Monitoring load peaks with IO-Link current sensors
As industries embrace digitalization , new and innovative ways to cut costs are emerging , and one key approach is through energy optimization . A crucial aspect of this strategy involves closely monitoring instances of high energy demand . Unexpected spikes in electricity usage can result in significant additional expenses , particularly in energy-intensive production settings . This is where STEGO ’ s ESS 076 Smart Sensor Current steps in . In this article , we will explore how this intelligent current sensor , equipped with an IO-Link interface , provides an effective solution for keeping a close eye on load peaks . Not only does it help in monitoring these peaks , but it also plays a role in enhancing overall energy efficiency .
Avoid unpleasant surprises For manufacturing companies , unexpectedly high electricity bills are among the most unwelcome surprises . December , in particular , can turn into a financial pitfall . Speaking of December : why is this month so crucial when it comes to the total cost of electricity consumption ? The reason is that a high peak load in December can result in a subsequent increase in electricity costs for the entire year , imposed by the grid operator . But what if there was a way to avoid these unpleasant surprises ? Combine the measuring of electricity consumption per machine and employing peak shaving – a you get a smart strategy to prevent peak loads and shield yourself from unwanted additional payments . This article dives into how precise electricity measurement , especially with the ESS 076 Smart Sensor Current from STEGO , holds the key to a stress-free year-end .
Monitor electricity in real time Current sensors like the ESS 076 offer straightforward real-time
74 FDPP - www . fdpp . co . uk monitoring of power consumption in systems and machines . The potential for efficiency gains is significant , especially in energyintensive applications . This becomes evident in our case study with STEGO client , LEGROM . Specializing in plastic injection moulding , LEGROM operates an extensive array of injection moulding machines , known for their high energy demands as they heat and process plastic granules under high pressure . In the past , the immediate or simultaneous activation of injection moulding machines at LEGROM resulted in unexpected additional electricity costs . Retrofitting the machines with a current sensor proved to be a much more cost-effective solution compared to dealing with additional payments . This is crucial , considering that in an industrial setting , these extra electricity costs can quickly escalate into five-digit sums .
Current sensors for retrofitting
From the outset , LEGROM recognized that advancing energy flow monitoring would depend on peak shaving . Kim Waldmann , Managing Director at LEGROM and an industry expert in injection moulding , drew on his experience across various injection moulding companies to understand that
information is the key resource for more efficient processes and risk mitigation .
For LEGROM , the digitization process was carefully planned as a well-thought-out use case . However , the approach needed to be “ minimally invasive .”
An intelligent retrofit application for current measurement became crucial for their operational technology ( OT ). Integrating sensors into the numerous machines in the injection moulding shop floor had to be quick and straightforward to minimize both time and complexity . The goal was to keep machine downtimes to a minimum to avoid disruptions to production capacity and productivity . Waldmann explained , “ The integration of the STEGO current sensors was uncomplicated . We only needed to disconnect the machines from the power supply and route the live cable through the ESS 076 . The sensor can measure up to 100 A AC without direct contact , perfectly fitting our current condition monitoring needs . The sensors ’ practical latching mechanism ensures secure and simple attachment to the power line .”
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