d1.3 public report

Public Report on WP1Deliverable D1.3 / WP1 / TASKs 1.1 / 1.2 / 1.3

INCREASE OF AUTOMOTIVE CAR INDUSTRY COMPETITIVENESS THROUGH AN INTEGRAL AND ARTIFICIAL INTELLIGENCE DRIVEN ENERGY

MANAGEMENT SYSTEM

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2. The car manufacturing industry

1. Introduction

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Index

3. The “intelligent Energy Management System (iEMS)

4. The pilot plant: SEAT Martorell

5. Conclusions and next steps

1.1 EuroEnergest Project

1.2 Project Consortium

1. Introduction

3

Index





This report presents the main results and conclusions of the work done during the first period of the project EuroEnergest.

This document shows:

The results from the automotive industry analysis.

The general structure of an iEMS and its advantages for energy management.

A description of the SEAT Martorell plant where the system will be tested.

The process to implement the EuroEnergest software in the car manufacturing industry.

1. Introduction

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The aim of the project is to reduce, at least by 10%, the energy consumption in the automotive industry by developing an intelligent Energy Management System (iEMS).

1.1 EuroEnergest Project

This development will be implemented on a real site (SEAT facilities, in the outskirts of Barcelona – Spain) for its industrial trials and validation.

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The EuroEnergest project is a collaborative project between technology centres, universities and private companies to develop a system of intelligent energy management for the automotive industry.

This project is supported by the European Commission under the 7th Framework Programme

1.2 Project Consortium

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2.1 The car manufacturing process

2.1 Energy and environmental impact

1. Introduction

Index




5. Conclusions and next steps7

Generally speaking, there is not one automotive manufacturing plant which is exactly like any other. Some similarities can be found among recently built ones but the old plants have been regularly updated to cope with constantly changing market needs.


Initially, fully integrated factories were constructed, but over the years, the outsourcing process has generally extended and many production steps have been externalized to other companies.

The profile of industrial plants is very dynamic and not a homogeneous facility. This is one of the

biggest challenges of the EuroEnergest project:

“to be flexibly enough in order to be adapted to this heterogeneous environment”

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Despite the fact that all car manufacturing processes can be standardized, they are not necessarily located within the same production environment.

2.1 The car manufacturing process

Logistics (material receipt) Press Bodyshop Painting Assembly Quality

review

Logistics (car

distribution)

These vehicle production systems continue operating with the same logic but the difference is that some of their internal processes have been outsourced or there has been an improvement in terms of the technology used.

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With regards to energy consumption, during 2011 the average energy consumption for the production of a vehicle was 2,5 MWh (from data from major vehicle manufacturers).Variances above and below this typical value may be due both to the difference between vehicle models and the difference in the production process.

2.1 Energy and environmental impact

From an environmental viewpoint, the resulting CO2 emissions from the production of vehicles, is 0,65 tons of CO2 per vehicle.

Since there is a direct relationship between energy consumption and CO2 emissions, it can be assumed that the differences are due to the mix of primary energy sources used.

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1. Introduction

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Index






An Energy Management System (EMS) is a set of tools used to manage a facilities energy information.

Perhaps most importantly, intelligent energy management provides a platform that empowers real-time insight, analysis and control, as well as integration with the expanding smart grid infrastructure.

Intelligent energy management solutions build on traditional and informed demand response practices by incorporating several new elements that help energy sources and energy consuming systems leverage a true, two-way dialogue.

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EuroEnergest software uses information from different sources. Most important of these are weather databases, and data about the production plan.

This information needs to be continually updated by means of an online server.

Unfortunately, industrial processes carried out in the automotive sector are subject to strict privacy policies, leading to the introduction of limitations on information availability.

For this purpose a distributed software implementation across different servers has been chosen, to enhance the protection of the company's confidential data from external attack.

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As the software design is conceptualized today, a number of finite elements (energy generation/consumption equipment) are modeled. If required, it is possible to incorporate new models, such as the introduction of further types of renewable energy generation systems.

The EuroEnergest iEMS aims to combine available energy sources (electrical/gas grid, renewable and CHP) to supply the energy

demand in a car manufacturing environment. 14

1. Introduction

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Index




4.1 Assembly

4.2 Painting



The EuroEnergest project will be implementable in any car manufacture industry, but the first industrial scale trials will be done at the SEAT Martorell factory.

This SEAT factory covers a total of over 2.800.000 m2.

The project will be focused on Bodyshop and Painting workshops which will be fully analyzed and monitored.

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4. The pilot plant: SEAT MartorellThe primary energy consumption at SEAT is 700 GWh, with gas being the most highly used energy source (550 GWh) representing a 78%. The remaining 22% is electricity from the grid (150 GWh).

Part of gas supply is used to generate overheated water and electricity in the CHP.

In terms of energy consumed in each workshop (540 GWh), electricity is the most high demand source (260 GWh) with the 48% of the total consumed, followed by thermal energy (200 GWh) with 37% and gas (80 GWh) with 15%

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4.1 BodyworkWith regards to the two workshops where the EuroEnergest system will be implanted, the bodywork processes take place in the 100.000 m2 of the workshops 1.

Its main purpose is to give corrosion resistance, geometry and sealing to the cars structure.

More than 1.800 employees work together with 3.000 robots.

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4.2 PaintingIn the Painting process, more than 1.000 people work to get 2.000 cars painted every day. Approximately 75 robots are used to paint each car during the different process steps.

The painting process is the most intensive in terms of electricity, thermal energy, gas and water consumption. The percentage of gas used (around 30%), is much higher than the average of the other workshops. This is due to the fact that some ovens use gas directly to provide high temperatures. 19

1. Introduction

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Index





5. Conclusions and next stepsThe analysis done on WP1 concludes that:

One of the biggest challenges of EuroEnergest project is that the profile of industrial plants is a very dynamic and non-homogeneous

As the EuroEnergest software is conceptualized today, a number of finite elements (energy generation/consumption equipment) are modeled and it is this modular structure which allows the solution of a wide range of situations.

Painting and Bodywork workshop have been selected at SEAT due to their differences in energy use in their HVAC systems. They represent both the use of HVAC for comfort and process.

There are significant differences between the energy used and the CO2 emission per car manufactured, but these differences may be due to differences in processes and the wide range and type of vehicles manufactured.

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Proj

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rogr

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5. Conclusions and next stepsThe following diagram shows the methodology, in general terms, to be used to implement the software in a car manufacture industry.

STAGE 1

STAGE 2

STAGE 3

STAGE 4

STAGE 5

STAGE 6

ANALYSIS

SOFTWARE IMPLEMENTATION

ON-LINE MODELLING AND DATA ACQUISITION

PLAN

IEMS TEST AND REFINEMENT

EVALUATION AND REPORTING

EXPLOITATION

The car manufacturer provides information about the plantFirst energy models are definedCritical constrains and relevant variables are studied.

Relationships with different models are defined into the iEMS structure.Historical and Real data is collected to define specific generation/consumption models.

First models outputs are used to define on-line models.Extra measurements are detected and a data acquisition plan is defined.

iEMs is implemented at SEAT facilities and plugged to live data.The first results allow to test and refine the iEMS operation.

iEMS software is trialled and its performance is evaluated. Energy savings and CO2 emissions are reported and validated.The software is examined to determine its ability to be adapted to other environments and necessary modifications are defined.

The software is prepared for its exploitation and sale to potential customers in automotive industry.

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http://www.euroenergest.eu/[email protected]

http://www.euroenergest.eu/

mailto:[email protected]

d1.3 public report

Technology