Research and development in industrial energy – innovations for efficiency
We create technologies that transform industry.
In the R&D department of DB Energy, we combine engineering, data, and innovation to increase energy efficiency,
recover energy, and reduce CO2 emissions in production facilities.
R&D at DB Energy supporting the energy transition
The R&D department of DB Energy is a team of engineers, analysts, and energy experts working on solutions that reduce energy consumption and CO2 emissions in energy-intensive sectors.
In research and development projects:
- we develop proprietary technologies for measurement, analysis, and monitoring of energy consumption,
- we advance systems supporting heat recovery, industrial refrigeration, cogeneration, and trigeneration,
- we test innovative methods for upgrading installations under real industrial conditions,
- we collaborate with technical universities and technology partners to accelerate the commercialization of new solutions.
R&D activities are closely linked to practice – every developed tool or technology has real applications in industry, delivering measurable energy and cost savings.
The experience gained from implementing R&D projects for our clients has shown us the value of building our own innovation hub. That is why in 2014 we created an internal Research and Development Department at DB Energy. Since then, we have focused on creating and refining technologies that have a real impact on industrial energy efficiency – from proprietary diagnostic systems to solutions optimizing processes in real time. Our strength lies in combining engineering knowledge, project experience, and understanding of production facility needs, ensuring that DB Energy innovations reach the industry directly.
Development of an innovative diagnostic system for pump, fan, and compressor operating parameters
The project aims to create, by DB Energy S.A., an innovative online solution for diagnostics of pump, fan, and compressor operating parameters. As part of advanced industrial research and development work, the Applicant plans to develop a solution that will expand the Applicant's offer with a new service: a system for inexpensive and rapid comprehensive verification of the operating condition of pump, fan, and compressor units used in production processes, based on mechanical and electrical parameter measurements, with online access to a database system for validating collected data.
Main research tasks
Development of a diagnostic system as a key component of the entire solution. The device will be equipped with a set of sensors enabling monitoring and measurement of various operating parameters of pumps, fans, and compressors.
Construction of a diagnostic system for pumps, fans, and compressors. This task involves creating a system integrating multiple measurement setups developed in the first task and tested in the second.
Testing the measurement system. The tests aim to confirm that individual components of the developed system function correctly under conditions close to real-life operations.
Development of software to operate the online system. The result will be a ready-to-deploy diagnostic system for pumps, fans, and compressors, enabling assessment of the device’s condition and energy efficiency, ultimately reducing energy consumption, CO2 emissions, failure costs, industrial downtime, and planned maintenance.
Thanks to its innovative functionalities, the system enables inexpensive and rapid detection of disturbances or inefficient operation, allowing broader use of continuous drive monitoring in industry than before.
Project value: 2 090 384.10 PLN.
European Funds contribution: 1 410 897.87 PLN.
DiagSys – drive diagnostic system
[project completed]
In 2016, the R&D Department of DB Energy started one of the key projects in its history – DiagSys, an advanced remote drive diagnostic system for industrial processes.
The goal of DiagSys was to create a solution that allows for:
- continuous machine monitoring and rapid fault detection, minimizing the risk of costly downtime,
- optimization of energy consumption in industrial drives – the main energy consumers in facilities.
Differentiators compared to traditional diagnostic methods
integration with industrial automation allowed real-time control of process efficiency,
measurements conducted online, without interrupting equipment operation,
an intelligent database eliminates the need for expert interpretation, while offering remote consultation capabilities,
implementation costs lower than vibroacoustic or thermographic testing.
By analyzing current signals, DiagSys performs a full range of vibroacoustic tests without direct intervention in the drive – installation is fast, safe, and possible even at a considerable distance from the machine. The device is user-friendly and available in a portable version, enabling diagnostics of multiple machines in one facility.
A significant value of the project is the database containing millions of industrial fault records. This allows DiagSys to provide accurate recommendations even for machines being diagnosed for the first time, without a lengthy “learning” process.
The project is funded under the Intelligent Development Operational Program 2014-2020, Sub-measure 1.1.1 "Industrial research and development work carried out by enterprises". Competition number: 1/1.1.1/2015.
Project value: 5 974 021.85 PLN.
Funding value: 3 727 676.11 PLN.
