. The meter also measures numerous other parameters like voltage and power factor 3. Software in the S7-1200 controller evaluates the measurements and saves statistics on the energy consumption in a data log. It’s connected to the PG/PC and HMI through a SCALANCE industrial router using PROFINET IE buses 4. The HMI displays the measured values and enables operators to evaluate parameters such as power consumption peaks over time 5. The controller can also send the data log onto the PG/PC in the form of standard web pages Energy meter module In an application such as that shown in Figure 4, an SM 1238 energy meter module can be used for data acquisition (Figure 5). It can be used in single and three- phase supply systems up to 480 VAC. These modules can provide S7-1200 controllers with the data needed to support compliance with ISO 50001, 50003, 50004, and 50006 requirements. They can record over 200 electrical measurements and energy values, including:

■ ISO 50006 expands on how to meet ISO 50001 requirements,

including the development and maintenance of energy

performance indicators (EnPIs) and energy baselines (EnBs) for ongoing performance monitoring The EnPIs and EnBs in ISO 50006 enable the effective measurement and management of energy performance, which can help to optimize energy efficiency. In addition to improvements in sustainability, better energy management leads to significant cost savings. The standard defines the starting point (EnBs) and meaningful performance metrics (EnPIs), and it identifies four types of indicators: ‘absolute’ and ‘relative energy performance indicators’, along with ‘statistical’ and ‘technical’ models. Siemens’ S7-1200 controllers can simplify the implementation of these ISO standards and support highly effective energy management systems. Automation system designers can add an energy meter module to enable measurement, evaluation, and display of energy consumption data in real time. Figure 4 illustrates a typical application: 1. The motor represents a typical load being monitored for energy

Conclusion

To simplify and accelerate the deployment of sustainable Industry 4.0 factory networks, automation system designers can use the S7-1200 family of PLCs and expansion modules. These solutions support a wide range of secure communications options, have integrated control functions and digital and analog IOs, and are expandable to support a wide array of applications, including energy management.

connectivity. An RS-485 communication board like the 6ES72411CH301XB0 resides inside an S7-1200 PLC (“CPU”) and is used to communicate with a motor drive (the SINAMICs V20) through the USS/Modbus RTU interface. The ‘SM’ on the right comprises an IO-Link master communications module like the 6ES72784BD320XB0. The IO-Link master is connected to two sensors on the left and center, as well as to an IO-Link hub on the right. The hub can connect to additional IO-Link devices.

energy management, which in turn relies on more granular and real-time energy consumption data. It increasingly begins with the consideration of ISO 50001 standards for operational energy management. This is a foundational standard that provides a framework of requirements, including the development of policies, targets, and objectives for more efficient energy use, and the use of data to measure the results. ISO 50001 is supported by additional standards, including: ■ ISO 50003 ensures the effectiveness of energy management systems (EnMS). It encompasses auditing, personnel competence requirements, and the duration of audits and multi-site sampling ■ ISO 50004 helps organizations

Figure 5: The SM 1238 is an energy monitoring module for single and three-

phase power systems. Image source: Siemens