Energy Simulation of Compressed Air Systems …€¦ · 17/06/2015 · Tecnomatix Plant Simulation...

Tecnomatix Plant Simulation Worldwide User Conference 2015

Siemens Industry Software

11© INPRO, Germany Streng Confidential – für internen Gebrauch 11© INPRO, Germany Streng Confidential – für internen Gebrauch 11© inpro 2015 Plant Simulation Worldwide User Conference June 15 - 17, 2015 – Stuttgart, Germany

inpro

D. Wolff (inpro), J. Nagel (Volkswagen)

June 17th, 2015

Energy Simulation of Compressed Air Systemsusing Tecnomatix Plant Simulation


Air

0,78

0,21

0,01nitrogenoxygenother



Volkswagen Group AcademyUmbrella organization of all academies for all brands and locations of VOLKSWAGEN AGwith the goal of uniform standards of quality and competences all over the world.

AutoUni – Institute for Production, Logistics & Components

3PMX-1 / K-SE-61Stand: 15.05.2015

Volkswagen Group

Knowledge transferKnowledge exchangeKnowledge generation

CommitteeDepartments

Universities, technicalcolleges and research

establishments

AutoUniInnovative knowledge partner, which combines science and practice to provide futureknowlegde in coorporation with worldwide renowned universities.

• Qualification on academic level• Networking of the participants across all brands• Impulses of science

Institute for Production,Logistics & Components


Innovationsgesellschaft für fortgeschritteneProduktionssysteme in der Fahrzeugindustrie

• Founded: 1983

• Location: Berlin

• ~100 Engineers & Developers

• 3.000 m2 Laboratory

• Development Center

inpro




Production Systems and Information Processes

Competences• Virtual commissioning

• Data structures forthe digital factory

• Knowledge management

• Human-machine interface

• Development of CAE tools

• Energy Optimized Planning


Motivation

Complexity of modern production systems incurs the use of digitalplanning tools, supporting integrated energy management.

Cost pressure and political decisions require energy consumptiontransparency and continuous efficiency improvement

in production systems.




Energy Use in Car Manufacturing

For comprehensive energeticevaluation, system boundaryshould include peripherics.

In machining, compressed air andcooling lubricant systems aremajor energy consumers.

Existing Potentials• Air generation (speed controlled

pumps)

• System dimension

• Intelligent compressor control(switch-on/switch-off)

generationgeneration processingprocessing distributiondistribution

simulative approach

Bubbles: potential savings estimateBubbles: potential savings estimate


1 Greenfield• Dimensioning of CA storage/compressor train

• Screw compressors consume ca. 1/3 of nominal powerduring full load when idle. The use of „intelligent“compound controls aims at reducing these idle times:efficient operation mode for generator

2 Brownfield• Planning of standby intervals for applications

through creation of manufacturing batches:efficient operation mode for application

Simulation Use Cases




Functional Chain:

CA supply is a typical system of 2nd periphery and its consumptionis directly linked to the production program.

Compressed Air Systems (CAS)

generationgeneration processingprocessing applicationapplicationdistributiondistribution


Compressor Types

Piston Compressor

Screw Type Compressor

Turbo Compressor

flow rate[m3/h]pr

essu

re[b

ar]




Compressor Operating Strategies

partial load

compressorstrategy

internal superiorfocus

cascadepressurecorridor

frequencycontrol

speedcontrol

delayedidling

control

idlingcontrol

inter-mittentcontrol

full load



partial load

compressorstrategy



frequencycontrol

speedcontrol

delayedidling

control

idlingcontrol


full load




Sensor or pressure switch puts compressor into „full load“ or „stop“;depending on net pressure

• best energy balance, for system with big storage

Simulation Strategy: Intermittent Control

pressure gradient

pow

erin

take



partial load

compressorstrategy



frequencycontrol

speedcontrol

delayedidling

control

idlingcontrol


full load




Sensor or pressure switch puts compressor into „full load“ or „idle“;depending on net pressure. „Idle“ consumes minimum energy withoutproducing air.

• Reduction of power-on-phase reduces switching cycles wear & tear on drive

Simulation Strategy: Idling Control

pressure gradient

pow

erin

take



partial load

compressorstrategy



frequencycontrol

speedcontrol

delayedidling

control

idlingcontrol


full load




Sensor or pressure switch puts compressor into „full load“, „idle“ or„stop“; switching the latter two based on a defined delay time

• Hybrid solution

Simulation Strategy: Delayed Idling Control

pressure gradient

pow

erin

take

tv: delay time


Pilot Case „Component Manufacturing“





CA Generation and Storage

Compressor/Container Consumer


CA Consumers

Compressor/Container


Consumer




Model

statesensor

currentconsumption

rate

CA container(pipe system and

storage)

CA consumer(machine)

CA generator(compressor)

parametrization & visualization

uptimelogger

specificconsumption

logger

consumptionlogger

currentpressure

leak rate

consumptionparameters

compressorcontrol

allocationmapping

switchingcycle

logger


Simulation




Seamless Digital Energy OptimizationPlanning

Operation

Knowledge

Commissioning

Simulate & OptimizeEnergy Use

Plan EnergyEfficiency

Analyze energyconsumption

Energy OptimizingControl Systems

Energy standards

Prepare EnergyOriented Automation

Pic central: Siemens AG


inproSteinplatz 210623 Berlin

P. 0049 30 39997-0F. 0049 30 39997-117M. [email protected]

www.inpro.de

Thank you for your kind attention.

mailto:[email protected]

http://www.inpro.de/

Energy Simulation of Compressed Air Systems …€¦ · 17/06/2015 · Tecnomatix Plant Simulation...

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