From Energy Blind Spots to Full Visibility in Automotive Manufacturing

A building-level energy monitoring system enabling sub-metering, compressed air optimization, and environmental safety management for reliable energy visibility and system optimization.

Project Key Result

  • Full energy visibility achieved across the entire facility
  • Unit energy consumption becomes measurable at workshop and product level
  • Compressed air leakage reduced from over 15% to below 5%
  • Clear energy usage boundaries established across workshops
  • Up to 18 hours/day reduction in manual inspection workload
  • Faster response to safety risks and abnormal conditions
  • Data foundation established for energy optimization and decision-making

Project Overview

Project Name Wuxi Weifu Mashan Manufacturing Facility
Location Mashan, Wuxi, China
Industry Automotive Manufacturing
Facility Scale Approx. 150,000 m², including multiple production workshops (injector, plunger, hydraulic components, precision machining) and power distribution facilities
System Type Building-Level Energy Monitoring System
Deployment On-premise (Local Server)
Devices & Sensors • ~150 Smart Energy Meters
• 6 Smoke Sensors
• 18 Temperature & Humidity Sensors
• 6 Water Leakage Sensors
• 4 Pressure Sensors
• 4 Flow Meters
Data Acquisition 5 Data Collectors and 1 Power Monitoring Control Cabinet
Key Functions Real-time energy monitoring, building-level energy analysis, automated reporting, and environmental monitoring

Customer Challenge

Lack of Unit-Level Energy Measurement
  • No independent measurement of electricity and compressed air across workshops and products, making unit energy consumption untraceable.
Insufficient Safety Management in Power Distribution Rooms
  • Distributed power rooms face fire, water leakage, and unauthorized access risks, with inspections relying on manual work only.
Unmonitored and Inefficient Compressed Air System
  • Aging pipelines lead to leakage rates exceeding 15%, with no real-time monitoring in place.
No Unified Energy Data Platform
  • Energy data is fragmented, with no centralized platform to support visibility, analysis, or decision-making.

What We Implemented

Factory-wide Sub-metering System for Power Distribution
  • Sub-metering is deployed across distribution circuits and key process equipment, establishing a plant-wide energy data acquisition system.
Online Environmental Monitoring for Power Distribution Rooms
  • Remote sensors are installed in distribution rooms to monitor smoke, temperature, humidity, and water leakage, replacing manual inspections.
Compressed Air Monitoring and Leakage Analysis
  • Pressure and flow sensors are deployed across four compressed air systems to monitor usage and identify leakage within the network.

System Architecture

A structured three-layer architecture connecting data acquisition, measurement, and platform-level analysis for reliable energy monitoring and system operation.

Platform Layer
  • Hosts the energy management system, enabling data storage, visualization, and analysis.
Acquisition Layer
  • Collects and aggregates data from field devices, ensuring unified system access.
Measurement Layer
  • Measures energy consumption and environmental parameters across equipment and facilities.

 

Layer Device Type Description Quantity
Platform Layer Local Server Deploys the on-premise energy management system, supporting data storage and visualization 1
Acquisition Layer Data Collectors Collect data from various meters and energy devices, enabling unified system integration 6
Measurement Layer Multi-function Energy Meters Monitor key equipment and critical power distribution circuits 150
Measurement Layer Gas Flow Meters Measure compressed air flow consumption 4
Measurement Layer Pressure Sensors Measure pressure in compressed air pipelines 4
Measurement Layer Water Leakage Sensors Monitor water leakage in power distribution rooms 6
Measurement Layer Temperature & Humidity Sensors Monitor temperature and humidity in power distribution rooms 6
Measurement Layer Smoke Sensors Monitor smoke conditions in power distribution rooms 6

Result

Full Energy Visibility with Sub-metering

How it works
  • A factory-wide sub-metering system is deployed across distribution circuits and key production equipment, enabling energy measurement at both workshop and product level.
What you get
  • Energy visibility shifts from total-only to sub-metered insights.
  • Unit energy consumption per product becomes measurable.
  • Clear energy responsibility across workshops.
  • Data becomes traceable, comparable, and analyzable.

 

Compressed Air Efficiency Improved with Leakage Control

How it works
  • Pressure and flow sensors are deployed across the compressed air system to monitor usage and establish correlations between workshop consumption, energy use, and air demand, while identifying leakage points.
What you get
  • Leakage detected through real-time monitoring (from >15% to <5% after optimization).
  • Clear usage boundaries between workshops.
  • Data foundation for system optimization and energy-saving actions.

 

Safer and Smarter Power Distribution Room Management

How it works
  • Remote environmental monitoring is implemented across distribution rooms, continuously tracking smoke, temperature, humidity, and water leakage, with automatic alerts for abnormal conditions.
What you get
  • Up to 18 hours/day reduction in manual inspection workload.
  • Faster response to safety risks and abnormal events.

 

Related Products

The physical devices responsible for data measurement, collection, and transmission.

Wired IoT Gateway ECSY001

ECBD005 Panel-Mounted Digital Multifunction Power Meter

 

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