SCIENTIA

The project consortium consists of the SMEs Postberg + Co GmbH, Kassel and inTec automation GmbH, Baunatal as well as the Department of Computer Architecture and System Programming - Institute for Computer Architecture and System Programming (ICAS) at the University of Kassel.

Postberg + Co GmbH has expert knowledge in the field of compressed air and has developed and patented a large number of sensors and fittings since it was founded in 2003. inTec automation GmbH was founded in 1997 and has expert knowledge in the field of industrial automation and control technology. The programming of programmable logic controllers, IPCs and databases is one of the core competencies of the SME, as is process and system visualization. The Institute for Computer Architecture and System Programming at the University of Kassel has long been researching prototyping and the verification of various (programmable) electronic systems in a wide range of applications. These include, for example, the Internet of Things (IoT), safety-related system-on-chips (SoC), automotive electronics, autonomous vehicles, railroad technology, industrial automation, logistics, robotics and medical devices.

The use of compressed air plays a major role in numerous areas of daily life, especially in industrial production. A modern and efficient compressed air supply makes a significant contribution to achieving the current climate targets. The efficiency potential for optimization in Germany alone is 8 terawatt hours (TWh) per year or 5 megatons (MT)_{of CO2e}. This corresponds to around 1 percent of the measures required to initiate the energy transition. The current bitkom study "Climate effects of digitalization" sees a total_{CO2e savings potential}of 61 MT in industrial manufacturing by 2030 if digitalization is accelerated. The significant energy savings will be made possible by intelligent sensor technology and AI-based control in the area of compressed air supply. The main starting points for this are heat extraction from the compressors, process optimization in compressor control and clocking, innovative leakage management and, finally, preventive maintenance of the compressors. The project therefore focuses on "digitalized compressed air volume flow measurement" directly downstream of the compressor. The advantage of measuring this value on site is that the real operating conditions can be taken into account. Immediately occurring faults are detected, other system components can be included and, as a result, the efficiency of the compressors can be increased.

According to the VDMA, around 62,000 compressors are operated in Germany every year, each with an average operating time of 3,500 BH p.a. The efficiency potential of these compressors is diverse but has not yet been exploited. Preventive and condition-based maintenance based on the reliable energy efficiency parameter of the individual compressor is not yet possible. This results in the need for a volume flow measurement directly downstream of the compressor in order to check the performance data of the compressors and ensure their energy efficiency for continuous operation. The efficiency of the individual compressor will serve as a third and new control variable for higher-level and AI-based compressor control systems in order to achieve the maximum possible system efficiency.

15.12.2020 - 14.01.2023 / 462,971.00 EURO