SO LUTION PAPER

SM ART ENERGY FOR

INDUSTRY & BUILDINGS
The innovative link between machine and energy data.

INITIAL SITUATION
In times of skyrocketing energy prices, scarce
resources and the quest for climate-friendly
industrial solutions, the topic of energy opti-
mization is on everyone‘s lips. Companies are
doing everything they can to systematically
increase energy efficiency in production and
reduce energy consumption – and therefore
costs – in the long term.
Most, however, disregard that traditional ener-
gy management quickly reaches its limits when
it comes to this task. A real breakthrough can
only be achieved by bringing together two
dimensions that were previously considered
individually: The linking of IoT data, which
typically involves the condition of machines
and systems, energy data on the energy pro-
curement and consumption of a production
facility. That‘s precisely what Device Insight‘s
Smart Energy Solutions enable.

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Smart Energy for industry & buildings
GOALS
With our new solution approach, we have set
ourselves ambitious goals. First and foremost,
we want to help companies with energy-flexib-
le production to manage their energy holisti-
cally and proactively. Self-generated electricity
is to be used sensibly, battery storage utilized
optimally, and the overall control of infras-
tructure and buildings improved.
If you do not purchase a fixed electricity quota
and are not locked in by a fixed price, you can
save a lot of money. Currently, energy prices
can fluctuate by up to 100% in a single day.
Electricity should therefore be purchased at
the most favorable time and used to replenish
stored electricity – ideally in an automated
manner. In the future, entire production plan-
ning processes will be flexibly adapted to time
windows in which energy is cheaper.
The first step is to identify where potential
for optimization lies. When and where is un-
necessary consumption (e.g. standby mode)
taking place? How can the expected solar day
be optimally used over the next 48 hours? How
can supply gaps be filled in a cost and emis-
sion-optimized manner? We address all these
issues with our Smart Energy Solutions –
relying thereby on intelligent planning
algorithms.
SOLUTION
Device Insight‘s Smart Energy Solutions are
cloud-based energy optimization systems.
The underlying IoT solution can either be de-
ployed ready-to-use or integrated into a com-
pany‘s energy capture and control systems via
standardized interfaces. The solution‘s intuiti-
ve and configurable user interface is based on
the IoT framework CENTERSIGHT, which com-
bines Device Insight‘s own IoT building blocks
with services provided by Microsoft Azure.
Companies can independently integrate ma-
chine and energy data via open interfaces. Of
course, if you wish, we at Device Insight can do
this for you. For an initial pilot, implementation
takes on average only 2 weeks, an extended
proof of value 4 to 8 weeks. But what is so spe-
cial about it?
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Smart Energy for industry & buildings
MODE OF ACTION
The actual smart core of Smart Energy consists
of optimizer algorithms that enrich the solu-
tion. Device Insight relies on a combination of
established machine learning algorithms for
predictions and classic optimizer algorithms
for planning such as Mixed Integer Linear
Programming (MILP for short). The prerequi-
site for applying these algorithms is to repro-
Ready UI framework example: Showing
power supply, PV generation, battery
in state of charge and consumption by
HVAC system of a production.
Ampel kleiner
duce the energy generation and consumption
values and interdependencies in a mathema-
tical model. This includes the physical condi-
tions and constraints of an operation. Models
are already available for various components,
such as solar power generation and battery
storage that only need to be configured.
THE IMPLEMENTATION
OF A PILOT
TAKES 2- 8 WEEKS
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Smart Energy for industry & buildings

Data Management & Monitoring

1
Logging of energy consumption (machines & buildings) and energy generation
data. Dashboard visualization with an intuitive configurable UI.

Asset & Context Modeling

2
Description of characteristics and expected asset behavior in terms
of energy generation (energy sources & storage, e.g. solar yield based
on weather data) vs. energy consumption (by machines & buildings).

Configuration of degrees of freedom and constraints

3
Definition of output parameters and targets per desired interval
(e.g. temperature on weekdays at production start 06:00). Use of
historical empirical values.

Optimizer algorithms

4 Based on the model, configuration and predictions, optimizer algorithms

generate recommendations for the best possible utilization of degrees of
freedom within the energy management system.

How it works:

Internal data sources, i.e. IoT data on perfor-
mance, condition, consumption of machine-
ry and equipment, as well as energy data (ge-
neration, storage), are merged with external
weather and electricity price forecasts. The
relationship between expected energy produc-
tion and energy consumption is then modeled
mathematically. In addition, certain margins,
i.e. degrees of freedom, are defined for energy
management, taking into account production-
specific conditions. Based on this information,
the optimizer algorithms run as a cloud work-
load. Now for the magic part: The algorithms
evaluate the data and correlations, deriving
recommendations to enable better planning
and rapid countermeasures for flexible, con-
sumption and CO2-relevant parameters in pro-
duction and buildings. The result ranges from
the optimized use of a single battery storage
unit to the overall more efficient and profitable
energy management of a plant.

