Smart Energy Monitoring is an IoT based system designed to monitor energy consumption (electricity, air, gas, and CO₂) in real-time in industrial production areas. The system connects measuring devices such as flow meters (to monitor wind usage) and kWh meters (to monitor panel/machine electricity usage) to the PLC, then the data is transmitted to the IoT Gateway and sent to the monitoring server using the MQTT protocol. The data is then processed and visualized in the form of an interactive digital dashboard.
Challenge
In the manufacturing industry, the energy monitoring process has been manual. The engineering team must check measuring instruments in the field one by one to record electricity or air consumption data. This method is time-consuming, risks human error, and does not provide real-time data.
The impact of this manual method:
- Energy consumption data is only available per week or per month
- There is no notification when there is a spike in energy consumption
- The process of analyzing and reporting is slow
- There is no historical data that can be accessed quickly for comparison between lines or areas
- Decisions related to controlling energy consumption are delayed.
Project Goal
This project aims to present an IoT based energy monitoring system that can help the engineering team monitor energy monitoring in real-time without having to make manual notes to each measuring instrument in the field. In addition, this system is designed to present energy consumption data in the form of a visual dashboard that is easily accessible, making it easier to analyze, report, and make operational decisions when there are spikes or discrepancies in energy consumption in the production area.
Features Offered
The features that have been implemented are :
- User Authentication and Authorization: System login to restrict access only to authorized users.
- User Management: Setting users, roles, and permissions as needed.
- Dynamic Master Data: Users can create and manage production line data, device types, and energy parameters.
- Device Registration: Registration of measuring devices such as flow meters and kWh meters into the system.
- Parameter Setting: IoT Gateway reads data from PLC and sends it to the server using MQTT, with predefined parameters.
- Summary Monitoring: Real-time monitoring of energy consumption (electricity, compressed air, gas, CO₂) with date, line, and energy type filters.
- Single Line Diagram: Digital visualization of the device position in the production layout, details of its status and energy consumption can be seen.
- Top Frequency: Displays the highest energy usage with the amount displayed according to the user's customization, can be filtered by line or energy type.
- 3D Building Dashboard: Displays 3D building image along with its energy consumption, can be clicked for breakdown per production line.
- Report & Export: Energy usage report that can be filtered per period, then exported to PDF/Excel.
- Settings:
Result
Post implementation, the system has been able to:
- Present real-time energy consumption data.
- Reduce delays in over consumption detection.
- Facilitate consumption analysis per line, per area, and per energy type.
- Provide automatic and accurate reports.
- Improve the work efficiency of the engineering team without the need for manual control to the field.