The goal is to achieve "green production" and improve productivity, and therefore profitability, across the entire company by reducing energy supply costs, efficiently distributing electricity, balancing peak loads, optimizing electricity consumption with computer systems, and implementing an advanced energy distribution concept as part of a company-wide energy management system compliant with DIN EN 16001. To achieve this, the power and data networks require a converged and standardized communication system. An energy control system will be installed for the largest electricity consumers. This will include, for example, monitoring technical energy processes, managing electricity consumption, and raising user awareness.
Communication as a Prerequisite for Efficiency.
Currently, the ability of industrial equipment to communicate is still considered an auxiliary function. However, isolated operation is counterproductive to improving the efficiency of industrial processes. A lack of diagnostics is detrimental to system availability, while energy-efficient operation of a system is only possible if energy consumers are identified. And these two aspects can only be achieved through communication. Therefore, the goal should be to make all devices operating on a network visible and controllable.
The Hierarchy of Communication and Power Supply in Industry.
In industry, equipment and systems are powered by three basic lines: power, data, and signals. High-power devices always have a 400-volt power connection, but their communication capacity is less than 50%. These devices must be integrated into a power grid to enable seamless and comprehensive management. This leads to clear requirements for the power grid. When a device is connected to the power grid, it must be immediately detectable; its power consumption must be quantifiable, and the load must be disconnected locally. These power grid management functions require only a minimal portion of the network bandwidth.
Functions such as automation, on the other hand, require fast communications for real-time data transmission. For example, automated optical inspection systems need a broadband communications system.
Installation of a Communications System Over the Power Grid:
To reduce additional installation costs, HARTING has chosen communication via power supply cables as the method for managing basic power grid functions. However, as networks converge, this should be no different from communication via separate communication cables. Therefore, Ethernet has been chosen as the foundation for power grid communications so that basic functions can be expanded as needed. Intelligent functions will transform traditional unmanaged power grids into a smart power network. Network components will play a critical role because only through these components will it be possible to implement the topologies required by industry. Therefore, these HARTING Smart Power Network units form the backbone of the network: HARTING has learned from this situation and is the first company to configure power grid components with communication capabilities.
Using Standard Ethernet:
An Ethernet network is managed by managed network components. The function of these managed switches can be logically transferred to the HARTING smart Power Network units.
One of the main management functions in any network is visualizing the topology and the connected participants. If Ethernet is selected for communication in utility networks, the communication network topology is the same as that of the electrical networks, since both the communication system and the power supply use a single cable. Therefore, the many standard Ethernet functions can be used for managing the electrical network.
This avoids proprietary solutions. The system is open and scalable, since the incorporation of independent communication lines guarantees greater bandwidth without compatibility limitations.
Power management functions
Comprehensive solutions are required to map the various topologies of power and data networks, which can transmit consumption data without additional data cables to control rooms, for example, and which allow monitoring of the network status without the need for additional installations or programming.
The integrated automatic topology detector is especially useful when commissioning a network for the first time and for managing and visualizing the installed power distribution system. As soon as the system starts up, the electricity distributors and their consumers are detected and displayed with current consumption figures on an industrial computer or main screen.
It is also possible to integrate a load management system. The goal is to prevent exceeding predetermined maximum load values.
Therefore, it makes sense to predetermine which loads will allow automatic switching based on the load.
Condition monitoring:
The condition monitoring of loads in the power distribution system and in machinery and equipment is based on the regular recording and analysis of relevant data, ensuring safe and efficient operations. In addition to measuring output at the distribution frames, the entire electrical distribution network and its HARTING smart Power Network units are continuously monitored. Any changes in the installation and network quality are analyzed and recorded. This means
that voltage drops, potential cable breaks, or incorrect connections, for example, can be detected immediately before a system failure occurs.
Energy Consumption:
A comprehensive overview of energy consumers is essential for effectively reducing energy costs. To this end, the HARTING smart Power Network units in each sub-distributor or control cabinet utilize an integrated measurement circuit to capture and store data for calculating electricity consumption. The simplest way to reduce energy consumption is to disconnect consumers. The standardized I/O system in the manageable power distribution systems allows for the disconnection of unnecessary consumers or systems via a PLC, without requiring any additional protocols.
Visualization:
All measurement data from the installation is processed on industrial computers.
The data is read from the HARTING smart Power Network units via a standardized communication interface, processed, and archived.
Significant changes in measurement values are recorded, analyzed, stored, and displayed on industrial computers or in the control room, depending on their importance. The power of the entire installation or of each output circuit, for example, is calculated. Utilization relative to nominal power is also displayed, as well as an overload alarm.
Benefits
• Automatic recognition of the power grid by smart power distributors.
• Increased system availability through grid status monitoring functionalities.
• Recording and analysis of energy consumption on the grid.
Author:
Andreas Huhmann, Strategy Consultant Connectivity & Networks, Germany, HARTING Technology Group,
