Integration of control and measurement devices into CAD models of industrial power systems: Metrological aspects of accuracy and impact on energy efficiency

Abstract

The research relevance is determined by the growing need of industrial enterprises to improve modelling accuracy and energy efficiency, which directly depends on the integration of control and measuring instruments into Computer-Aided Design (CAD) models of industrial power systems. The study aimed to justify the possibility of using CAD systems for the integration of control and measuring instruments, incorporating the metrological aspects of accuracy and their impact on the reliability of digital models and the efficiency of energy consumption management. The research methodology included a classification analysis of control and measuring instruments according to their functional and metrological characteristics, the application of a formula for the relative error of quantitative assessment of instrument accuracy, as well as the modelling of various scenarios for data integration in CAD environments (AutoCAD, SolidWorks, Engineering PLAN). The classification of control and measuring instruments into high-precision (δ≤1%), medium-precision (δ=1-5%) and low-precision (δ>5%) was investigated. The study determined that the use of low-accuracy instruments led to a 12-15% reduction in the reliability of CAD models and caused additional energy losses of up to 8% in production processes. In contrast, high-precision instruments ensured deviations of no more than 0.8%, increased the accuracy of energy consumption forecasting by 10-12% and contributed to a reduction in operating costs by 6-7%. The integration of control and measuring instruments into digital twins of industrial facilities was analysed, which optimised equipment utilisation, reduced energy losses by 9% and increased the equipment utilisation rate from 82% to 89%. The study concluded that the correct selection and classification of control and measuring instruments is critical for the stability of digital models and their practical value. The study confirmed that the combination of metrological reliability of instruments and digital design technologies creates conditions for effective energy consumption management. The practical significance of the results is determined by the possibility of their application for optimising the design, modernisation and management of industrial power systems, incorporating quantitative indicators of accuracy and energy efficiency.