About Project SM
The overall project objective is to develop an industry-accepted SM Platform that can be scaled to a diverse set of manufacturing operations. Specifically, the project plans to (1) design and demonstrate the application of a prototype SM Platform for two diverse commercial test beds, (2) demonstrate a 30% reduction in waste heat generation at each of the test beds, and (3) work with a group of leading automation vendors to catalyze low-cost commercialization of the technology developed.
The SM Platform will be designed based on current manufacturing and IT industry standards; basic hardware and software components that will be used have already been successfully demonstrated. In addition, an energy productivity metric and an application toolkit will be defined so that they can be tailored to a specific business situation. The project will involve the use of two test beds—one in a hydrogen production plant, and the other in a forging and heat treating operation. For each test bed, sensor-driven modeling, measurement, and simulation systems, in conjunction with the SM Platform, will be developed, deployed, and operated, allowing energy consumption to be managed in real time. An Energy Dashboard developed for each test bed will provide situation awareness by integrating the energy productivity metrics with real-time information. Previously unavailable intelligence will be used to identify overall operations improvement opportunities at both test beds. Finally, outreach programs will be created to disseminate the technology.
This three-year project began in September 2013.
• Develop operational prototypes of the SM Platform framework, initial modeling and workflow tools and energy performance metrics, and test bed installation plans (Year 1).
• Use test bed data to analyze the dominant factors for energy use and optimal forging furnace performance (Year 1).
• Begin test bed operations and develop strategies and integrated energy performance metrics (Year 2).
• Implement model-based design and control using the SM Platform framework (Year 3).
• Populate the SM Platform with functionalities and toolkits developed from the test bed work (Year 3).
• Implement expanded SM Platform framework along with new test bed demonstrations (Year 3).
The commercialization of the SM Platform will require significant cross-industry collaboration. Specific project tasks are dedicated to the commercialization process and include (1) upgrading the industry community website to include interaction, input, and co-development;
(2) analyzing the savings from deployment of the SM Platform compared to other systems; and (3) testing industry community websites as portals for accessing and distributing application resources. The project will launch SM Platform workshops, webinars, and conferences targeted to individual industry segments, with a focus on small and medium-sized organizations.
• Ensuring timely access to high-quality data from test beds.
• Integrating all desired functionalities into the SM Platform.