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 its foundation in 2003. inTec automation GmbH was founded in 1997 and has expert knowledge in the field of industrial automation and control engineering. The programming of programmable logic controllers, IPCs and databases is one of the core competencies of the SME, as is process and plant visualization. The Institute for Computer Architecture and System Programming at the University of Kassel has long been researching prototyping as well as the verification of various (programmable) electronic systems in a wide range of applications. These include, for example, the Internet of Things (IoT), safety-oriented System-on-Chips (SoC), automotive electronics, autonomous driving 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 manufacturing. An up-to-date 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 approximately 1 percent of the measures required to initiate the energy turnaround. The current bitkom study "Climate effects of digitalization" sees a total_{CO2e savings potential of}61 MT by 2030 in industrial manufacturing if digitalization is accelerated. The significant energy savings will be made possible by intelligent sensor technology and control based on AI in the area of compressed air supply. Key starting points for this are heat extraction from the compressors, process optimization in compressor control and cycling, innovative leakage management, and finally preventive maintenance of the compressors. The focus of the project is therefore the "digitized volume flow measurement of compressed air" directly behind the compressor. Measuring this value on site has the advantage that real operating conditions can be taken into account. Immediately occurring malfunctions are detected, further plant components can be included and, as a consequence, the efficiency of the compressors can be increased.

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

15.12.2020 - 14.01.2023 / 462,971.00 EURO