
Integrated power and energy measurement technology
Product portfolio for energy management in accordance with ISO 50001
Oficina central México
Beckhoff Automation, S.A. de C.V.
Product portfolio for energy management in accordance with ISO 50001
Beckhoff offers an integrated solution for real-time energy monitoring that records electrical parameters such as voltage, current, and power directly within the EtherCAT I/O system. This transparency reduces machine downtime, prevents component oversizing, and enables a rapid response to grid faults such as phase failures. Deviations from normal operating conditions, including increased power consumption due to bearing wear, are detected early to allow for timely interventions.
The system portfolio, designed for ISO 50001-compliant energy management, includes EtherCAT Terminals, measuring transformers, and a software library for monitoring with TwinCAT. It supports preventive maintenance, increases production efficiency, and offers scalable flexibility – from simple energy monitoring to comprehensive network and load analysis.
In addition to basic monitoring, Beckhoff provides detailed analyses of key grid parameters, including frequency, active power, reactive power, and apparent power. Seamless integration into control systems eliminates the need for external measurement technology, as all measurements are carried out directly within the EtherCAT I/O system. Real-time processing enables instant detection of grid fluctuations and anomalies, allowing for immediate corrective action directly in the control system. This not only improves fault management, but also enables predictive maintenance by detecting early signs of machine wear – minimizing downtime in the process.
Key benefits:
From grid monitoring and process control to high-end power monitoring, energy management in machinery and the energy industry calls for adaptable solutions. Beckhoff’s power and energy measurement terminals are engineered for a wide range of applications and optimized to meet diverse requirements. The scalable portfolio includes:
As a system provider, Beckhoff integrates powerful sensors directly into the PC-based control with its SCT current transformers – from measured value acquisition through to cloud-based data transmission. Users can choose from a range of scalable designs and performance classes to ensure an ideal fit for any application. The extensive SCT portfolio includes:
The TwinCAT Power Monitoring function is a powerful PLC library for evaluating raw current and voltage data. It allows users to calculate RMS values for current, voltage, and power – available as instantaneous, average, maximum, or minimum values. What’s more, the library offers comprehensive grid analysis functions, including frequency determination, frequency spectrum analysis, and harmonic evaluation, as well as the calculation of total harmonic distortion (THD) for evaluating the grid quality.
The function blocks support both 1-phase and 3-phase systems. The TE1300 TwinCAT 3 Scope View Professional and TF6420 TwinCAT 3 Database Server products are suitable for visualization and long-term storage of the measurement data.
The TF6735 TwinCAT 3 IoT Communicator App offers a simple and flexible solution for remote monitoring and analysis of TwinCAT process data – anytime, anywhere.
Measuring current and voltage at multiple locations is essential in many applications, e.g. to accommodate distributed loads or address spatial constraints. Nevertheless, precise power calculations can be ensured by synchronizing and processing the measurement values in real time.
A highly accurate synchronization process ensures reliable power data, even when current and voltage readings are taken separately. This includes the calculation of apparent power, active power, and reactive power, enabling a detailed analysis of energy consumption and grid quality. The technology not only allows for flexible placement of the measuring points, but also ensures that the recorded values are synchronized with high accuracy. As a result, power assessment quality remains consistent, regardless of the physical distance between measurement points.
Beckhoff has developed the Power Quality Factor (PQF) to simplify the evaluation of current performance data as much as possible for users. This guide value provides a single numerical indicator of voltage quality within a system’s environment, eliminating the need to separately analyze frequency, voltage, THD/harmonics, and symmetry. For example, if a machine error occurs and the PQF simultaneously drops to zero, it suggests that the issue is likely due to a change in the power supply rather than the machine itself. This approach not only helps to identify symptoms and effects more quickly, but also speeds up root cause analysis. At the same time, a falling PQF can be used as an early warning system.
Standard I/O system signal voltages are typically ≤ 48 V. In power measurement applications, however, signal voltages often reach ≥ 230 V, requiring additional safety measures to prevent personal injury. This is why Beckhoff offers several options for identifying power measurement terminals.
By completing the power measurement chain from the sensor to the cloud, PC-based control specialist Beckhoff simplifies energy management approaches and improves the availability of machines and production facilities.
Romande Energie SA, one of the five largest energy utilities in Switzerland, employs EL3453 power measurement terminals and other EtherCAT Terminals from Beckhoff in its substations to safeguard the availability of its grid. This is implemented with the help of a secondary data acquisition system that can compensate for partial or total failures of the primary acquisition path.
In order to protect against grid fluctuations, Korean engineering firm, Power21 has developed an Energy Storage System (ESS) for frequency control. EL3773 EtherCAT Terminals with eXtreme Fast Control (XFC) technology perform high-precision frequency measurements.
PC-based control for heat and energy supply in the Hermos energy center in Mistelgau, Germany.
The drying and processing of wood is a process that requires a lot of energy. Holzwerke Weinzierl nevertheless manages to generate more power than it consumes. The basis for this achievement is a modern energy management system.
One of Alstom’s latest wind power projects was put into service near Glasgow, Scotland. The additional 217 MW of installed output is sufficient to supply 124,000 households with power. Fast EtherCAT communication and the corresponding Beckhoff I/O components form the backbone of this onshore project, one of the largest in Europe.