Issue link: https://iconnect007.uberflip.com/i/976095
68 SMT007 MAGAZINE I MAY 2018 energy efficiency considerations are taken into account right from the earliest stages when designing the production system. The Energy Efficient Production Floor Design Celestica embarked on an effort to both under- stand and permit the full control of its factory floor from an energy consumption/efficiency perspective several years ago as part of its effort to understand the impacts of Industry 4.0 on its operations. As mentioned earlier, the first phase of this initiative required that the data collection backbone be designed in such a way that disparate pieces of equipment and software could easily gather and exchange information. The second part involved the development of sensors and control circuits to permit for autonomous measurements and control of critical pieces of production equipment. Once deployed, data had to be gathered to under- stand energy consumption by factory floor location. This permitted detailed energy usage data to be gathered. Data analytics were then performed on this historical data to understand the relationship between energy consumption and resulting shop floor temperature. The first site deployment resulted in energy savings significantly exceeding that of the vehicle assembly plant example presented earlier. Eventually, an autonomous control system will be deployed and tied directly to the production MRP/MES system to permit for active control of air handling units and equipment on the shop floor based on the actual production fore- cast and schedule. Measurement and Control Hardware Specific measurement and control hard- ware had to be developed to facilitate both the monitoring of the shop floor tempera- ture as well as the autonomous power on/off control of all the pieces of equipment on the production floor, which were either significant contributors of heat or large consumers of elec- tricity. This included: SMT reflow ovens, wave solder machines, ICT testers, environmental test chambers, and the air handling control units. Custom I/O control boards/sensors were designed including temperature/humid- ity, power (high voltage and current), digital, analog and communication modules. This func- tional combination of sensors allows measur- ing, monitoring and control of almost any type of equipment including but not limited to light- ing and air handling units (Figure 5). Figure 5: IIoT board designs.