Plants, Energy, and Production

Modern energy, production, and plant systems are becoming increasingly complex. The integration of renewable energy, rising demands for energy efficiency, and the digitalization of industrial processes require powerful methods for the analysis, simulation, and control of technical systems.

In our »Plants, Energy, and Production« research area, we develop mathematical models and customized software solutions for the design, monitoring, and optimization of complex technical systems. Our work ranges from energy generation and distribution networks to industrial drive and production systems, and even down to individual machines and components.

 

A key focus is on the modeling and simulation of dynamic systems. We use physically based models, numerical simulation methods, and model order reduction techniques to efficiently represent and analyze complex relationships. The models we develop form the basis for Digital Twins, real-time simulations, and model-based observer and control systems.

Building on this, we develop methods for condition monitoring, system analysis, and control. Using mathematical methods, we can measure and predict the condition and stress levels of even hard-to-access components. This enables the early detection of malfunctions, the assessment of plant condition, and the optimization of operating strategies. We have many years of experience, particularly in the field of vibration and torsional monitoring of rotating machinery.

In addition, we support companies with issues related to energy efficiency and energy management. This includes the analysis and optimization of energy-intensive production processes as well as the modeling and control of energy flows in electrical transmission and distribution grids. A particular focus is on the integration of renewable energies, the use of smart storage and consumption concepts, and the development of robust solutions for reliable and cost-effective plant operation.

From mathematical modeling through the development and validation of controllers to integration into existing hardware and software systems, we support the industry throughout the entire development process and develop customized solutions for demanding applications in industry, energy, and manufacturing.

Example Projects

 

Controller Design for Complex Systems

Control algorithms from standard PID-control to complex distributed and model-predictive controllers

 

Optimize Heating Plant Processes

Our researchers develop and implement methods to intelligently monitor and automate plants. In this way, we save energy and costs.

 

Data and Analysis Platform to Increase Energy Efficiency

Project OpenMeter - simple, open access to extensive real consumption data from the German energy system

 

Intelligent Control in Beverage Production

BMWi-Project DESPRIMA – Demand Side and Production Management for Beverage Filling Processes

 

The EU project »UPWARDS«

The next generation of multiphysical simulations specializing in wind flow, turbine mechanics and their interactions

 

Energy Efficient Annealing Lehr

Model-based control to minimize the energy input of an annealing lehr by using new, innovative actuators

 

Power Generation and Distribution

Modeling, monitoring and control of energy producers, energy distribution networks and energy efficiency of consumers

 

 

MathEnergy – Control Concepts for Power Grids

 

Multi-network model-based monitoring and control for planning and operation

 

 

Vibration Monitoring Systems for Power Plants

We develop intelligent monitoring systems that detect damage to power plant turbines at an early stage, thereby preventing outages.

 

Process Analysis via Machine Learning

Detection of dependencies of quality and performance variables on process parameters

 

Active Damping

Automated controller design for active vibration damping with non-linear actuator behavior

 

Hardware in the Loop

Real-time and robust system models for controller design and validation