Smart approach to air compressors

As we move towards a global landscape that connects electronic components and smart devices via the internet, the possibilities for more efficient and productive manufacturing processes are limitless. 

Rather than be apprehensive of an era and workplace that reduces the need for human intervention, the advantages of a more streamlined, ‘smart factory’ that can digitally mine and transmit diagnostic information need to be embraced. And there are very few manufacturing or industrial sectors better placed to exploit this shift than compressed air.

In an industry where safety and high productivity are critical, a greater level of computerisation can ensure all of these areas are fully optimised, plus a few more such as energy efficiency and sustainability.

Correct diagnosis is a problem cured

The key to the success of a compressed air smart factory and its associated industries lies in the receipt of reliable diagnostic information and data from system, which can be delivered via remote diagnostics tools from any location in the world to any person or digital device so that they can act upon the messages displayed.

The operator of a compressed air system no longer has to be on site to monitor and control the status. They can perform this from anywhere via an iOS or Android device. Data can include status, maintenance messages, temperature and pressure, which would all be digitally transmitted and displayed for them to view, analyse if necessary, and act upon. All of this would be much more timely and swift than having to react to the unexpected. 

Far from completely removing the human element, the digital conversation between devices either alerts specialists to fix an issue, or keeps them free to perform other tasks.

It’s not just faults that can be recorded; an effective diagnostics tool, such as the BOGE airstatus web portal can also condition monitor and observe up to 32 components from anywhere in the world and store data for up to 24 months, so standard maintenance work can be pre-arranged at a time that does not have an adverse effect on production targets. The BOGE airstatus web portal allows an operator to receive and view all of this information and status messages from a computer or in the cased of the APP, to a smart device such as a smartphone or tablet, via GSM, GPRS or real-time Ethernet.

Understanding advantages and reaping rewards

For an industry such as compressed air that demands maximum efficiency and productivity, early detection and reaction to a problem ensures that repairs can be carried out in a planned, co-ordinated fashion that either reduces or eliminates shutdown altogether. This in turn decreases disruption to the manufacturing cycle, and also the usual maintenance costs that are incurred when there is an unforeseen breakdown of machinery. 

Remote and regular monitoring also allows for maintenance to be scheduled in rather than then performed in an ad hoc manner.

The introduction of a more digitised industrial process also paves the way towards a more energy efficient way of working without putting a dent in the bottom line. Greater computerisation allows people to be more mindful of how and when they use resources, thus creating a more ethically minded and sustainable society. Compressed air system users will certainly reap the benefits. Historically, inefficient or faulty air compressors have been notorious for wasting energy, but moving to a computer-controlled system of early detection offers huge potential to save energy and cost, as well as reducing waste.

Fourth revolution

This communication evolution is all part of what is commonly being referred to as the fourth industrial revolution. Escalating at a very fast rate, it’s vital that compressed air operators remain unafraid and in charge of the smart devices that are controlling the smart factories. By remaining in the driving seat while relinquishing monitoring power to a smarter device, humans will remain in the best position to get utmost efficiency and profitability from their machines.