Saving energy Energie sparen withPROFIenergy PROFIenergy mit

PROFINET
Answers for industry.

Protect the environment and reduce costs: Energy efficiency in production

No company can afford to ignore todays major issue of energy efficiency. Legislation, public opinion, and increasing cost pressure will ensure that more efficient use of energy remains high on the agenda for industry.

Load prole (kWh, 15 min intervals)

Weekend
12 10 8 6 4 2 0

Weekend

Energy consumption during standby periods today: approx. 60 percent of the energy consumed during production

Up to 80 percent energy savings with PROFIenergy

Energy savings potential with PROFIenergy

Legal frameworks such as the Kyoto Protocol, EU regulations, trading with emission certificates, and the Renewable Energy Sources Act are contributing factors, but more than anything the rising cost of energy is forcing plant and machine operators to act. They need to significantly reduce their energy costs not just for electricity but also, for example, for heating/cooling and compressed air. In addition, of course, they must comply with environmental protection regulations. Rethinking for greater efficiency The new attitude in industry is also taking the form of voluntary commitments by companies. Automation offers the potential for more energy-efficient production in this regard. The German Electrical and Electronic Manufacturers Association, for example, estimates that the use of modern automation in indus-

trial plants in Germany could save up to 25 percent of the energy currently used. As one of the leading technology companies in the field of automation technology, Siemens has already developed a large number of solutions for transparent visualization of energy consumption and for improving energy efficiency in production. Utilizing production standby periods Today, although specific measures are being taken to reduce energy consumption in production operations, no attention has been focused on breaks, even though this is an area with enormous potential. In order to harness this additional potential, the Automation Initiative of German Automobile Manufacturers called on the

PROFIBUS & PROFINET International at the end of 2008 to define a manufacturerindependent profile with which energy consumption in production can be easily reduced during standby periods. Work began at the beginning of 2009 with the participation of 13 companies from the automation industry, including Siemens, which was in at the start. Redefining energy efficiency with PROFIenergy The PROFIenergy profile is based on the Industrial Ethernet standard PROFINET and was officially released at the beginning of 2010. At Hannover Fair 2010, Siemens was one of the first manufacturers to present products with PROFIenergy functionality. Siemens is now working with well-known industrial companies to implement the new technology in routine industrial applications.

Environmentally friendly mobility right from the start

Our cars will set new standards also in terms of climate protection. In its production processes, Daimler AG is rigorously implementing a philosophy of significantly reducing both energy consumption per produced unit and the resulting carbon dioxide emissions. PROFIenergy plays a part in achieving this goal.

The next series we will install will feature PROFIenergy components.

[Jrgen Kbler | He promotes the implementation of energy-saving measures with PROFIenergy at Daimler.]

Identifying potential Especially in view of rising energy costs, the issue of energy efficiency in production is no longer just a matter of environmental protection but is becoming a basic question of competitiveness. In the future, companies will simply no longer be able to afford to waste energy. As one of the most innovative companies in the automotive industry, Daimler AG has already been working for some time on optimizing and minimizing its power consumption. Some time ago, Daimler AG carried out tests in the body shop to investigate the potential savings that could be achieved during production breaks. The expected results were confirmed: energy consumption in breaks remains at a high level. The reason for this is that until recently, expensive additional investments were required in the equipment in order to ensure that it could be switched off.

Developing answers The idea behind PROFIenergy then emerged as the solution to this problem. We were not willing to accept this situation, said Jrgen Kbler, manager of controls technology at Daimler in Sindelfingen, Germany. So we thought, What can we do to integrate the standby functionality into the automation technology? Together with other car manufacturers, Daimler initiated a white paper within the framework of the fieldbus organization PROFIBUS & PROFINET International (PI) defining the key points of a suitable energy-saving profile for production automation. An important aspect was that the profile should be simple and open to enable the implementation of both cost-effective and manufacturerneutral solutions. The result was the PROFIenergy profile for PROFINET, which was published by the PI at the beginning of 2010.

Implementing solutions By now, Siemens, as one of the first manufacturers, has presented products that support PROFIenergy. This is a huge step toward deploying PROFIenergy in plants also at Daimler. The next series we will install will feature PROFIenergy components. As our controller supplier, Siemens will play a central role in these projects. Since the PLC (programmable logic controller) is the PROFIenergy controller as well, the PLC will ultimately form the core of the entire system. We will introduce the first components in the field and then gradually expand the range, states Kbler. His declared goal is that every automation component will have PROFIenergy inside in the future.

