Periodic Reporting for period 3 - E2COMATION (Life-cycle optimization of industrial energy efficiency by a distributed control and decision-making automation platform)
Okres sprawozdawczy: 2023-11-01 do 2025-01-31
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 concuurent and 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 which have been achieved by the Project 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) and Process Control (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.
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 concuurent and 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 which have been achieved by the Project 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) and Process Control (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.
E2CE2COMATION project developed an overall platform for energy monitoring and optimization through 5 technical work packages (WPs).
- WP2 built the project reference framework based on industrial requirements for the usage of the E2COMATION platform, and defined the validation scenarios for the two pilot value-chains of the project, mapping technological modules onto the demonstration use-cases with corresponding KPIs.
- WP3 addressed the modular and scalable monitoring, automation and decision-making platform, with the purpose of completing and complementing shopfloor brownfield installations in existing plants. Respective solutions have been developed and totally deployed on premises of all use cases. Overall final results are:
R1) the CPSizer, as the combination of IEC61499 solution for interacting with existing automation, and the EMon tool, to perform fingerprinting and subsystem emulation of machinery, acting also data collector
R2) SDS solution for raw data storage, handling and creation of dedicated aggregated information view
R3) the overall Decision Support System, as unique platform to operate all E2COMATION tools
- WP4 acted on digital models of discrete processes for simulation and of continuous processes, and the connection between shopfloor and DSC- on one side - and high end tools-on the other side. Respective solutions have been developed and deployed on premises.Overall final results are:
R4) Digital twin for continuous process
R5) Multiperspective simulation framework for discrete event simulation
R6) APAMA tool for stream analysis
R7) Trendminer for self service analytics
- WP5 developed high end optimization tools for energy efficient factory solution both for discrete manufacturing (EAPS) as well for the continuous process optimization - combining the MTEC and EAPC. The S-TEG tool cooperates with these, by optimizing (co)generation system management. Respective solutions have been fully developed and installed onsite.
Overall results are therefore:
R8) EAPS (Energy Aware Planning &Scheduling tool)
R9) MTEC (Machine Tool Energy Configurator)
R10) EAPC (Energy Aware Process Control tool)
R11) S-TEG (Smart Thermal Energy Grid)
- WP6 addressed the high end tools managing the sustainability perspective across process/product life-cycle management of intra- and inter-factory streams. Respective solutions have been fully developed and installed.
Overall results are:
R12) s-CAPP: a tool for sustainable process planning
R13) LCAC tool: a tool for LifeCycle Assessment and Costing based on process/products near real time LCA monitoring
R14) LCA-driven SCM: a platform for supply chain management based on performance and sustainability indicators.
- WP7 and WP8 addressed the full validation campaign of all the E2COMATION platform in the Woodworking and Foob&beverage sectors respectively.
-WP9 addressed the dissemination and exploitation of all the project results, with four of them close to the market.
- WP2 built the project reference framework based on industrial requirements for the usage of the E2COMATION platform, and defined the validation scenarios for the two pilot value-chains of the project, mapping technological modules onto the demonstration use-cases with corresponding KPIs.
- WP3 addressed the modular and scalable monitoring, automation and decision-making platform, with the purpose of completing and complementing shopfloor brownfield installations in existing plants. Respective solutions have been developed and totally deployed on premises of all use cases. Overall final results are:
R1) the CPSizer, as the combination of IEC61499 solution for interacting with existing automation, and the EMon tool, to perform fingerprinting and subsystem emulation of machinery, acting also data collector
R2) SDS solution for raw data storage, handling and creation of dedicated aggregated information view
R3) the overall Decision Support System, as unique platform to operate all E2COMATION tools
- WP4 acted on digital models of discrete processes for simulation and of continuous processes, and the connection between shopfloor and DSC- on one side - and high end tools-on the other side. Respective solutions have been developed and deployed on premises.Overall final results are:
R4) Digital twin for continuous process
R5) Multiperspective simulation framework for discrete event simulation
R6) APAMA tool for stream analysis
R7) Trendminer for self service analytics
- WP5 developed high end optimization tools for energy efficient factory solution both for discrete manufacturing (EAPS) as well for the continuous process optimization - combining the MTEC and EAPC. The S-TEG tool cooperates with these, by optimizing (co)generation system management. Respective solutions have been fully developed and installed onsite.
Overall results are therefore:
R8) EAPS (Energy Aware Planning &Scheduling tool)
R9) MTEC (Machine Tool Energy Configurator)
R10) EAPC (Energy Aware Process Control tool)
R11) S-TEG (Smart Thermal Energy Grid)
- WP6 addressed the high end tools managing the sustainability perspective across process/product life-cycle management of intra- and inter-factory streams. Respective solutions have been fully developed and installed.
Overall results are:
R12) s-CAPP: a tool for sustainable process planning
R13) LCAC tool: a tool for LifeCycle Assessment and Costing based on process/products near real time LCA monitoring
R14) LCA-driven SCM: a platform for supply chain management based on performance and sustainability indicators.
- WP7 and WP8 addressed the full validation campaign of all the E2COMATION platform in the Woodworking and Foob&beverage sectors respectively.
-WP9 addressed the dissemination and exploitation of all the project results, with four of them close to the market.
Progress beyond the state of the art
The project addressed novelty 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, 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
Achieved results at 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) Machine Tool Energy Configurator (MTEC) 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.
Registered impacts across use cases:
WOODWORKING&FURNITURE VALUE CHAIN
cumulated average energy reduction by 10-14%
improved environmental performance of involved products, with insight for Life Cycle Cost reduction of at least 15%
FOOD AND DRINK VALUE CHAIN
energy reduction by 10% in ratio energy/product
improved environmental performance of involved products,with insight for Life Cycle Cost reduction of around 7%
The project addressed novelty 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, 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
Achieved results at 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) Machine Tool Energy Configurator (MTEC) 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.
Registered impacts across use cases:
WOODWORKING&FURNITURE VALUE CHAIN
cumulated average energy reduction by 10-14%
improved environmental performance of involved products, with insight for Life Cycle Cost reduction of at least 15%
FOOD AND DRINK VALUE CHAIN
energy reduction by 10% in ratio energy/product
improved environmental performance of involved products,with insight for Life Cycle Cost reduction of around 7%