Look at consumers separately
Main and secondary electrical consumers are recorded via suitable measuring points.
Energy consumption needs
a reference to production.
Measured values become meaningful when they can be assigned to plants, periods and quantities produced.
The main meter shows rising consumption, but not which line or batch is responsible for it. Individual measuring points deliver values at different intervals; downtime and productive running time are hard to separate. A reliable analysis therefore starts with a measurement plan and a consistent assignment. Only then can changes be compared and possible measures be justified on technical grounds.
Start now at no cost
In a free first conversation we clarify which meters exist, which plants carry the largest share and which reporting duty applies to you.
Scope of services
Assign energy to production
Time references connect continuous measured values with production batches.
Compare trends
Individual and aggregated meter views support the search for conspicuous changes.
Looking at energy and production together
IQstruct Engineering connects energy meters and large consumers such as compressed air generation.
The measured values are linked with production information and provided for the agreed analysis. The assignment can concern the site, line, machine, process, product or order and depends on the metering concept and the available data.
Compressed air generators and other secondary electrical consumers influence the energy use of a production. Measuring points and the production reference are therefore planned together. This creates a basis for historical comparisons; whether a change has a technical or an organisational cause is then assessed in the context of the process.
Batch reference
The energy use of a batch becomes visible
Time references connect continuous measured values with the quantity produced.
Approach in the project
Ai1
Create the metering concept
A metering point plan organises electrical consumers and production areas.
Ai2
Connect the meters
Energy meters are connected to the edge PC, for example via RS-485 and suitable converters.
Ai3
Configure Aurora
Adapters and data flow are set up in Aurora without programming.
Ai4
Check incoming energy data
Current values, timestamps and trends arrive in the dashboard and are checked.
Which energy is recorded
Electricity
Transformer stations and main and secondary consumers are recorded via measuring points.
Compressed air and secondary media
The energy for compressed air generation and other media is included in the analysis.
Own generation
The photovoltaic system and the combined heat and power plant can be included in the balance.
Measured values and our own middleware
Energy and media meters are connected via common industrial interfaces.
Which meters and protocols fit is clarified during the survey.
Project experience
Energy data monitoring at a brick works
Looking at energy and production together at a backing brick works.
IQstruct Engineering has delivered energy data monitoring for a backing brick works. The solution brings together values from transformer stations, the photovoltaic system and the combined heat and power plant with production data. Consumption can therefore be viewed in relation to the batches produced. Meter trends are available individually, aggregated and historically. The example shows why a single meter reading does not yet provide a reliable statement about the energy demand of a production step.
Frequently asked questions
We are glad to answer your detailed questions in a personal conversation.
Is a batch assignment a measurement per individual item?
The batch-related assignment shows the energy use of a produced quantity. It does not involve a measurement per individual item.
Do you name specific savings?
We only quantify savings on the basis of reliable measured values from your plant.
At which level can consumption be assigned?
By site, line, machine, process, product or order, depending on the metering concept and the available data.
Further industry solutions
Every industry has its particularities. That calls for a reliable partner who knows the requirements and delivers suitable solutions.
- Process engineeringA plant runs continuously, and its energy consumption decides the cost per tonne.
- Battery production and e-mobilityNew lines go into operation in quick succession, and their material flow changes with every product change.
- Food and beverageEvery batch needs its traceability, and cleaning interrupts production at a fixed rhythm.
First conversation
Arrange a free first conversation
Describe your task. We agree a date and discuss the possible project scope.
Ai1
You request an appointment
Ai2
We discuss your requirements
Ai3
You receive a quotation for the agreed scope
Tobias KuckBusiness Development ManagerTakes up new projects, coordinates offers and accompanies the cooperation from the first enquiry.
Free first conversation
Describe your task in the contact form. We come back with a proposed date.
Arrange a first conversationBooking calendar
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Not quite what you need?
Discover further suitable services.
Industrial data acquisition
Acquire production and energy data from PLCs, meters and existing devices.
Analytics and visualisation
Make trends, relationships and deviations in production data visible.
AI data analysis and forecasting
Use pattern recognition and forecasts to examine production and energy data in a targeted way.