Top 10 IoT Cases for Energy Management in Factories
There are many cases of IOT (Internet of Things) factory energy consumption management. They achieve precise monitoring, optimal control and intelligent management of factory energy consumption through IoT technology, significantly improving energy utilization efficiency and reducing operating costs.
The following is a detailed introduction to ten typical cases of IOT factory energy consumption management:
Case 1: Smart factory energy management system of a photovoltaic plant
Background:
A photovoltaic plant is faced with the problems of high equipment energy consumption and serious energy waste. It needs to build an intelligent energy consumption management system to optimize equipment energy consumption and improve energy utilization efficiency.
Solution:
Tianze Zhiyun cooperated with the photovoltaic factory to create a smart factory energy management system. The system combines industrial intelligence algorithms and models with big data analysis of factory systems to predict and diagnose energy consumption and health status of equipment.
Implementation effect:
- Intelligently optimize the energy consumption of fans, pumps, air compressors, ice machines and other equipment, realize intelligent equipment health management, and reduce equipment failure rates and safety accident rates.
- The system can intelligently schedule equipment usage in the next 12 hours and send predictive maintenance recommendations 2 weeks in advance.
- The overall energy saving of the air compressor system is 5%, and the overall energy saving of the ice machine system is 6%.
*According to statistical calculations of the system’s application year data, 10 1,500-horsepower air compressors saved more than 2 million yuan/year, and 12 1,360-ton ice machines saved more than 500,000 yuan/year.
Case 2: Blast furnace gas intelligent balancing system of a steel group in Shandong
Background:
A steel group in Shandong faced problems such as imbalance in gas supply and demand, large pressure fluctuations in the pipeline network, and low energy utilization efficiency. It needed to build an intelligent gas balance system to optimize energy management.
Solution:
Tianze Zhiyun worked with its partners to build a blast furnace gas intelligent balancing system for a steel group in Shandong. The system monitors pipeline network pressure and gas production and consumption fluctuations of each equipment in real time, and provides gas consumption suggestions for main operations through intelligent model prediction and calculation.
Implementation effect:
- Avoid the suspension of steel rolling production due to pipeline network pressure, and improve the refinement of energy management by the dispatching department.
- The gas emission rate is reduced from 5% to less than 1%, and the gas pipe network pressure stability rate is increased from 70% to 95%.
- According to preliminary estimates, the system brings annual economic benefits of 23 million yuan to the enterprise.
Case 3: iEMS smart factory management platform of a factory
Background:
A certain factory faces problems such as low level of informatization, lagging information, high costs, low efficiency, and high energy costs. It needs to build an intelligent factory management platform to optimize energy management.
Solution:
Advantech introduced the iEMS smart factory management platform to this factory. By integrating equipment and systems such as power distribution, cooling sources, air compressor stations, and constant temperature and humidity, the platform provides digital and visual management of factory equipment while monitoring the detailed usage of various energy sources in the enterprise in real time.
Implementation effect:
- Breaking down information silos and building a one-stop intelligent operation and maintenance platform, extending equipment life by 20% and improving management efficiency by 25%.
- Realize distribution system topology and status monitoring, feeder line monitoring, and support video security images.
- Carry out power quality analysis and power safety monitoring to improve the operating efficiency of the cold source system and achieve group control energy saving optimization.
- Monitor the operating status of air compressor stations and provide group control optimization to reduce energy costs.
Case 4: AIRIOT Smart Factory Energy Saving Management System
Background:
A certain factory faced problems such as difficulty in achieving energy-saving goals, rising comprehensive energy costs, high costs of internal communication and collaboration, difficulty in equipment troubleshooting, and low employee awareness of energy conservation. It needed to build an intelligent energy-saving management system to optimize energy management.
Solution:
The flexible smart factory energy-saving management system based on the AIRIOT Internet of Things platform brings new ideas to factory energy management. This system combines the Internet of Things, big data, cloud computing and other technologies to collect energy consumption and operation information of each energy consumption monitoring point, and form a statistical analysis of energy consumption by classification, sub-item and sub-region.
