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The twin concept is increasingly used for optimization tasks in the context of Industry 4.0 and digitization. The twin concept can also help small and medium-sized enterprises (SME) to exploit their energy flexibility potential and to achieve added value by appropriate energy marketing. At the same time, this use of flexibility helps to realize a climate-neutral energy supply with high shares of renewable energies. The digital twin reflects real production, power flows and market influences as a computer model, which makes it possible to simulate and optimize on-site interventions and interactions with the energy market without disturbing the real production processes. This paper describes the development of a generic model library that maps flexibility-relevant components and processes of SME, thus simplifying the creation of a digital twin. The paper also includes the development of an experimental twin consisting of SME hardware components and a PLC-based SCADA system. The experimental twin provides a laboratory environment in which the digital twin can be tested, further developed and demonstrated on a laboratory scale. Concrete implementations of such a digital twin and experimental twin are described as examples.
In this paper we report on further success of our work to develop a multi-method energy optimization which works with a digital twin concept. The twin concept serves to replicate production processes of different kinds of production companies, including complex energy systems and test market interactions to then use them for model predictive optimizing. The presented work finally reports about the performed flexibility assessment leading to a flexibility audit with a list of measures and the impact of energy optimizations made related to interactions with the local power grid i.e., the exchange node of the low voltage distribution grid. The analysis and continuous exploration of flexibilities as well as the exchange with energy markets require a “guide” leading to continuous optimization with a further tool like the Flexibility Survey and Control Panel helping decision-making processes on the day-ahead horizon for real production plants or the investment planning to improve machinery, staff schedules and production
infrastructure.