Flexible production for less energy independence

Many manufacturing companies are now investing in their own renewable energy. Solar panels, wind power and batteries help to reduce energy costs and reduce dependence on the electricity grid. Yet one question remains central: how can you make the most of that energy when supply fluctuates?

We have developed a proof of concept in which a production process can run entirely on self-generated energy. By intelligently adjusting the production speed to the available energy, companies can make maximum use of their own energy and significantly reduce their dependence on the electricity grid.

From challenge to opportunity 

The availability of renewable energy is variable. Solar panels only generate power in sunlight, wind energy depends on weather conditions, and batteries have limited storage capacity.

Production processes today are still designed for a stable energy supply. Machines run at a fixed speed, regardless of how much energy is available at that moment. Yet there is flexibility in many manufacturing processes. When machines can adjust their speed, a significant opportunity arises: aligning production with the energy available at that moment.

Two algorithms for energy-driven production 

Two complementary algorithms make it possible to utilise the available energy as efficiently as possible.

Production aligned with available energy

We have integrated a real-time energy balancing algorithm that adjusts the production speed to the availability of energy from, for example, solar panels, wind or a battery.

When there is plenty of renewable energy available, production can run faster. When supply is lower, the system automatically reduces the speed. This keeps production in balance with the available energy and ensures maximum use of the organisation’s own energy.

Adaptive and efficient

A variable production speed also means that the energy efficiency of machines becomes important. After all, not every motion profile is equally efficient. That is why we also use a motion profile optimisation algorithm (OptiM) to determine the optimal motion profile at different speeds. This algorithm minimises energy consumption and takes into account conditions specific to the production process, such as synchronous movement with multiple actuators.

In our simulations, we saw that this can lead to a reduction in energy consumption of up to 33%.

Complete independence from the grid 

Combining both algorithms results in a production process that:

• adjusts the production speed to the available renewable energy
• whilst producing using the most efficient motion profile

The result is a production process that utilises the available energy as efficiently as possible: 

Simulation using realistic industrial data: We carried out a simulation study based on a cold forming machinery process. We used historical data on solar and wind energy in combination with a realistic industrial investment in these renewable energy sources.

In your production environment 

Would you like to know what this could mean for your production environment? This research forms part of a broader European research initiative in which we are developing strategies to integrate flexible energy consumption into production planning.

Our aim is to help companies make better use of the flexibility potential of their production processes.

Contact us and discover how we can work together to explore the possiblities for your production.