Energy efficiency and system availability can be increased, operating processes and maintenance optimized and the value creation process in enclosure and system construction simplified.

Like the entire energy system, electrical energy distribution is also changing, influenced by factors such as changing load conditions, a growing number of electrical consumers and, in particular, increasing networking and automation in industrial environments, buildings and infrastructure. Added to this are stricter standards and increased requirements for operational energy management. The consequences: The planning and operation of electrical energy distribution is becoming more complex and the technical demands on the underlying products and systems are increasing - particularly with regard to their flexibility, communication and integration capabilities.

In order to adequately support dynamic, networked production environments, hardware and software must interact smoothly with systematic data management. This begins during the electrical engineering planning stage, long before the actual construction of an industrial control cabinet. Digital twins can be used to simulate and virtually test the interaction of electrification and automation components as part of automated, efficient control cabinet engineering. This helps to avoid errors in the real world right from the start.

Fail-safe power supply

Where everything is interconnected, the availability of systems and components is more important than ever. If a single element in the manufacturing process fails, the entire system can be damaged under unfavorable circumstances and the entire production process comes to a standstill. Electrical power distribution in automated environments must therefore combine maximum safety with the greatest possible flexibility.

The 3VA miniature circuit-breakers show how powerful protective components can ensure the necessary safety and flexibility in digital factories. They protect cables, devices and industrial systems from electrically induced damage and failures by safely switching off the power in the event of faults such as short circuits or overloads. In addition, they are increasingly taking on other operationally relevant tasks, such as recording energy or status data. In the age of Industry 4.0, they therefore create transparency about all demand values and critical system statuses, which is particularly important, and lay the foundation for efficient and reliable production processes.

Integration into industrial automation

The technical basis for integrating electrical power distribution into automated environments is provided by communication-capable components, such as the 3VA molded-case circuit-breakers and 7KM PAC measuring devices from the Siemens Sentron portfolio. The molded-case circuit-breakers and measuring devices are available directly in the TIA portal. This makes electrification an integral part of the automation solution.

The technical basis for integrating electrical power distribution into automated environments is provided by communication-capable components, such as the 7KM PAC measuring devices from Siemens' Sentron portfolio. © Siemens

Standardized interfaces ensure efficient interaction between all components in the industrial communication network. All data for molded-case circuit-breakers and measuring devices is available in the central engineering environment. This allows the devices to be parameterized and commissioned directly via the TIA portal. This enables engineering with just one tool and intuitive configuration of the power distribution system. Status monitoring and the collection of energy and diagnostic data are also conveniently possible.

The recorded data on current, voltage and energy can be used for detailed evaluations and systematic management of processes in production automation. Malfunctions in the system are identified at an early stage, failures are prevented and overall operation is made more energy-efficient. Among other things, the energy data can be used to assess the system status and network quality and to optimize energy consumption and capacity utilization. The energy consumption per day, shift, line or production unit, for example, is determined as the basis for energy efficiency measures. For example, the evaluation of energy consumption during production time compared to non-production time provides initial indications of potential savings. Comparisons with other systems, for procedures or processes, in a factory or across all sites lead to the discovery of further potential. The precise, reproducible and reliable measured values form the basis for systematic energy and plant monitoring. This opens up enormous savings potential for companies and is the basis for sustainable operational energy management.

Data management in the cloud

Sivacon 8MF system enclosures are used in mechanical and plant engineering, control technology, wind power, photovoltaics and many other sectors. © Siemens

Finally, all recorded energy data can also be made available in MindSphere, the cloud-based IoT operating system from Siemens, via MindConnect components and are thus available for specific evaluations. The resulting recommendations for action can continuously optimize production systems - for example, in terms of their energy requirements or availability. For predictive maintenance, it is also possible to identify potential problems at a very early stage so that the right decisions can be made at the right time. Companies can thus increase the productivity and efficiency of their entire operation. They benefit from reduced downtime, increased production, more effective use of their equipment and overall greater competitiveness.

Automated, networked production systems place new demands on the electrical power supply. Intelligent components such as communication-capable compact circuit-breakers and measuring devices adapt to these requirements. They create transparency, ensure optimum system availability and, last but not least, minimize engineering costs. They therefore make a significant contribution to the safe, efficient implementation of digital Industry 4.0 applications.

Jochen Ziegner, Product Manager for Energy Monitoring and Cloud Solutions at Siemens Energy Management