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Automotive
Optimizing Automotive Production: AI-Driven Cooling System Enhancements
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Bavaria, Germany
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The client is a leading automotive manufacturer, known for its high-quality vehicle production. They are a multinational automotive conglomerate with various facilities. The specific site in question is a large-scale automotive plant with extensive central utility infrastructure.
Initial Challenge
The production processes require a precise and a historically grown and complex cooling system. The numerous components involved didn’t always operate in perfect harmony, leading to inefficiencies. Significant untapped energy efficiency potentials existed, which could be harnessed through optimal control of demand, temperature, and humidity fluctuations. Addressing these challenges required a comprehensive assessment, pinpointing inefficiencies, and developing a strategic plan to maximize energy savings and operational efficiency.
The Solution
When the automotive client embarked on their search for an AI-based solution to optimize their operations, etalytics’ software proved to be the perfect fit. The Control Optimization solution of our etaMIND AI Suite can be used to analyze and optimize the operation strategy. Coupled with the Energy Intelligence infrastructure of the etaONE platform and etaEDGE IIoT gateways, data acquisition is realized in real-time and the optimization control loop is closed by updating setpoints in the building control system. The provided scalability and precision precisely met their requirements.
Measured Results
- Creation of the data infrastructure by deploying the etaONE platform, the etaEDGE IIoT gateway and the etaMIND AI suite.
- Analyzing and implementing different optimization patterns
- Use of the most efficient chillers
- Optimal operation of the equipment at partial load
- Optimized recooling of the components
- Continuous hydraulic balancing in the chilled water network
- Identification of faulty measuring points
- Achieving more transparency through virtual measuring points
- Training and deploying energy forecast models to anticipate future energy system states
- Modelling of plant dynamics to achieve full transparency on the operating behavior of the components according to influencing factors
- Calculation of the optimal operating strategy for the components considering both saving targets and wear minimization
- Implementation of dashboards for visualization and monitoring of the system and optimizers
- Ongoing monitoring of optimization results and system operation in etaONE
What's Next
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