Benefits for equipment manufacturers 1 Implements energy-management concepts with minimal effort for long downtimes (weekend) and for the first time also for short standby periods 1 Machine concepts easy to adapt 1 Easy to integrate in established product families 1 Uses existing mechanisms and familiar PROFINET services

Benefits for plant operators 1 Lower energy and production costs with no production loss 1 Compliance with company/internal, operational, and statutory environmental regulations 1 Effective investment protection: existing equipment can be retrofitted

Energy saving during standby periods: PROFIenergy

With PROFIenergy, mechanical engineers can easily design systems that save energy. Plant operators benefit from reduced energy costs and an improved environmental impact assessment.
PROFIenergy is a PROFINET-based data interface that allows individual devices or entire subsections of a plant to be switched off automatically in a highly selective manner and without the aid of external hardware. The power-down process is coordinated on a vendor-independent basis and is controlled centrally. Other automation components can continue to operate during breaks, so safetyrelevant sections of the plant remain in operation.

Conveyor
Switch-off time = 1 min Switch-on time = 1 min Minimum dwell time = 2 min Resulting minimum break time = 4 min

Robot
Switch-off time = 3 min Switch-on time = 5 min Minimum dwell time = 2 min Resulting minimum break time = 10 min

Controller
Knows the device switching behavior Coordinate switch-off and switch-on sequence

Easy savings coordinated and centrally controlled With PROFIenergy, switch-off and switch-on times and minimum dwell times can easily be incorporated. This permits the definition of a minimum pause time required for switching off various devices. A robot cell application example is as follows: 1 The conveyor must have a two-minute lag and a two-minute lead time in relation to the robot. 1 An appropriate switch-off and switch-on sequence can be defined for the individual systems, as can a minimum pause time for the entire unit. 1 Switch off of the entire cell is then performed centrally and automatically by the controller.

Conditions:

Conveyor must be switched off 2 min after the robot and switched on 2 min before the robot. Start of break: 12:00 End of break: 12:45

S_P

Conveyor
ON 2 min slowing down 2 min running in

E_P

OFF S_P ON +5 +6 +42 +43

Robot

E_P

OFF 12:00 +3 +40 12:45

With PROFIenergy, all functions necessary to switch equipment off during downtimes are incorporated directly in the control components and can be addressed by a master controller via a standard protocol. The special feature of PROFIenergy is that the profile is universal. Simple mechanisms All the basic functions required for controlling the devices are defined in PROFIenergy, including protocol processing, transport mechanisms, the control interface, and status functions, thereby ensuring that PROFIenergy offers maximum openness and fits into virtually any automation environment. PROFIenergy also enables lowcost and detailed recording of measured values directly at the device. This provides a simple means of acquiring energy consumption data for components or units. These data can be used for power consumption optimization measures.

Simple implementation Siemens provides the user with function modules for PROFIenergy and implements the appropriate commands and status functions in the devices. Plant and mechanical engineers and the plant operators continue to coordinate the switch-off and switch-on sequences and the activation signals for the process as before. PROFIenergy projects can be implemented, for example, by setting up a system of break types short breaks, long breaks, and unplanned breaks. Information about which components should be switched off during which break types is stored in the controller.

The energy-saving stars: Products for PROFIenergy

At Hannover Fair 2010, Siemens presented the first products with which PROFIenergy can be readily implemented seamlessly integrated into Totally Integrated Automation, of course.

Energy-efficient production with PROFIenergy and SIMATIC ET 200S The PROFIenergy-compatible PM-E RO power module for the SIMATIC ET 200S High Feature and corresponding function modules allow easy implementation of energy-efficient solutions by means of PROFIenergy. The SIMATIC ET 200S PM-E RO power module is especially well suited for switching off individual devices separately. It switches off individual inputs and outputs selectively and disconnects loads from the power supply.

PROFIenergy with SIMATIC S7 controllers and I-Device The PROFIenergy functionality can be easily incorporated and processed in STEP 7 programs via reloadable function modules. The PROFIenergy protocol is supported by the SIMATIC S7 controllers. In connection with the PROFINET I-Device function that is available for the SIMATIC S7-300 CPUs 315-2 PN/DP, 317-2 PN/DP, and 319-3 PN/DP, it is also possible to set entire system sections to energy-saving mode. Moreover, system sections can be networked in this way and energy-saving functions coordinated across the board.

