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FEATURE Smart factory and AI
Intelligent energy management
Sam Tilley, Regional General Manager for UK, Ireland and the Nordics at Omron, discusses the key parameters needed to reach sustainable manufacturing
T
he approch of many factory managers
it!” This is understandable, particularly if it relates to a process that took a long time to get right, or a line or machine that is running reliably. However, reducing Scope 1 greenhouse gas (GHG) emissions in the order of magnitude necessary to meet 2050 targets will and processes – even those that are working perfectly.
Intelligent energy management, or the optimisation of energy use, can help identify potential areas of improvement, and guide the adoption of practical, feasible ways to decarbonise operations.
Materials handling and GHG emissions It generates around 2,640 grams of CO2
per
combusted litre of diesel, resulting in 5,280-7,920 grams of CO2
emissions an hour. So, there’s
room for improvement. Autonomous mobile robots are battery
powered, making them the perfect fossil-free They are also intelligent enough to return to the charging station when not in use, further conventional linear conveyors, and, unlike traditional autonomously guided vehicles, they navigational beacons. Robotics can also drive greater energy
pallets common. With fewer pallets equalling lower per unit carbon emissions, optimising programming. Cobot palletising solutions work alongside people to quickly calculate pallet patterns for easy implementation, and
Reducing wasted energy Almost everything in a factory requires power, In an average industrial facility, 10-30% energy consumption is used to generate compressed air. Yet, up to a third of that air is often wasted, due to leaks, misuse, over-pressurisation and pressure drops. Smaller compressors for reduced needs, using electronic speed variators
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and heat recovery systems, and limiting class IE4 requirements, will help increase
The importance of inverters shouldn’t be overlooked either. Today these incorporate regenerative energy capabilities. Replacing old
Data-driven change
Strategies that harness the IoT and AI models can analyse a factory’s real-time energy usage then implement appropriate solutions, which could be as simple as adjusting the settings on inverters. This data is collected from sensors throughout the facility. Old lines may not have these, at least not in the correct locations or with the required accuracy, but they can be a worthwhile investment, providing insights they may otherwise be hidden. When such a system was used to continuously monitor the air and operational it found hours in which production and quality implement a new policy on air conditioning and related costs.
Adapting to a sustainable future Whilst there are areas of manufacturing where small adaptations can lead to big savings, reaching net zero will also require fundamental changes to the collection and analysis of production data and the movement of goods will play a role, but any manufacturing facility, more sustainable.
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Automation | June 2024 33
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