- moneo: IIoT platform
- Use cases
- Consumption metering via pulse outputs
Consumption metering via pulse outputs or an S0 interface using moneo RTM
Optimised energy consumption through automated consumption metering
With little effort and without interfering with existing systems, consumption data can be recorded and used to optimise energy consumption:On the one hand potential energy savings are shown, on the other hand it becomes evident where energy is wasted.
Many counters or sensors feature pulse outputs or S0 interfaceswhich can be used for automated consumption metering. Among others, heat meters, electricity meters, water meters, flow sensors and gas meters have S0 interfaces.
Initial situation:
Consumption metering is common practice in many sectors of industry today, but has not yet become automatic in many cases. This means that there is no central evaluation of individual consumption, peak consumption or the sum of all consumption. Outside the operating hours, there could be additional unintentional consumption which cannot be identified. Neither can cost drivers in energy consumption be identified.
Aim of the project:
For the assessment, optimisation and cost reduction of the total energy consumption, automatic metering of the consumption is necessary.
- Centralised visualisation of all consumption data
- Analysis of consumption
- Multiple counters are combined into one total counter
- Identification of energy-related cost drivers
- Consumption metering outside the operating time
- Identification of peak consumption periods
Implementation:
In addition to the selected meters or sensors, the following basic components are necessary to implement such a project:
- IO-Link counter module (DP2302)
- IO-Link master (e.g. AL1350)
- 24V power supply (e.g. DN4011)
- M12 connection cable (e.g. EVC014)
- connection cable with plug (e.g. EVC076)
The counter module detects the pulses and adds them up. This counter value is transmitted to the IO-Link master via IO-Link and then processed by moneo RTM.
Result:
Transparent energy consumption thanks to moneo RTM. The visualisation of the total consumption also makes it possible to identify energy guzzlers. This in turn saves costs and energy. The assessment of peak loads means more planning reliability.
Bottom line:
In summary, this is an effective contribution to the energy transition since energy waste can be identified and avoided.
System structure
Example 1 – electricity meter with S0 interface
Example 2 – heat meter with S0 interface
Example 3 – flow sensor with pulse output
Dashboard
The dashboard provides a quick overview of all consumption values. The different visualisation elements offer a clear and concise presentation of the respective consumption values. In the following example this is illustrated by two electricity meters measuring the consumption of line 1 and line 2. Using the Calculated Values function, the total consumption was determined, which can be displayed additionally:
- Line 1 power consumption
- Line 2 power consumption
- Total consumption (lines 1 + 2)
Analysis
moneo permanently stores the data in the background. This enables detailed analysis of the consumption values at a later stage. Flexible analyses allow users to compare different process data. Peak consumption periods can thus be easily identified. These insights can then be used for optimisation.
Calculated values
The IO-Link adapter transmits the detected pulses to the moneo system. The Calculated Values function converts them into immediately usable process data.
Example 1: calculation of the consumption in kWh based on the counted pulse values
The DP2302 has two counters (main counter and batch counter). The maximum counting range of the main counter is 0 to 99,999,999. If the maximum is exceeded, it is reset to zero and the batch counter is incremented by one. This makes it possible to count values > 99,999,999. The batch counter must be included in the calculation. In this example, 1 pulse corresponds to 1 Wh. So only with the main counter it is possible to count up to 99,999 kWh (= 99,999,999 pulses). With the batch counter, the counting range can be increased by a factor of 9,999 (approx. 999 million kWh = 999 MWh).
Power consumption (kWh) = ((Batch counter * 99,999,999) + Main counter) / 1,000
- Data source main counter
- Data source batch counter
- Constant 99,999,999
- Multiplication of batch counter with maximum value of main counter
- Addition of batch counter + main counter
- Constant for converting Wh to kWh
- Division of the counter value by the constant 1
- Total consumption in kWh
Example 2: adding together multiple counters for the total consumption
- Data source counter line 1
- Data source counter line 2
- Addition of values (line 1 + line 2)
- Total consumption in kWh
