How To Monitor Air Compressors Using Cloud Technology

Modern air compressors come with monitoring and data gathering technologies that can give you unrealized cost and workflow benefits.

Monitoring and data gathering technologies can produce meaningful information that can be visualized, tracked over extended time periods and used to make insightful decisions. By knowing the status of your compressed air equipment at all times and being able to react to it you can spot and fix deviant behavior at an early stage.

Because you’re able to generate meaningful data, broadcast alerts, and take pre-programmed actions using smart algorithms, you are effectively being proactive with your compressor maintenance – also known as preventative maintenance. Preventative maintenance leads to long-term energy efficiency and reduces ageing over the life span of your compressor. This leads to improved cost savings as well as better workflow for your staff.

After the first 7 to 8 years air compressors will need a strict maintenance schedule or inefficiencies may begin to develop, which if neglected can turn into an issue which needs repairs. But by applying monitoring and data gathering technologies to your compressor installation you will reduce the chances of having unexpected major repairs.

With proper maintenance and care of your air compressors you can expect to extract well over a decade’s worth of good performance out of your machines. On the other hand, without proper care your machine could give you a decade’s worth of costly, disruptive, inefficient performance and stress. That’s why we’d advise you to purchase air compressors from a manufacturer that has data gathering or smart monitoring systems built-into their machines.

Download: A Beginner's Guide to Connected Compressors

Monitoring and data gathering in air compressors involves the use of Remote Monitoring, Central Controllers and Cloud Computing as well. All 3 of these technologies will help you achieve maximum air compressor performance, while decreasing energy wastage and minimizing downtime over the lifespan of the machine. 

Remote Monitoring involves the placement of sensors at useful locations along the air compressor installation. The sensors collect data on system pressure, temperature, volume, energy consumption, along with loaded hours, unloaded hours and other data points. The sensors connect to a system that can broadcast the information to a remote terminal on-site or off-site. With the information gathered by this system you get valuable insights that allow you to stay on top of maintenance, repairs, compressor performance and operational trends.

Modern air compressors come with a digital control unit installed that allows the user to read and adjust the operational settings that influence compressed air output. When an industrial application requires more than one air compressor then a separate central control unit performs this function for all the machines. Digital control units allow programmatic actions to be taken in response to feedback from the remote monitoring sensors. For example, remote monitoring can sense the load and pressure changes on the compressor installation. And using this data a calculated adjustment can be made to prevent pressure fluctuations from crossing a range. 

Cloud computing refers to the technology architecture that allows for decentralized, on-demand access to computing power, data insights and programmatic action. It operates on a similar principle as web-based email clients, allowing users to access all of the features and files of the system without having to keep the bulk of that system on their own computers. This technology enables users to access large amounts of data over a secure, online network connection. For example, users can access compressor operation information via cloud based monitoring software like SMARTLINK from their mobile device anywhere: in office, at home or even while traveling. You are always able to quickly share that information with other stakeholders anywhere in the world.

In short, remote monitoring systems gather data from all the machines, cloud computing technologies process the data, and central controllers run the programmed responses.

A big part of the company’s success has come from our consistent breakthroughs in optimizing its products for energy savings and efficiency. One of our best innovations is the SMARTLINK data monitoring program for air compressors. 

SMARTLINK intelligently gathers, compares, and analyzes data to help compressed air users increase maintenance and service efficiency. SMARTLINK actively monitors over 30 data points of your compressed air equipment and presents a service timeline that shows you the service needs of every machine, with scheduled visits and clear service reports. Case-studies show that users have increased their uptime by 3% a year, while saving up to 30% through improved energy efficiency that accumulates over the life span of the air compressor.

--> Learn more about the case study from our white paper

The foundations for SMARTLINK were developed in-house years ago, well before ‘Internet-of-Things’ technology started to gain mainstream traction. The company set its sights on modernizing the IoT platform, aiming to give customers easier access to more useful data that could help drive the factories of the future.

Partnering with Microsoft and OrangeNXT, Atlas Copco successfully rebuilt its remote management platform on the Azure cloud. And the new system is transforming the customer experience by putting clear, actionable insight at decision-makers’ fingertips. 

Data security is a concern for anyone with sensitive data. After all, when files, programs, and other data aren't kept securely onsite, how can you know that they are being protected on line? In fact, the key to cloud-based technology’s security is the encryption of data being transmitted over networks and stored in databases. By using encryption, information is less accessible by hackers or anyone not authorized to view your data. Atlas Copco takes security seriously. SMARTLINK uses commercially standard methods of data transmission and encryption. And its data storage policies are GDPR compliant. Customers can speak directly with an Atlas Copco Privacy Officer to clear any doubts. 

And did you know that all Atlas Copco compressors come equipped with SMARTLINK? If you own an Atlas Copco product, we strongly recommend that you start incorporating the technology in your work flow.  

To learn more about how Atlas Copco’s monitoring and data gathering technology for air compressors works click here. We’re also offering our customers a FREE on-site or virtual demonstration of how to set up and use SMARTLINK in their facility. Feel free to use the contact form to get in touch and call our local team in the UAE.