What is a smart compressor and does it make a difference?
Rapid technological advances have taken many products we use daily to another level. Cars, phones, watches or TVs – all have become “smart” to make our lives easier. The same also applies to industrial settings. That includes smart compressors.
But what does such a smart compressor look like, and what can it do?
What makes a smart compressor?
There are three main ways in which compressors have become “smarter.” First, they offer advanced connectivity. For many people, connectivity is what comes to mind when they think of “smart”. But for a compressor, the ability to adapt and optimize its operation to its working conditions might be even more important. Finally, compressors become smarter as their individual features become intelligent.
Before we take a closer look at these 3 levels of intelligence, let’s take a look at the benefits they provide. Advanced connectivity, adaptive operation, and intelligent features allow compressors to…
- Boost air system reliability and efficiency
- Offer new, remote control and monitoring options
- Allow for a connected production
- Adapt to ambient conditions
Let’s take a closer look at these smart features and technologies.
Advanced connectivity
This is an area in which huge strides have been made. Gone are the days in which an operator had to walk the production floor to take compressor readings and adjust parameters.
Controllers are the foundation of advanced connectivity. The Atlas Copco Elektronikon® is a state-of-the-art example. It offers a host of control and monitoring options and algorithms such as customized timers and efficiency controls.
If you are using more than one unit, then Atlas Copco also has a controller for you too. The Equalizer can coordinate up to six compressors. For example, it can distribute the workload in a way that it is perfectly balanced between all units. Or you can choose to primarily run the newest machines to maximize efficiency. It can also set two pressure bands for different times of day, such as your day and night shifts.
Do you use more than six units? Then the Optimizer is the controller for you.
Remote monitoring
Remote monitoring plans such as SMARTLINK allow you to monitor the performance of your air compressor from a computer, smartphone or tablet. SMARTLINK also presents you with insights to identify opportunities for optimization. And it shows you service timelines and maintenance alerts.
A connected production
If you are running a connected production, you will want to know about OPC UA-enabled compressors. OPC UA stands for “open platform communications unified architecture.” In technical terms, it is a machine-to-machine communication protocol that was developed for industrial automation. In layman’s terms, it is a universal language that allows different machines in a production facility to “talk” to each other. This ensures that industrial processes run much more smoothly, efficiently and reliably.
Now, for the first time ever, you can get a compressor equipped with OPC UA, developed by Atlas Copco. The future truly has arrived.
Smart, adaptive operation
Until recently, compressors only offered by-the-book, preset operation. Smart models on the other hand adapt their performance to their operational conditions and to the air system demands.
A key innovation was variable speed drive (VSD) technology. It allows compressors to match their motor speed to the actual air demand. Introduced more than two decades ago, VSD still belongs in this chapter about important innovations. That’s because the technology has been refined in that time. A VSD air compressor of the latest generation can now offer energy savings of up to 60% compared to fixed-speed models.
Atlas Copco’s newest VSD compressors also feature the revolutionary Smart Temperature Control system. It adjusts the oil injection temperature to the actual running conditions. This real-time optimization ensures maximum compression efficiency and eliminates the risk of condensation to boost reliability.
Algorithms are increasingly making the difference. The new GA VSDS, for example, comes with an intelligent Boost Flow Mode and a limp mode. The former lets you meet peak demand by exceeding the compressor’s maximum capacity for a certain amount of time without harming the compressor. Limp mode ensures the compressor keeps working even when something is wrong.
On the fixed-speed side, the smart unload algorithm in the latest generation of Atlas Copco GA+ optimizes the compressor’s time to unload to reduce energy use.
Intelligent features
Even mechanical components are getting more intelligent. Smart water drains for example ensure the automatic removal of condensate, auto-cleaning, and the detection of potential issues.
Consumable sensors continuously monitor the pressure drop in the inlet filter, the oil filter and the oil separator to optimize performance.
Smart compressors – less work, better performance
All these technologies add up to a smart compressor. It is a supremely connected machine that is much easier to manage and monitor. More importantly, it makes your production more efficient, reliable and sustainable thanks to its adaptable performance and intelligent features.
Are you interested in a smart compressor? Our experts are always happy to answer your questions. They can also help you find the intelligent solution that best meets your needs. So contact us today!
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