Periodic Reporting for period 2 - E2COMATION (Life-cycle optimization of industrial energy efficiency by a distributed control and decision-making automation platform)
Reporting period: 2022-05-01 to 2023-10-31
The European countries are facing unprecedented challenges resulting from increased dependence on energy imports and scarce energy resources, and the need to limit climate change and overcome the economic crisis. The continuous increase in energy efficiency, supported by innovations, is a valuable means to address these challenges. Improving industrial energy efficiency at the European Manufacturing level requires the integration of energy data, such as historical data, real-time data and real-time predicted energy cost, into the production management systems based on the given and individual industrial task. In parallel, manufacturing systems are complex systems since many parameters, related to the environment, usage of materials, components, machines, cells, lines and supply chains, collectively influence the energy as well as the sustainability performance of production processes.
E2COMATION project takes up and addresses these challenges providing solutions that can support industrial energy efficiency. The approach results in a new paradigm shift towards holistic optimisation of energy usage at multiple hierarchical layers of the manufacturing process and considering the whole life-cycle perspective. The framework developed within the project operates from the field level by collecting information and data to the factory level by managing and optimising the production.
The project overall objectives are:
- Holistic analysis of energy-related data streams for production performance forecasting;
- Life-cycle conceptual paradigm applied to digital twinning of factory assets;
- Factory-level integrated multi-objective optimization architecture;
- Modular and scalable automation platform for distributed monitoring and supervision;
- Comprehensive simulation environment enhanced with energy and environmental performance;
- Energy Aware Planning and Scheduling tool (EAP&S);
- Life Cycle Assessment and Costing tool (LCAC) integrated in a company Decision Support System;
- Sustainable Computer Aided Process Planning (s-CAPP);
- LCA-driven supply chain management (SCM) and business ecosystem.
E2COMATION project takes up and addresses these challenges providing solutions that can support industrial energy efficiency. The approach results in a new paradigm shift towards holistic optimisation of energy usage at multiple hierarchical layers of the manufacturing process and considering the whole life-cycle perspective. The framework developed within the project operates from the field level by collecting information and data to the factory level by managing and optimising the production.
The project overall objectives are:
- Holistic analysis of energy-related data streams for production performance forecasting;
- Life-cycle conceptual paradigm applied to digital twinning of factory assets;
- Factory-level integrated multi-objective optimization architecture;
- Modular and scalable automation platform for distributed monitoring and supervision;
- Comprehensive simulation environment enhanced with energy and environmental performance;
- Energy Aware Planning and Scheduling tool (EAP&S);
- Life Cycle Assessment and Costing tool (LCAC) integrated in a company Decision Support System;
- Sustainable Computer Aided Process Planning (s-CAPP);
- LCA-driven supply chain management (SCM) and business ecosystem.
E2COMATION project has five technical work packages (WPs) responsible for the design and development of the technologies. These WPs have progressed as expected, in particular:
- WP2 aims at transforming the pillar structure of the DoA into a well-defined reference framework for the main developments of the project itself. Organized over three tasks, mostly concurrent, the corresponding activities have been the analysis of the industrial requirements for the usage of the E2COMATION platform, the definition of the validation scenarios for the two pilot value-chains of the project and the mapping of technological modules of E2COMATION onto the demonstration use-cases and corresponding KPIs.
- WP3 addresses the modular and scalable monitoring, automation and decision-making platform, with the purpose of completing and complementing shopfloor brownfield installations in existing plants. The four tasks focused on understanding requirements from ROYO, KEAS, MAHOU and CONDIS use cases, the definition of MQTT as communication mechasism as well as the DSC role and data flow gathering and the design of Edge-to-Cloud computing framework for pervasive life-cycle optimization background infrastructure. Respective solutions have been developed and partially deployed on premises.
- WP4 acts on the connection between shopfloor and DSC- on one side - and high end tools-on the other side. Specifically, the work done completed the analysis and definition of technical requirements per each use case and the development of some tools, such as the improvement of an existing solution by SIGMA to enable comprehensive energy monitoring at a reasonable cost and fully integrated and the elaboration and initial design of the concepts of Digital Twin by KUL. Further to this, automatic stream analysis as well asl self analytics tools were addressed. A comprehensive approach and framework to multipèerpsective simulation was developed. Respective solutions have been developed and some partially deployed on premises.
- WP5 contains and develops high end optimization tools for energy efficient factory solution. Organized over four tasks, it results in the understanding of the data available from ROYO and KEAS facilities, acting as use cases for the woodworking value chain and in the characterization of their machines, workflows and energy flows. EAPO (energy aware process optimization) was specialised into a solution for discrete manufacturing - the EAPS (Energy Aware Planning &Scheduling tool) as well as one integrated suite for the continuous process - comprising the EAPC (Energy Aware Process Control tool) in collaboration with MTEC (Machine Tool Energy Cnfigurator). Both being complemented by the SMART TEG tool, aimed ay unit committment problem solving in (co)generation system management. Respective solutions have been developed.
- WP6 addresses the high end tools managing the sustainability perspective across process/product life-cycle management of intra- and inter-factory streams. Activities focused on examination of end user needs and expectations, considering different levels of advancement and perception of sustainability. Moreover, activities related to tools development were completed, resulting in i) the LCAC tool , and ii) the LCA driven verticalization of Bloomy AI Decision platform as Supply Chain Management tool.
- WP7 and WP8 addressed the validation activities for the Woodworking and Foob&beverage sectors respectively, developing plans for validation. Some activities related to plant sensorization and tools deployment have been already completed.
- WP2 aims at transforming the pillar structure of the DoA into a well-defined reference framework for the main developments of the project itself. Organized over three tasks, mostly concurrent, the corresponding activities have been the analysis of the industrial requirements for the usage of the E2COMATION platform, the definition of the validation scenarios for the two pilot value-chains of the project and the mapping of technological modules of E2COMATION onto the demonstration use-cases and corresponding KPIs.
