Com­plete life­cy­cle ef­fi­ciency

DEMM Engineering & Manufacturing - - INTERNET OF THINGS - DE­TAILS, KAESER COM­PRES­SORS NZ, WWW.KAESER.CO.NZ E-MAIL: INFO.NEWZEALAND@KAESER.COM

What was once sim­ply a dream is now be­com­ing re­al­ity: new prod­ucts and ser­vices in the com­pressed air pro­duc­tion sec­tor are bring­ing In­dus­try 4.0 to life, says Kaeser.

Many be­lieve that we are now en­ter­ing the fourth in­dus­trial rev­o­lu­tion – In­dus­try 4.0 – where man­u­fac­tur­ing is led by cy­ber­phys­i­cal sys­tems.

Cy­ber- phys­i­cal sys­tems nor­mally com­prise of com­put­ers, net­works and phys­i­cal pro­cesses all in­te­grated to­gether. Send­ing in­for­ma­tion back and forth, the com­put­ers and net­works mon­i­tor and control the phys­i­cal pro­cesses, with feed­back from the phys­i­cal pro­cesses also im­pact­ing the sub­se­quent com­pu­ta­tions.

Us­ing cy­ber- phys­i­cal sys­tems al­lows man­u­fac­tur­ers to merge the phys­i­cal world with the vir­tual world and is some­times called the In­ter­net of Things (IoT).

WELCOME TO I NDUSTRY 4.0

When it comes to com­pressed air pro­duc­tion, in­tel­li­gent con­tract­ing model- based so­lu­tions, such as Sigma Air Utility, have been avail­able for quite some time. Com­bin­ing highly ef­fi­cient, in­no­va­tive prod­ucts with in­tel­li­gent en­gi­neer­ing and pre­dic­tive main­te­nance ser­vices, has in essence laid the foun­da­tion for In­dus­try 4.0 in the com­pressed air pro­duc­tion sec­tor. Now, thanks to new com­mu­ni­ca­tions tech­nolo­gies and ser­vices, such com­pressed air con­tract­ing mod­els are be­ing fur­ther re­fined and im­proved.

These so­lu­tions not only in­clude the com­po­nents of the com­pressed air sta­tion itself but also the many ser­vices ren­dered through­out its life­cy­cle such as op­ti­mal com­pressed air sup­ply sys­tem de­sign and reg­u­lar main­te­nance, not to men­tion en­ergy man­age­ment, the plan­ning of new sys­tems and ex­pan­sion of ex­ist­ing ones.

To take full ad­van­tage of their In­dus­try 4.0 ca­pa­bil­i­ties, com­po­nents must sup­port ef­fi­cient control in com­bi­na­tion with other ma­chines and pro­vide real-time op­er­at­ing data for mon­i­tor­ing pur­poses, as well as be­ing able to for­ward all rel­e­vant data to mas­ter control sys­tems.

Mod­ern com­pres­sors and com­pressed air treat­ment com­po­nents are there­fore equipped with in­ter­nal con­trollers based on in­dus­trial PC tech­nol­ogy which are able to pass data to a mas­ter control sys­tem via in­ter­faces such as Eth­er­net. The data gen­er­ated by the com­po­nents are first de­liv­ered to a mas­ter con­troller, such as the Sigma Air Man­ager 4.0 (SAM 4.0).

This con­troller acts as an ac­tual man­age­ment sys­tem for the com­pressed air sta­tion as well as a cen­tral node for the for­ward­ing of rel­e­vant data.

Ad­vanced man­age­ment sys­tems must meet de­mand­ing chal­lenges. They must be ca­pa­ble of ef­fi­cient and pre­dic­tive com­pres­sor control, tak­ing into ac­count a range of con­tribut­ing fac­tors, such as switch­ing and control losses. They must also be able to han­dle the vol­ume of in­com­ing data from the com­pres­sor sta­tion, com­pil­ing it ap­pro­pri­ately and send­ing it on to a su­per­or­di­nate ser­vice cen­tre.

MUL­TI­PLE LEV­ELS OF FUNC­TION­AL­ITY

These ad­vanced con­trollers al­low for vary­ing l evels of i nvolve­ment by ex­ter­nal ser­vice providers so op­er­a­tors can choose to per­form the eval­u­a­tion and ser­vic­ing of the sys­tem them­selves. In this case, the mas­ter con­troller is in­te­grated into the op­er­a­tor’s control sys­tem.

