Optimizing Energy Efficiency in Factory Production Systems

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FAULHABER Antriebssysteme

ROHM Semiconductor GmbH

MEV Elektronik Service GmbH

Analog Devices SAS

Synchronized industrial Ethernet protocols, such as Profinet and EtherCat use modified Ethernet network interfaces to support real-time synchronization of data with clock jitter as low as 1µs. These network interfaces support both synchronized motion control for production efficiency and factory network connectivity for production system management.

Engineering Efficiency: Rapid Customization

Modelling tools enable drive companies to quickly customize control algorithms for end applications without significant investment in trial and error tuning on the factory floor.

Automated machines are complex interconnected systems requiring the support of multi-disciplinary engineering teams. Figure 3 illustrates just some of the key design functions needed to support the development of automation equipment. Typically, many of these engineers work in different companies and so the various suppliers in the chain must support designers performing the integration work. Modelling tools from companies like MathWorks support complete system models, including state control, motion algorithms, motor and machine load.

Specialized electromagnetic and mechanical design tools generate behavioral models of the ac motor and the machine increasing the accuracy of system models. While the complete design process cannot be fully automated, the number of prototype builds can be significantly reduced.

The control algorithm for a new motor or machine can be developed and tested on a simulation platform before prototypes are built. Automatic code generation tools allow rapid deployment of the control algorithm on the test platform. Each design iteration provides new data to improve the accuracy of the system model. Automatically generated control code combined with proven system application code can be used in the production drive system. Drive companies can thus rapidly deploy new control functions optimized for specific applications to optimize energy efficiency and automation productivity.

Reference:

[1] Paul Waide; Conrad U. Brunner, "Energy-Efficiency Policy Opportunities for Electric Motor-Driven Systems", International Energy Agency Working Paper 2011.

[2] EUREL Task Force, "Electrical Power Vision 2040" EUREL General Secretariat, February 2013

* * Aengus Murray ... is Motor and Power Control Applications Manager for Industrial and Instrumentation at Analog Devices.

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