Published: September 25, 2024
The Impact of Smart Sensors on Energy Efficiency in Industry 4.0 Factories
Industry 4.0, also known as the fourth industrial revolution, is a term that describes the transformation of modern industry through the integration of advanced technologies such as the Internet of Things (IoT), artificial intelligence (AI), and automation. One of the key aspects of Industry 4.0 is the drive to increase energy efficiency in factories and production plants. Smart sensors play a key role in achieving this goal by providing the necessary data to optimize energy use.
Smart Sensors – What Are They and How Do They Work?
Smart sensors are devices equipped with a microprocessor that can collect, process, and transmit data in real time, enabling automatic management of production processes. Unlike traditional sensors, smart devices have the ability to analyze and interpret the information they collect, allowing them to make autonomous decisions or provide recommendations to operators. The global sensor market is estimated to reach $300.5 billion by 2029 (compared to $179.7 billion in 2023).
These advanced electronic devices used in industry monitor parameters such as temperature, humidity, pressure, flow, amperage, vibrations and many others. The collected data is then sent to a central system, where it is analyzed and interpreted. IoT technology allows the connection of sensors into integrated networks, providing a comprehensive picture of what is happening in the factory.
Smart sensors not only monitor machine performance, but also contribute to energy savings. By precisely collecting and analyzing data, factories can continuously monitor energy consumption and optimize their operations, which has a direct impact on operating costs and energy efficiency.
There are many examples of smart sensor applications in various industrial sectors. In the automotive industry, they can monitor the energy consumption of welding and painting robots, optimizing their work or signal unnecessary machine activity during production downtime. In the electronics industry, humidity and temperature sensors can ensure optimal conditions in cleanrooms, minimizing energy consumption for air conditioning. The food industry can use sensors to precisely control pasteurization and sterilization processes, reducing heat energy losses, as well as to control refrigeration equipment and adapt their operation to current conditions.
A detailed analysis conducted by EY showed that even with a low level of implementation, industrial companies can benefit from the introduction of smart sensors. It is estimated that among nine industries analyzed, such as automotive, chemical and energy, increasing sensor saturation will increase profit margins (EBITDA) by 11-34% by 2030.
Benefits of Implementing Smart Sensors in Factories in the Context of Energy Efficiency
Smart sensors contribute to improving energy efficiency in Industry 4.0 factories in many ways, including the following:
- Real-time Energy Consumption Monitoring – smart sensors can track the energy consumption of machines and systems in real time. This allows factories to immediately respond to sudden spikes in energy consumption and identify which devices are operating inefficiently. This allows for ongoing adjustments to production parameters, which reduces unnecessary energy consumption.
- Automation of Process Optimization – smart sensors, by collecting data from machines, can automatically adjust their operation to conditions, eliminating excessive energy consumption. For example, when a machine is operating at low efficiency, the system can automatically reduce its power or operating time, reducing energy consumption without operator intervention.
- Failure Anticipation and Predictive Maintenance – sensors can monitor the technical condition of devices, predicting moments when machines are likely to break down and suggesting the optimal time for service. This allows maintenance to be carried out before problems occur, which prevents inefficient operation of devices, which can lead to energy waste.
- Better Energy Management across the Entire Factory – intelligent systems can integrate data from various sensors across the entire factory, creating a complete picture of energy consumption at every stage of production. This approach allows industrial plants to better plan energy consumption, optimize machine operation, and implement procedures that minimize losses.
- Reduction of CO2 Emissions – thanks to improved energy efficiency, companies can significantly reduce their energy consumption, which directly results in reduced greenhouse gas emissions. As a result, companies can implement more sustainable development strategies, which is beneficial both for the environment and their image.
However, these are not the only reasons why the use of intelligent sensors contributes to improving energy efficiency in Industry 4.0 factories. Because they provide huge amounts of data, they can be successfully used to conduct detailed energy audits. By analyzing the information collected by sensors, it is easy to identify areas where the greatest energy savings can be achieved.
Based on historical data and current measurements, sensors can create precise models that predict future energy demand. These forecasts can help plan production processes better, avoid peaks in energy consumption, and take advantage of cheaper tariffs. Factories equipped with smart sensors can also actively participate in energy management in the grid, for example by storing energy during periods of low demand and feeding it back into the grid during peak periods.
Pragmile: Optimizing Energy Efficiency with Infrared Sensors and Thermal Imaging
For a client from the commercial real estate sector, Pragmile has developed a thermal image recognition tool aimed at optimizing space utilization and energy efficiency in smart buildings. Precise forecasting using an AI-based platform that analyzes data from infrared sensors in real time has significantly improved energy management processes in buildings. This type of solution will also be successfully used in industrial plants.
Infrared sensors can significantly impact energy efficiency in Industry 4.0 factories, especially in the context of detecting the presence of employees. One way is to use them to automatically control lighting in rooms. By detecting the presence of people, the lights can be turned off in rooms where no one is.
They can also monitor the presence of employees in different zones of the factory and adjust the operation of heating, ventilation and air conditioning systems to current needs. When a room is empty, these systems can be automatically turned off or adjusted. Infrared sensors can also analyze the patterns of presence of people in different parts of the industrial plant. This data can be used to optimize the spatial layout, as well as manage resources and processes.
Each of the above-mentioned applications of infrared sensors leads to a significant reduction in energy consumption, which results in increased energy efficiency and, consequently, lower operating costs.
Investment in the Implementation of Smart Sensors in Industry 4.0
The use of smart sensors in Industry 4.0 factories is an investment that brings many benefits in terms of energy efficiency. They can not only reduce energy-related operating costs, which has a direct impact on the company’s profitability, but also improve the reliability of energy systems and increase production efficiency. The long-term benefits resulting from their implementation make them a key tool in the development of a modern and sustainable industry.
Smart sensors have huge potential for further development. New technologies such as artificial intelligence and machine learning (ML) can further optimize their operation, enabling more precise prediction and automation of processes.
As energy costs rise and pressure increases to reduce greenhouse gas emissions, companies will have to focus increasingly on energy efficiency, which makes smart sensors an indispensable element of every modern production plant. Solutions for energy management in factories are already available on the market, such as the Energy Cloud Factory™ from Mitsubishi Heavy Industries, which combines the capabilities of IoT, AI and advanced analytics.
Businesses that don’t want to fall behind their competitors should adapt to the changing technological environment as soon as possible and use data generated by smart sensors to make better business decisions.
If you would like to discuss the possibilities of cutting-edge energy efficiency solutions tailored to your company’s needs, schedule a no-obligation, free consultation with Marcin Jabłonowski – Managing Director and AI Solutions Architect at Pragmile.
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