Al­ter­na­tively, op­er­a­tors can opt for a con­ven­tional ser­vice agree­ment. Or, in or­der to take ad­van­tage of fur­ther ser­vices, they can choose a pre­dic­tive main­te­nance ser­vice model, and then there’s the op­tion of re­mote di­ag­nos­tics. Real-time mon­i­tor­ing of a full range of sen­sor data en­ables im­me­di­ate re­sponse to un­usual op­er­at­ing sta­tuses and lays the foun­da­tion for op­ti­mal ser­vice plan­ning. Thanks to in­tel­li­gent pre­dic­tive tools, op­er­a­tors will al­ready know what’s going to oc­cur in the com­pressed air sta­tion.

Such ad­vanced so­lu­tions rep­re­sent the high­est level of op­er­a­tional re­li­a­bil­ity and of­fer some key ad­van­tages; op­er­a­tors are re­leased from the bur­den of per­form­ing main­te­nance and ser­vice on the com­pressed air sta­tion, out­sourc­ing al­lows cus­tomers to benefit from the very lat­est knowl­edge and ex­per­tise in the com­pressed air tech­nol­ogy sec­tor and it de­liv­ers clear- cut cost ad­van­tages. More­over, real-time mon­i­tor­ing gives the ser­vice provider a de­tailed pic­ture of what is hap­pen­ing in the com­pressed air sta­tion and pe­riph­eral equip­ment.

AL­WAYS UP TO DATE

If ir­reg­u­lar­i­ties oc­cur, a no­ti­fi­ca­tion is au­to­mat­i­cally sent to the ser­vice provider; this then trig­gers pre­ven­ta­tive mea­sures. So­phis­ti­cated al­go­rithms fur­ther al­low spe­cial­ists to pre­dic­tively es­ti­mate whether po­ten­tial dis­rup­tions may oc­cur in the near fu­ture and if so, to take ap­pro­pri­ate pre­ven­ta­tive mea­sures.

Such needs- based main­te­nance cuts costs and pre­vents sys­tem fail­ures. Op­er­a­tors en­joy sig­nif­i­cantly en­hanced re­li­a­bil­ity, cost- op­ti­mised ser­vic­ing, longer sys­tem ser­vice life and assured spe­cific power. How­ever, the ben­e­fits ex­tend far be­yond the guar­an­teed high avail­abil­ity of their com­pressed air sys­tems. Life­cy­cle costs can be re­duced by up to 30 per­cent as the spe­cial­ist can ad­just the en­ergy per­for­mance of the com­pressed air sta­tion ac­cord­ing to de­mand.

And, the use­ful­ness of the data does not end there! Through anal­y­sis of how prod­ucts be­have dur­ing dis­rup­tions the ser­vice provider is able to iden­tify pat­terns and causes of mal­func­tions in or­der to ul­ti­mately de­velop and op­ti­mise the com­po­nents and fur­ther en­hance op­er­a­tional re­li­a­bil­ity in the fu­ture.

EN­GI­NEER­ING BASE: THE I DEAL PLAN­NING TOOL

To take full ad­van­tage of a com­pressed air sys­tem’s In­dus­try 4.0 ca­pa­bil­i­ties an­other key ser­vice is re­quired: proper plan­ning. This in­volves gath­er­ing all the pa­ram­e­ters and com­po­nents rel­e­vant for com­pressed air pro­duc­tion in a plan­ning tool, such as En­gi­neer­ing Base, which al­lows op­er­a­tors to sys­tem­at­i­cally track ev­ery as­pect of their com­pressed air sys­tem through­out its en­tire life­cy­cle. This also ul­ti­mately serves as the foun­da­tion for in­tel­li­gent ser­vices such as pre­dic­tive main­te­nance.

En­gi­neer­ing Base is a pow­er­ful tool that records and main­tains data, stor­ing it se­curely and en­sur­ing it is al­ways up to date thanks to real-time trans­mis­sion and eval­u­a­tion.

In terms of plan­ning new sys­tems, it el­e­vates op­ti­mal de­sign of the com­pressed air sta­tion to a new level. The data is also an ideal re­source when op­ti­mi­sa­tion mea­sures are to be im­ple­mented and it saves time when it comes to ex­pand­ing or re­con­fig­ur­ing the sys­tem.

CON­CLU­SION

Op­er­a­tors that choose to take ad­van­tage of In­dus­try 4.0 com­pressed air tech­nol­ogy so­lu­tions will en­joy highly ef­fi­cient com­po­nents and all of the ben­e­fits of pre­ci­sion plan­ning. Yet the whole pack­age is far greater than the sum of its parts: a state- ofthe-art sys­tem in terms of en­ergy ef­fi­ciency; which in turn trans­lates into the most sig­nif­i­cant re­duc­tions in en­ergy costs; not to men­tion in­no­va­tive ser­vices like pre­dic­tive main­te­nance, which re­duce other ser­vice costs through­out the sys­tem’s en­tire life­cy­cle.

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