SPEAR

Project results

Instead of using estimated or simplified models for simulation-based optimisation, the SPEAR solution makes use of real device-provided simulation models in order to produce highly accurate forecasts for the energy consumption of industrial production processes. The accuracy of these forecasts, together with the optimisation algorithms developed, enables a significant reduction of energy consumption and costs.

SPEAR created a flexible and highly generic optimisation platform and did not focus on isolated industry sectors; a broad spectrum of application domains was supported, like production processes in common plants, production lines, buildings, hybrid drives, and wind turbine drive trains. The energy-specific optimisation of new and existing production plants during virtual commissioning and running production was also supported.

Exploitation

By helping companies to optimise their energy usage, SPEAR enables them to manage resources more effectively and increase their productivity in a sustainable manner.

Specifically, with the results of SPEAR and the experience gained in the field of virtual commissioning, Reeb- Engineering is able to already predict the energy consumption of an Automated Guided Vehicle (AGV) during the development process of the vehicle. This prediction allows the optimisation of the battery size, the driving path, the charging time and ultimately the manufacturing and operating costs.

KANCA, one the leading forging companies in Türkiye, has seen a decrease of 4 kWh/kg (8%) thanks to the project results and Atkas, a pioneer in the sector of air suspension system production, has improved its energy optimisation by 5%.

Swedish project partner and service provider ÅF has improved its service by being able to consider energy in the virtual commissioning of plants. And Algoryx has updated its AGX Dynamics simulation tool with a new module that can compute energy consumption. This has been used in several research projects that use AI together with the simulation software to create smart control and path planning, for which energy optimisation has been one theobjectives. The customers include users and manufacturers of different heavy machinery in areas like mining, forestry and construction - industries that have a lot of potential when it comes to reducing energy needs and lowering emissions.

Sensing & Control Systems (S&C), a Spanish SME, has integrated the SPEAR results into its proprietary commercial platform, enControl™, extending it from smart homes to the industrial sector and incorporating novel functionalities and services created during project development for the management of ovens and other intensive energy-consuming machineries in related businesses.

In addition to energy optimisation and business impact, several new employees and nine PhD students have been taken on across the consortium as a direct result of the SPEAR project.

SPEAR will allow companies of all sizes to reap such benefits by making its results available as free software prototypes. Further dissemination is taking place through the formation of two standards. This should allow for a greater uptake of renewable energies and give SPEAR a vital role in reducing CO₂ emissions and slowing the speed of climate change throughout society as a whole.