Energy management concept reduces the energy used as well as manufacturing costs


Energy efficiency and costs  

Record and evaluate data and increase energy efficiency

  • Sustainable production through optimum use of energy and resources.
  • According to the German law governing energy services and other energy efficiency measures (EDL-G), large companies must record at least 90 percent of their entire energy consumption and implement active energy and load management.


Cyber physical systems record energy and resource requirements  

Cyber physical systems record requirements

Industrie 4.0 focuses on the development and organization of self-controlling manufacturing processes by means of cyber physical systems (CPS). Among other things, the cyber physical systems contain sensors that record the condition values of the respective application.

If the sensor structure is extended to include measured energy values, the first step in energy data acquisition is complete. Based on the concept that an intelligent product is described as a digital product, the energy characteristics of the product can in future be part of this description. This enables conclusions to be drawn as to the resource requirements throughout the entire lifecycle of a product. The analysis of globally available data also enables new conclusions and recommendations to be made with regard to resource-optimized production.


Operating state diagram for energy-efficiency cyber physical systems  

Energy-efficient cyber physical systems

In Industrie 4.0 solutions, every autonomous processing station generally has its own PLC that controls its local functions. The higher-level control system is informed of the system's current capacity utilization as well as the processing status of the variants currently being manufactured.

An energy management concept can reduce the amount of energy used as well as manufacturing costs without inhibiting productivity. In this case, a connection and disconnection strategy needs to be developed in order to optimize the way in which the processing stations of the CPS use energy according to requirements. The control system monitors the active stations and can read a description of their properties.

The data required in order to choose the right connection and disconnection strategy includes the switchable operating states and their energy level, the associated transition conditions and times, as well as the mutual dependencies between the system parts and components.

At the heart of the energy management concept is an instance that selects the connection and disconnection strategies on the basis of the production steps required for the components or variants. The required data is taken from the digital product description. The challenge here is to ensure that a disconnected processing station is restarted automatically in time for it to be ready for production at the planned time.


The implementation of the forward-thinking Industrie 4.0 project means not only consistent engineering but also seamless communication. It also promotes the economical use of available resources.

On this basis, energy characteristics can be integrated into the digital product description in order to draw conclusions about resource requirements. A suitable energy management concept can then calculate connection and disconnection strategies in order to make the individual processing stations as energy-efficient as possible.

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