Implementation of an Energy Metering System for Smart Production

Digitization is consecutively changing more and more areas of human living. Many products are designed increasingly ""smart"" and connected to their environment. Not only products but also the necessary production facilities and systems are subject to digital change. The goal is to achieve a wide range of improvements and increase the efficiency and flexibility of the interlinked production systems. In Industry 4.0, important production parameters are measured and monitored with the help of sensors. Based on analyses of those data, adjustments and improvements of the production system can be performed. This paper presents the concept and physical implementation of an advanced energy metering system on a factory demonstrator, the so-called SmartFactory 4.0. It produces beverage coasters, which can be designed freely by the customer in shape, material and colour and is produced directly or remotely through a web application. The SmartFactory 4.0 consists of three production modules, which are connected to one another by means of media and information technology. The advanced energy metering system is designed in order to measure and monitor energy consumptions in various production steps. Those data are compared to previous simulations. Steps for the improvement of the energy efficiency of the SmartFactory 4.0 are derived. This paper presents first test results from the application of the system. For different individualized gravures and two different colours (green and orange) with various depths of the produced beverage coaster, energy consumptions of the production have been metered over time. The measured data are analysed and evaluated, and suitable steps for improvement are given. Finally, this research provides suggestions for scaling the energy metering system to larger production systems, and a systematic procedure for implementation is given. This research constitutes one step in the direction of utilizing the concept of the digital factory twin for the improvement of energy efficiency and sustainability of production systems.