Implementation effect:
- Realize real-time monitoring and visual management of various energy sources in the factory, generate energy consumption reports, and locate high-energy-consuming equipment and processes.
- The system homepage management cockpit visually displays the overall energy usage and real-time environmental status of the factory.
- Intelligent control of equipment enables lighting optimization, spray control, heat energy utilization, etc. to improve resource utilization.
- Establish an equipment inspection mechanism to promptly detect potential equipment failures and avoid energy waste caused by abnormal production shutdowns.
- Carry out energy conservation and environmental protection training for employees, establish awareness of energy conservation and consumption reduction, and establish an energy consumption assessment mechanism for employees.
Case 5: Internet of Things Street Light Management System
Background:
As an important part of urban infrastructure, urban street lights have high energy consumption and operating costs. In order to reduce energy consumption and improve operational efficiency, it is necessary to build an intelligent street light management system.
Solution:
IoT-enabled streetlights can communicate with city public affairs managers, sending data about power usage, and remotely adjust lights to complement local environmental conditions. For example, dim the lights on moonlit nights and brighten them on rainstorms and foggy days.
Implementation effect:
- Adjust the brightness of street lights according to the climate, save energy and reduce energy costs.
- Realize remote monitoring and management of street lights and improve operational efficiency.
Case 6: Internet of Things transportation infrastructure monitoring system
Background:
The healthy operation of transportation infrastructure is crucial to smooth and safe urban transportation. In order to monitor the status of transportation infrastructure in real time and predict equipment failures, an intelligent monitoring system needs to be built.
Solution:
Sensors are placed at key points on roads and railways, and information sent back to headquarters is used to notify motorists of congestion points and provide alternative routes. At the same time, it can also be used to predict which equipment failures are imminent so that maintenance personnel can repair them in advance.
Implementation effect:
- Monitor the status of transportation infrastructure in real time to ensure smooth and safe traffic.
- Predict equipment failures and perform repairs in advance to avoid traffic jams and safety accidents.
Case 7: Internet of Things food and medical supplies temperature control system
Background:
Food and medical supplies require strict temperature and humidity control during storage and transportation to ensure their quality and safety. In order to achieve real-time monitoring and control of these sensitive goods, an intelligent temperature control system needs to be constructed.
Solution:
Logistics companies use airtight containers with environmental controls to preserve and transport food and medical supplies. The containers are equipped with sensors that send status reports to a central network, which monitors the containers to control humidity and temperature.
Implementation effect:
- Monitor the temperature and humidity of food and medical supplies in real time to ensure their quality and safety.
- Reduce deterioration and contamination of sensitive goods and improve customer satisfaction.
Case 8: Internet of Things Truck Tracking System
Background:
With the development of the logistics industry, trucks serve as the main means of transportation, and their operational efficiency and safety are crucial to the operations of logistics companies. In order to achieve real-time monitoring and tracking of trucks, an intelligent tracking system needs to be built.
Solution:
The mainstream logistics carrier is a truck equipped with sensors. These sensors can track the delivery situation along the way, select the best delivery route, track time, etc. At the same time, sensors are also used to track the driver’s speed, braking habits, etc. to ensure the safest and most environmentally friendly driving behavior.
Implementation effect:
- Monitor the operating status and location of trucks in real time to improve operational efficiency.
- Track the driver’s driving behavior to ensure safe and environmentally friendly driving.
Case 9: Internet of Things factory equipment monitoring system
Background:
The equipment in the factory is numerous and widely distributed. In order to achieve real-time monitoring and fault warning of these devices, an intelligent monitoring system needs to be constructed.
Solution:
Equipment within the factory is equipped with a variety of sensors that can automatically send alerts to a central factory operations monitoring network when they detect problematic components or other conditions that could trigger a failure.
