Data gathering in air compressor applications
As compressor designs evolved over the last few decades they have felt the touch of the digital revolution. What started off as simple digital readouts on the front panel of the compressor has morphed into fully integrated data gathering systems with automation powered by smart algorithms.
Monitoring the state of your compressor installation and generating data from it allows you to derive meaningful information and visualizations. This in turn empowers your decision making with regards to air compressor efficiency and servicing the bottom line.
These are some of the main parameters that affect the efficiency of air compressors, and they should be the focus of your data gathering methods.
- Intake conditions: ambient temperature, relative humidity, and absolute pressure (location and weather dependent).
- Power supply: measure voltage, power, power factor and frequency.
- The operating pressure or outlet pressure.
- Data on motor efficiency that will give insight into the wear and tear of the motor.
- Data on compressor unit efficiency, turbulence, friction of air etc.
- Water drainage, leakages and internal compressed air use.
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.
How data can be used to optimize your air compressor installation
In the past, monitoring the above efficiency related parameters was only possible by installing a data-logging unit on the compressor, letting it run for a week, taking it off, downloading and analyzing the data, and then presenting the findings.
Modern Air Compressors include sensors to gather the data. These sensors can detect changes in heat and vibration as well as collecting data on system pressure, temperature, volume, energy consumption, along with loaded hours, unloaded hours and other data points. The manufacturers of these machines support their clients by running 24/7 remote monitoring centers.
Monitoring sensors are being refined and improved, and they will evolve in parallel with the emergence of the ‘Internet-of-Things’ phenomenon – sometimes referred to as Industry 4.0. Manufacturers will investigate all avenues of information availability by giving devices within the air compressor additional capabilities. For example, flow meters can have the ability to measure density, temperature, viscosity, conductivity and pressure. Or devices that can detect process disturbances, or elements in the process that lead to a disturbed measurement. And instruments that can identify harmful water condensation in a compressed air system.
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. Remote monitoring systems gather data from all the machines, cloud computing technologies process the data, and central controllers run the programmed responses.
Centralized controllers link all of the compressed air machines together. They behave as the self-learning brains of the compressor room, making sure that installation is at optimal settings. The controllers have advanced touch-and-swipe interfaces for interactivity, built-in transmitting devices to send and receive data, and intuitive graphics displays. With all of the data collected by sensors and built-in monitoring devices the central controllers can run programmatic actions on behalf of the user.
These compressor monitoring technologies create smart systems. Users will receive energy efficiency recommendations based on the working parameters of their compressor installation. High level data visualisations and insights will show real opportunities with practical advice on how to improve the efficiency and reliability of their compressor systems.
This ultimately translates to better scheduling of energy-intensive tasks, better use of available resources, less down-time through preventative maintenance, adaptability, energy savings and time savings.
Discover how SMARTLINK optimizes compressed air systems
A big part of Atlas Copco’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 analyses 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.
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 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.
