Sensor-controlled light in the warehouse

Sensor-controlled light in a high-bay warehouse can reduce energy consumption without having to compromise on safety and functionality. However, whether such an investment is worthwhile and how much energy can actually be saved is often only roughly estimated in practice or based on empirical values. However, Steinel Professional has developed the PROLog measuring device to provide a sensible, fact-based basis for decision-making. In the example case, real data on the use of the storage areas and the existing lighting conditions were to be obtained in order to be able to quantify energy savings through sensor-controlled light.

The warehouse in question has seven aisles without daylight. In each of these aisles, 25 standard linear luminaires with an output of 65 watts each are used for permanent lighting during the warehouse's period of use. With a service life of around 10,000 hours, the luminaires consume 28,386 kWh of electricity, which generates costs of EUR 5,677 per year.

Facts instead of estimates

In the first stage of the analysis, the off-grid PROLog measuring device was installed at selected points in the warehouse aisles. With a range of up to 20 meters, it records data on user behaviour and the actual brightness in the warehouse. Over a period of 21 days, the device collected almost 300,000 measurement data. The PROLog evaluation software records all the data for the respective measuring range. The desired brightness value is set manually on the PROLog device before the measurements begin - in the example case, this is 100 lux.

IS 345 MX Highbay sensor from Steinel Professional. Photo: Steinel

The PROLog evaluation shows exactly how long the artificial light was switched on, how many hours people were present and therefore needed light and how long the light was switched on unnecessarily as the corresponding room area was not used. These real actual values are compared with ideal values through the use of sensor-controlled lighting. In addition to this specific usage and lighting data, other values such as energy and service cost rate, service life of the light sources and inflation rate are also included. This database is used to create a projection over one, three, five and ten years.

Highbay sensor for automatic light

For the high-bay warehouse in question, PROLog recommends reducing the number of luminaires to 13 per aisle. The output of only 43 watts is also considered sufficient. In future, 2 motion detectors are to be installed per aisle to control the light switching depending on usage. This means that the light will only be switched on when it is actually needed, i.e. when vehicles or people are in the aisle. Due to the high ceiling in the warehouse, the sensors must also provide precise detection results from a great height and also have a long and narrow detection field typical of aisles.

The installed IS 345 MX Highbay aisle sensor from Steinel Professional meets these requirements. The passive infrared sensor with an aperture angle of 90 degrees can be installed up to a maximum mounting height of 14 meters. When motion is detected, it switches the light on automatically and depending on use. The run-on time has been set to one minute in the example case. The desired response brightness can be between 2 and 1000 lux.

The result

After evaluating the PROLog measurement data, the number and power of the lamps in the high-bay warehouse is reduced. Special highbay sensors from Steinel Professional are installed for lighting automation. This means that the light is no longer switched on permanently, but is controlled according to use. These measures save 96.38% of the total costs, i.e. energy, replacement and service costs per year.

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