Controllers (e.g., the CPU 300 product family) can communicate as smart devices with higher-order or central controls by means of I-Device and can receive energy-management tasks via PROFINET command from the higherorder control. In a typical automation solution with several networked con-

trols, PROFINET not only can communicate via I-Device to lower-level devices in its capacity as I/O controller, but can act as an I/O device for I/O communication with other higher-level or central controls. This communication takes place simultaneously on the same bus.

SIMATIC ET 200S High Feature with PM-E RO power module

SIMATIC S7-300 controller

PROFIenergy frequently asked questions

Question Which products support PROFIenergy, and when will they be available?

Answer Siemens will equip its products with PROFIenergy in stages. The company already presented its first products at Hannover Fair 2010: the PM-E RO power module for the SIMATIC ET 200S High Feature and reloadable function modules for STEP 7. The SIMATIC S7-300 315-2 PN/DP, 317-2 PN/DP, and 319-3 PN/DP CPUs also support the PROFIenergy protocol. Your Siemens sales partner will provide you with the very latest information about all the products that support PROFIenergy.

Why should I use Siemens products with PROFIenergy?

Siemens integrates the PROFIenergy functionality into Totally Integrated Automation. Functional modules conceal the processing of the PROFIenergy protocol and enable straightforward programming and incorporation into the user program. In this way the user can easily take advantage of energy-saving functions within the standard platform with robust, proven, and efficient systems.

In what applications and industrial sectors can I use PROFIenergy?

PROFIenergy provides a means of reducing energy consumption during standby periods. As such, PROFIenergy is suitable for all industries with nonproductive times. This is the case, for example, in shift operation in the automotive industry or in demand-controlled conveyor systems in the logistics sector. PROFIenergy also forms the basis for effective load management aimed at countering imminent load peaks with selective disconnection of particular loads.

Is PROFIenergy complicated to install?

PROFIenergy is an easily installed data interface that uses the existing services and mechanisms of the PROFINET international communications standard. This allows the master module of the ET 200S to be upgraded by means of a simple firmware update for PROFIenergy. PROFIenergy can be easily reloaded into the application program via functional modules. This application example shows how simple PROFIenergy is to install: http://support.automation.siemens.com/WW/view/en/41986454

10

Question Can I retrofit PROFIenergy?

Answer PROFIenergy can be readily integrated into existing machines and systems via PROFINET. For example, the power module of the ET200S 3-PN HF simply needs to be exchanged for a PROFIenergy-compatible power module, while the corresponding firmware for the ET200S 3-PN HF is installed. Then all that is needed is to load the function modules into the SIMATIC CPU.

How much energy can I save with PROFIenergy?

The exact potential depends to a great degree on the specific application. However, measurements can demonstrate that there is considerable potential. Through the coordinated shutdown of devices that are not needed, it is possible to reduce energy requirements in long downtimes by up to 80 percent. Even in short standby periods, savings of up to 40 percent are possible.

What does PROFIenergy offer me as an end user?

You can realize unutilized energy savings potential, reduce your production costs, gain a competitive advantage, comply with statutory regulations and operational environmental agreements, protect your investments, and save natural resources.

Im a mechanical engineer. What do I gain from PROFIenergy?

You can easily integrate PROFIenergy into common product families, use existing PROFINET mechanisms, expand existing programs easily, and deliver machines enabling environmentally responsible and cost-effective production.

11

More information
Questions? Then please send us an e-mail: profinet-info.aud@siemens.com PROFIBUS International www.profibus.com/technology/ energy-efficiency More about PROFIenergy in the Internet at: www.siemens.com/profinet

Siemens AG Industry Sector Drive Technologies and Industry Automation Postfach 48 48 90026 NUREMBERG GERMANY www.siemens.com/profinet

Subject to change 08/10 Siemens AG 2010

The information provided in this e-brochure contains merely general descriptions or characteristics of performance that in actual case of use do not always apply as described or that may change as a result of further development of the products. An obligation to provide the respective characteristics shall exist only if expressly agreed to in the terms of contract.