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Smart Energy for industry & buildings
// Solution architecture
Smart Energy Solutions are multi-layered:
The customer‘s system (marked orange in
the graphic) provides machine and energy
data. In the IoT framework CENTERSIGHT sca-
le (lower level), machine and energy data are
stored as time series data, for example, to di-
rectly analyze the status or performance in
terms of energy consumption. In self-service
modeling, the relationship of the components
to each other is described and modeled mat-
hematically. In the asset model, production-
Weather Prices
Forecast Prediction Results
OPTIMIZER
CURRENT STATE, HISTORY
CENTERSIGHT scale
specific conditions are used to define margins
(degrees of freedom). Weather and electricity
price forecasts, for example, are used as exter-
nal data sources in the calculation. Machine,
energy and forecast data are then merged with
the model assumptions and evaluated using
the optimizer algorithms to produce recom-
mendations and predictions. The results can
be implemented manually or transferred di-
rectly to the control and monitoring systems.
CUSTOMER
CONTROL SYSTEMS
DATA
Self-service Modeling
Data Ingress
ASSET MODEL
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Smart Energy for industry & buildings

PRACTICAL EXAMPLE:
GERMAN AUTOMOTIVE COMPANY

Challenge

A leading German car manufacturer has set itself the goal of producing its
vehicles with 40% lower energy consumption by 2030. A model site is used
to pilot how a smart energy solution can be used to implement intelligent
energy supply and control. This involves exploring the possibilities for peak
shifting and memory control.

Solution

The Energy Optimizer Solution developed by Device Insight implements IoT-

based collection and analysis of energy and machine data, combined with we-
ather and electricity price forecasts. This results in predictions and recom-
mendations for smart energy management by the automaker. The energy
flow control is visualized clearly and compactly. Peak loads can be minimized,
and the feed-in and use of a photovoltaic system and battery storage can be
significantly improved. Flexible consumption, such as charging stations for
electric vehicles, can also be considered by the algorithm, and used optimally.
All in all, this enables a noticeable reduction in consumption and costs as
well as forward-looking energy strategy planning for the future.

The automotive
industry is a pioneer:
Smart energy manage-
ment is on its way
here – and serves as a
benchmark for other
industries.

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Smart Energy for industry & buildings

ADVANTAGES AND APPLICATION

• Reduce energy costs, improve CO2 balance

Energy consumption is reduced. This also reduces electricity and energy costs,
as well as CO2 emissions.

• Making energy consumption transparent

All energy consumption of production (machine data) and buildings (heating-
cooling-ventilation) recorded centrally and clearly displayed.

• Profit from analyses & forecasts

Asset-specific correlations are evaluated together with electricity price, weather,
and power generation data and to provide recommendations and forecasts.

• Increase energy efficiency

The planning and control of a production facility‘s infrastructure is optimized
holistically – for example, to avoid peak loads.

• Conserve resources
Energy storage systems are utilized optimally and with foresight. Generating your
own electricity becomes more efficient and profitable.

• Create sustainability
The goal of climate-friendly and intelligent production will indeed become a
reality in the medium to long term. Product characteristics are changing towards
"CO2-neutral products".

READY TO START
YOUR SM ART
ENERGY PROJECT?

Let us carry out an Energy Optimizer

"Quick Check" for your application.

Learn more now

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ABOUT DEVICE INSIGHT
Founded in 2003 in Munich, Device Insight GmbH is an IoT specialist, accompanying companies
in their digitization in the fields of Internet of Things, Industry 4.0 and artificial intelligence.
Based on a flexible IoT framework, Device Insight combines ready-to-use IoT building blocks
and individual applications for customized IoT services. System integration based on common
cloud providers and software development are combined to create tailored solutions that are
both fast and scalable. Device Insight supports global networking of machines, vehicles, plants
and devices and provides applications in the fields of data acquisition, condition monitoring,
predictive maintenance, machine learning, industrial analytics, AIoT (Artificial Intelligence of
Things) and Smart Energy. Device Insight is active in more than 15 countries, working together
with large enterprises and mid-size customers from various sectors, including machinery and
plant engineering, HVAC, commercial vehicles, vending, transport, energy as well as the Connected
Home environment. Services range from business case analysis and implementation to secure
IT operations. The company has been awarded “Internet of Things (I4.0 Leader Germany” on
numerous occasions by the ISG Provider Lens study. Since 2019, Device Insight has been a
subsidiary of automation specialist KUKA AG.

www.device-insight.com