- WP3 addresses the modular and scalable monitoring, automation and decision-making platform, with the purpose of completing and complementing shopfloor brownfield installations in existing plants. The four tasks focused on understanding requirements from ROYO, KEAS, MAHOU and CONDIS use cases, the definition of MQTT as communication mechasism as well as the DSC role and data flow gathering and the design of Edge-to-Cloud computing framework for pervasive life-cycle optimization background infrastructure. Respective solutions have been developed and partially deployed on premises.
- WP4 acts on the connection between shopfloor and DSC- on one side - and high end tools-on the other side. Specifically, the work done completed the analysis and definition of technical requirements per each use case and the development of some tools, such as the improvement of an existing solution by SIGMA to enable comprehensive energy monitoring at a reasonable cost and fully integrated and the elaboration and initial design of the concepts of Digital Twin by KUL. Further to this, automatic stream analysis as well asl self analytics tools were addressed. A comprehensive approach and framework to multipèerpsective simulation was developed. Respective solutions have been developed and some partially deployed on premises.
- WP5 contains and develops high end optimization tools for energy efficient factory solution. Organized over four tasks, it results in the understanding of the data available from ROYO and KEAS facilities, acting as use cases for the woodworking value chain and in the characterization of their machines, workflows and energy flows. EAPO (energy aware process optimization) was specialised into a solution for discrete manufacturing - the EAPS (Energy Aware Planning &Scheduling tool) as well as one integrated suite for the continuous process - comprising the EAPC (Energy Aware Process Control tool) in collaboration with MTEC (Machine Tool Energy Cnfigurator). Both being complemented by the SMART TEG tool, aimed ay unit committment problem solving in (co)generation system management. Respective solutions have been developed.
- WP6 addresses the high end tools managing the sustainability perspective across process/product life-cycle management of intra- and inter-factory streams. Activities focused on examination of end user needs and expectations, considering different levels of advancement and perception of sustainability. Moreover, activities related to tools development were completed, resulting in i) the LCAC tool , and ii) the LCA driven verticalization of Bloomy AI Decision platform as Supply Chain Management tool.
- WP7 and WP8 addressed the validation activities for the Woodworking and Foob&beverage sectors respectively, developing plans for validation. Some activities related to plant sensorization and tools deployment have been already completed.
Progress beyond the state of the art
The project addressed novlety contents in the following fields:
- collaboration scheme betewwn EAPO and Smart TEG, as a way to continuously coordinate energy aware production optimization, generating variable ancillary services demand, and (co)generation system variable committment.
- dynamic LCAC tool methoidology, as s flexible way to handle product/process dimensions, cooperatively interacting also with multiperspective simulation
- multiperspecive simulation as a service, encapsulating energy and LCA indicators
- combination of automatic stream analytics vs on demand analytics to monitor and query the process
Expected results until the end of the project:
- Multichannel measurement toolkit:
- Modular and scalable automation platform for distributed monitoring and supervision;
- Automatic stream analytics for analysis of energy-related data streams for production performance forecasting;
- Comprehensive simulation environment enhanced with energy and environmental performance;
- Factory-level integrated multi-objective optimization architecture;
- Energy Aware Planning and Scheduling tool (EAP&S) and Energy Aware Process Control tool (EAPC);
- Life Cycle Assessment and Costing tool (LCAC) integrated in a company Decision Support System;
- Sustainable Computer Aided Process Planning (s-CAPP);
- LCA-driven supply chain management (SCM) and business ecosystem.
Potential impacts
ENERGY CONSUMPTION REDUCTION OF AT LEAST 25%
Life Cycle Cost reduction of at least 15%
IMPROVED ENVIRONMENTAL PERFORMANCE OF THE INVOLVED PRODUCTS – FOOD AND DRINK VALUE CHAIN
IMPROVED ENVIRONMENTAL PERFORMANCE OF THE INVOLVED PRODUCTS – WOODWORKING&FURNITURE VALUE CHAIN
The project addressed novlety contents in the following fields:
- collaboration scheme betewwn EAPO and Smart TEG, as a way to continuously coordinate energy aware production optimization, generating variable ancillary services demand, and (co)generation system variable committment.
- dynamic LCAC tool methoidology, as s flexible way to handle product/process dimensions, cooperatively interacting also with multiperspective simulation
- multiperspecive simulation as a service, encapsulating energy and LCA indicators
- combination of automatic stream analytics vs on demand analytics to monitor and query the process
Expected results until the end of the project:
- Multichannel measurement toolkit:
- Modular and scalable automation platform for distributed monitoring and supervision;
- Automatic stream analytics for analysis of energy-related data streams for production performance forecasting;
- Comprehensive simulation environment enhanced with energy and environmental performance;
- Factory-level integrated multi-objective optimization architecture;
- Energy Aware Planning and Scheduling tool (EAP&S) and Energy Aware Process Control tool (EAPC);
- Life Cycle Assessment and Costing tool (LCAC) integrated in a company Decision Support System;
- Sustainable Computer Aided Process Planning (s-CAPP);
- LCA-driven supply chain management (SCM) and business ecosystem.
Potential impacts
ENERGY CONSUMPTION REDUCTION OF AT LEAST 25%
Life Cycle Cost reduction of at least 15%
IMPROVED ENVIRONMENTAL PERFORMANCE OF THE INVOLVED PRODUCTS – FOOD AND DRINK VALUE CHAIN
IMPROVED ENVIRONMENTAL PERFORMANCE OF THE INVOLVED PRODUCTS – WOODWORKING&FURNITURE VALUE CHAIN