Companies are faced with the challenge of improving their energy efficiency and reducing costs. Innovative sensor solutions such as the FTMg from SICK enable precise monitoring and optimization of energy flows, especially in compressed air, and promote sustainable production processes.
The challenge: Energy efficiency in compressed air requires energy monitoring
Energy efficiency and the reduction of energy costs are central challenges for companies striving for transparent processes. This is especially true with the new ISO 50001 standard from 2018. It defines the requirements for an energy management system (EnMS) and requires companies to measure and optimize their energy flows. To do this, they must record all energy consumption data transparently and derive appropriate measures to reduce energy consumption from the results.
This is already common practice in many companies for electricity, water, heating and air conditioning. It is often not monitored and optimized to the same extent as other energy sources. Leaks and inefficient use lead to considerable additional consumption and therefore unnecessarily high costs. Their management is complex, as pressure losses due to mechanical defects or wear and tear often go unnoticed, resulting in energy losses.
One solution is the subsequent integration of intelligent sensors into existing production processes. However, many systems are not designed for such an expansion. In addition, they must be designed in such a way that they not only record data, but can also visualize and interpret it in an understandable way. The introduction of a standard-compliant energy management system requires considerable investment in hardware and software as well as employee training.
The solution: Innovative sensor solutions for energy management
SICK AG, manufacturer of sensor solutions for industry, has developed the FTMg flow sensor specifically for energy management. It enables the precise and continuous measurement of compressed air consumption in real time, so that leaks can be detected and rectified at an early stage.
The FTMg integrates various measured values such as flow rate, pressure and temperature. This eliminates the need for additional sensors, which reduces installation and maintenance costs. The sensor is available in two versions: an Ethernet-based version with an integrated web server for optimized cloud connectivity and an industrial version that communicates via IO-Link as well as switching and analog outputs.
The data is visualized and evaluated via an integrated web server. This enables continuous energy monitoring. Additional monitoring and maintenance functions support companies in optimizing their energy consumption. For example, the energy data can be used to improve start-up and shut-down management, compressor speeds and peak loads.
The FTMg sensor integrates seamlessly into existing systems. Dashboards can be used to react quickly and effectively to unwanted events in order to reduce downtimes and optimize maintenance processes. The sensor also works together with a monitoring application from SICK. It ensures high data quality and a high security standard, which is particularly important when using cloud solutions.
The result: Improved efficiency and sustainability through FTMg
Using the FTMg sensor and the associated monitoring services leads to significant improvements in energy efficiency and cost savings. At one SICK customer, for example, the FTMg monitors the compressed air supply of an automated assembly system, thereby creating transparency regarding consumption and costs. At another customer, the sensor is used to record data on CNC machines, enabling comprehensive monitoring and optimization.
Overall, the introduction of the FTMg sensor in many companies has also improved the sustainability of production processes. The continuous monitoring and optimization of energy consumption enables companies to work more efficiently and protect the environment at the same time. The successful implementation in various industries and the positive feedback from users confirm the added value of this technology for energy-efficient and sustainable production.