Implementation effect:
- Monitor the operating status and fault conditions of the equipment in real time to improve the reliability and stability of the equipment.
- Provide timely early warning of equipment failures to avoid production shutdowns and safety accidents.
Case 10: Internet of Things Energy Management System
Background:
As energy prices rise and energy consumption increases, energy management becomes an important part of business operations. In order to achieve real-time monitoring and optimal management of energy, it is necessary to build an intelligent energy management system.
Solution:
Devices equipped with IoT sensors can monitor energy consumption, whether for individual homes, businesses, or data centers. These sensors transmit energy consumption data to a central management system for analysis and optimization.
Implementation effect:
- Monitor energy usage in real time and improve energy efficiency.
- Optimize energy management strategies and reduce energy costs.
These ten cases demonstrate the application and effect of IoT technology in factory energy consumption management. By building an intelligent energy management system, enterprises can achieve precise monitoring, optimal control and intelligent management of energy consumption, thereby improving energy utilization efficiency and reducing operating costs. These cases also provide useful references and lessons for other companies.
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FAQs
IOT factory energy consumption management refers to the process of using Internet of Things (IoT) technology to conduct real-time monitoring, data collection, analysis and optimization management of energy usage in the factory. It combines industrial automation, cloud computing, big data and other technologies to improve energy utilization efficiency, reduce energy consumption, and achieve the goals of energy conservation and emission reduction.
The advantages of IoT factory energy consumption management mainly include:
Real-time monitoring: Through the Internet of Things technology, the operating status and energy consumption of various energy equipment in the factory can be monitored in real time.
Data Analysis: The collected data can be analyzed in depth to help companies identify bottlenecks and waste points in energy use, providing a basis for optimizing energy use.
Intelligent control: Based on the results of data analysis, intelligent control of energy equipment can be realized, such as automatically adjusting equipment power, optimizing equipment operation strategies, etc.
Cost Savings: Through refined management, enterprises can more accurately predict and control energy costs and avoid unnecessary waste of energy.
Sustainable development: Helps enterprises achieve more environmentally friendly and sustainable production methods, in line with the green development concept of modern society.
Key equipment and technologies required for IoT factory energy consumption management include:
Smart Sensor: Used to monitor the consumption of electricity, water, gas and other energy sources. It is a basic component of the Internet of Things system.
IoT edge gateway: Deployed at various key nodes in the factory, it is responsible for collecting and processing data from sensors and actuators, and has powerful data processing and communication functions.
Cloud computing and big data technology: used to store, process and analyze collected data, and provide data visualization and decision support.
Industrial automation technology: used to realize remote control and automated operation of energy equipment.
Steps to implement IoT factory energy consumption management include:
Needs Assessment: Clarify the enterprise’s energy management needs and goals, and determine the energy equipment and areas that need to be monitored and controlled.
System Design: Based on the results of demand assessment, design the architecture and functional modules of the IoT system, including sensor placement, edge gateway configuration, cloud computing platform selection, etc.
Equipment Procurement and Installation: Purchase the required smart sensors, IoT edge gateways, cloud computing platforms and other equipment, and install and debug them.
System integration and testing: Integrate various devices into the Internet of Things system, conduct functional testing and performance optimization to ensure stable operation of the system.
Data analysis and optimization: Collect and analyze data, identify bottlenecks and waste points in energy use, formulate optimization strategies and implement them.
Continuous monitoring and improvement: Monitor and maintain the system regularly, and perform functional upgrades and optimizations based on actual needs.
There are many successful cases of IOT factory energy consumption management. For example, some large manufacturing companies have introduced IoT technology to realize real-time monitoring and optimized management of various resources such as electricity, water, and fuel in the factory, significantly improving energy utilization efficiency. Reduced operating costs. These successful cases show that IOT factory energy consumption management is an effective means of energy conservation and emission reduction, which can bring significant economic and social benefits to enterprises.
