Industry 4.0 ready compressed air systems

Often referred to as the fourth industrial revolution, Industry 4.0 is the automation of and data exchange in, manufacturing technologies which can be combined to create a ‘smart factory’.  

In the now connected and digital Industry 4.0 world, not only can people communicate and interact with each but also machines and computers through the Industrial Internet of Things (IIOT). Large quantities of information often referred to as Big Data are collected, through automatic sensors, which are then shared and subjected to advanced analytics. Using artificial intelligence and machine learning, these systems are enabled to understand processes and make decisions.

Real benefits

Despite many technological advances many still view smart factories as futuristic and their benefits largely theoretical. In a recent survey of UK manufacturing companies only 39% appeared to have implemented any form of Industry 4.0 to date. This is despite 80% saying they felt it would be an advantage. One major issue as stated by 30% of respondents, was lack of knowledge on its specific benefits.

However, manufacturers must be assured that Industry 4.0 technology is very real and is being used every day.  The practical application of industry 4.0 is best demonstrated in relation to existing BOGE systems. It also showcases that the rewards of Industry 4.0 are real too, including transformational effects on efficiency, reliability and flexibility in individual machines and entire production operations.

Machine networks

In order to create a smart factory, compressed air systems are the best place to start. Compressed air is often referred to as the fourth utility and is one of the essentials of modern manufacturing.

Modern compressor systems have a variety of networked features which allow one machine to act as a ‘master’ for a wider network. This makes decisions on which compressors to switch on, for example, and on what adjustments are necessary to meet the user’s requirements while optimising the equipment’s energy consumption, reliability and lifespan.  All but the very smallest of applications of compressed air systems require a distribution network; where pipes and valves will move air from the compressor installation to the point of use. In addition, there is usually interconnection between compressors. A large fixed-speed unit typically supplies the base-load of air while a smaller variable-speed machine kicks in to deal with peaks in demand. Additional machines in the network may include dryers, filters and storage devices.

Smart control

Control systems are well equipped for digital networking, from the most complex products to basic ones.  Through integrated fieldbus connections, one machine’s controller can be the master of many other machines.  Using built in internet links, staff can remotely monitor machine and system performance through a web browser or mobile app. Functions such as these make it easier and less expensive to install, configure, operate and maintain a compressed air system.

For larger and more complex installations, BOGE has developed a new generation of networked control systems: airtelligence provis 2.0, which continually monitors compressed air systems, whilst anticipating changes in demand.

Fully configurable, airtelligence provis 2.0 takes the specific characteristics of each installation into account. For instance, it can be set to make less use of the older and less efficient compressors, or to align maintenance intervals of different components by varying their running hours.

Data analytics & predictive maintenance

Industry 4.0 has a vital role to play in the development of predictive maintenance.  Many customers have taken the option of a secure internet link between their installation and the BOGE central analytics facilities. This will transmit 70 data points a second on pressure, temperatures, motor speeds and energy consumption.

Analysing data through the use of ‘learning’ algorithms helps the system to build an understanding of each customers normal operating conditions. In the event of any unusual activity or significant variation, a specialist engineer is alerted. They will then review the data and decide if there is a problem. The customer is then contacted, and corrective actions are undertaken.

If the change observed is considered unusual but acceptable, the system can be taught to ignore any recurrence of it.  The monitoring undertaken is a two-way process, as the algorithm understanding deepens, it can update parameters within a machine’s own controller. The machine can then alert on-site staff directly to any indication that a problem is developing.

The use of augmented reality can also provide maintenance staff with virtual support from remote experts who can view what the maintenance staff are seeing in real time, which adds extra guidance and support for a machine.

Annual reports for machines connected to BOGE’s analysis system are also provided, details are given on the how demand fluctuates over time, the efficiency and the cost of the compressed air production.

Future-proofing

Industry 4.0 can be easily and practically introduced to compressed air system installations. It is also vital to future-proofing customers’ investments and operations. It has a range of monitoring and reporting tools which mean system operators can understand energy consumption, system reliability and available capacity at a mere touch of a button.   BOGE simulation tools can also evaluate if maximum efficiency is being achieved. This benefit customers day after day. By reducing energy usage and enhancing maintenance operations, these advances bring about ongoing savings and a fast return on investment.

The subsequent reports can be used to assess what improvement would be achieved using a different system design, configuration or component. Continuous development of new and improved components continues, and again the effect of each alternate possibility can be simulated and assessed. Further options are also available, for example one is to create customised components if assessments show that further changes will have significant effects.

Whilst this may seem radical, none of it has required customers to invest heavily in additional infrastructure or capabilities. Industry 4.0 is ready to be embraced and with this technology already built into its products and services, BOGE is equipped to make your factory smarter today.

Mark Whitmore is General Manager of BOGE