Browsing by Author "Yesilyurt, Ozan"

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    Approach development for enabling energy flexibility in manufacturing companies with AGV lithium batteries through an algorithm-based ICT solution
    (Stuttgart : Fraunhofer-Institut für Produktionstechnik und Automatisierung IPA, 2024) Yesilyurt, Ozan; Sauer, Alexander (Univ.-Prof. Dr.-Ing. Dipl.-Kfm.)
    Manufacturing companies are currently dealing with a complex environment for their factories concerning current and future energy supply. The companies should pay electricity costs based on two readings. One is for the manufacturing company's energy consumption, and the other is for peak demand. The electricity suppliers contractually arrange pricing models with the companies based on the highest peak production load. Manufacturing companies face these load peaks in their manufacturing and pay high amounts of money because of the generation of peak loads. Therefore, different concepts and applications of energy storage systems, such as stationary and electric vehicle (EV) batteries, were studied and developed in manufacturing plants to minimize peak loads and enhance savings for the companies. Automated Guided Vehicles (AGV) can be considered electrical energy storage in manufacturing companies. According to the BIS Research’s study, the battery capacity and production of electrically powered AGVs will increase over the next three years. There will be approximately 273,000 operating AGVs worldwide in 2025. This high number of AGVs offers a large battery capacity that can be used for energy flexibility measures such as the load control method peak shaving in manufacturing companies. In addition, AGV usage in manufacturing plants is relevant for 78% of German companies. Moreover, the study shows that 64% of the companies are involved in integrating energy storage in their companies. This shows that AGVs offer great potential as transport vehicles and energy storage for manufacturing companies. AGV batteries can be used to enable peak shaving and to reduce electricity costs for companies. To realize this, AGV batteries require intelligent charging and discharging scheduling. This dissertation introduces a service for enabling energy flexibility in production with AGV batteries. First, overall and use case requirements are presented and compared to the existing research approaches to determine the challenges and scientific gaps in designing a generic approach. Then, the generic approach is created to use the AGV batteries as energy storage so that the peak loads in manufacturing companies can be reduced by using AGV batteries. The generic approach is instantiated through a “battery usage optimization service” to prove its feasibility. The service optimizes energy storage through three steps: In the first step, optimal charging and discharging points are calculated using energy consumption, renewable energy generation, and electricity prices during production. In the following working step, the data of the AGV routes, the AGV battery capacity consumption, the AGV charging, working and idle times are used to find out the availability of the AGV. In the end, a decision mechanism for charging and discharging scheduling determines when the AGV battery should be charged and discharged in consideration of battery degradation, availability of the AGVs, and charging station occupancies without negatively affecting the existing production situation. The benefits and potential of using AGVs as energy storage to reduce peak loads in a company are illustrated after a sensitivity analysis is performed with the calculated results by the service in three different use case scenarios. The results of the sensitivity analysis show that using AGV batteries as energy storage to minimize peak loads can be beneficial for the considered manufacturing companies under certain conditions, such as the availability of AGV batteries and the number of charging stations in the companies and the used battery capacity of AGV batteries in this dissertation. As a future work, the developed service can be developed to investigate further whether it is economical to reduce electricity costs of manufacturing companies by trading electricity in the intraday market with the help of the AGV batteries.