Smart Control for Industrial Solar- Thermal Systems [SAMMLER]

Integrating smart control technologies into industrial solar-thermal systems remains a key challenge for improving efficiency and reliability. While solar-thermal installations are increasingly adopted in manufacturing and processing industries, their control systems often rely on basic automation based on temperature differentials or fixed time schedules. The challenge is to design an intelligent, adaptive control system capable of optimizing solar heat generation, storage, and distribution in real time — even under fluctuating solar conditions and varying industrial heat demands. The solution must integrate sensors, IoT platforms, and lightweight AI algorithms for data-driven decision-making while maintaining robust performance in harsh industrial environments. Connectivity limitations in remote areas, sensor degradation, and a lack of standardized communication protocols further complicate implementation. The goal is to create a cost-effective, modular system that supports predictive maintenance, energy optimization, and easy retrofitting for both new and existing installations.

Technology Readiness Level (TRL): 7 – Existing solar-thermal technologies are mature; integrating smart, AI-driven control would raise the systemʼs operational intelligence toward TRL 8–9.

Expected Outcomes: Enhanced energy efficiency and system stability through real-time adaptive control, Reduced manual intervention and maintenance needs, Scalable retrofitting model for existing industrial solar-thermal installations, Lower operational costs and improved reliability for industrial users Impact on Operations: Smart control integration will enable dynamic management of heat flow and storage, improving thermal utilization and reducing waste. It will also strengthen competitiveness by offering industries a more automated, flexible, and cost-effective pathway to decarbonization. For system providers like SAMMLER, this opens new opportunities for digital product differentiation and market expansion.

Current State / Next Actions: Most industrial solar-thermal systems currently use basic programmable logic controllers (PLCs) or temperature-based differentials for automation. Emerging IoT and AI-enabled solutions exist but are not yet widely adopted due to cost, system complexity, and integration challenges. Advanced predictive and adaptive control strategies remain at pilot or prototype level.

Next Steps / Collaboration Opportunities: Joint development of modular control architectures, pilot and demonstration projects, and collaborative R&D proposals for national, bilateral, or EU-level funding.