Compressor connectivity has become an essential part of high-quality air systems. The latest compressors are packed with intelligent sensors that communicate the status of different components, measure heat levels, verify air output, and much more. These sensors often operate within a range of industrial IoT frameworks to provide detailed analytics in real-time.
Sophisticated remote data monitoring software allows plant managers to collect disparate data, analyse it, and make informed decisions. Connected compressors, whether using cellular connectivity from mobile devices or secure Wi-Fi, enhance real-time monitoring and control systems. These systems often integrate with supervisory control and data acquisition (SCADA) or programmable logic controllers (PLCs) to further streamline operations.
Smart factories that embrace technological advancements to achieve maximum uptime do not get left behind. Improved system optimisation leads to sustained performance, benefits from automated diagnostics and rapid reporting, and lower operating costs and reduced downtime. For example, Atlas Copco’s SMARTLINK platform provides these benefits while ensuring compatibility with existing industrial systems.
The Evolution of Compressor Connectivity
Previously, compressors only offered a small display confirming operational status. Occasional alerts popped up on the display, and audible alarms sounded. Staff needed to be constantly on hand to resolve issues as they arose. No advanced indication of a problem, like a component with a deteriorating performance, was provided.
Industry 4.0 and the Internet of Things (IoT) have changed air system management. Interconnected systems continually monitor performance and energy use. Monitoring software intelligently reviews incoming smart sensor data for the entire compressed air system. Air compressor connectivity allows managers to use cloud platforms and advanced real-time data monitoring for improved system optimisation.
Using centralised control systems, managers immediately see reduced performance or alerts about failing components. Remote management allows staff to leverage technology without relying on intuition and manual interventions. Modern connectivity systems also allow integration with energy recovery solutions to reuse heat generated by compressors.
Key Components of a Connected Compressor System
Remote Monitoring and Control Systems:
Enabling remote monitoring and control is vital for the manufacturing sector and other demanding industries. Control systems automate responses to monitor issues, improve uptime, and reduce costly breakdowns.
Monitoring software, accessed from the cloud, depends on sensors fitted throughout air compressors to provide data. This connectivity revolutionises energy efficiency, air pressure management, and sustained flow rates. Atlas Copco’s SMARTLINK solution allows secure access to these systems from multiple devices.
Predictive Maintenance:
Monitoring temperature variations, pressure levels, unexpected equipment vibrations, and other aspects is beneficial. Predictive maintenance, based on declining component performance, reduces system downtime.
Analytical software, like Atlas Copco’s SMARTLINK, gives managers enhanced tools to anticipate upcoming issues before they cause expensive breakdowns. Maintenance is planned around the necessary air production needs rather than as an impediment to it. This aligns with ISO 50001 standards for energy management.
Integration with Industrial Systems:
Existing industrial control systems, like supervisory control and data acquisition (SCADA) and programmable logic controllers (PLCs), integrate with Atlas Copco’s connectivity solution. This permits data sharing across multiple systems to get a big-picture overview of operational performance across the plant.
Enhanced performance visibility is essential for optimising systems, maintaining productivity, and reducing running costs. These systems also enhance the operational lifespan of connected equipment.
Energy Optimisation:
Estimates suggest air compressor systems use at least 12 per cent of the global industrial energy supply. Some systems consume far more. Reducing costs is always top of mind. Advanced connectivity solutions allow managers to access real-time data, efficiently manage performance, and lower energy consumption.
Intelligent control systems guide operator responses to get the most from the equipment at the lowest operating cost. This includes managing pressure levels, flow rates, and other aspects for greater energy optimisation. Atlas Copco’s variable speed drive (VSD) technology further ensures compressors operate efficiently at varying loads.
Benefits of Implementing Compressor Connectivity
Better Efficiency
Connected compressors feed operational data into monitoring systems that help reduce energy consumption. Most factory managers find they can cut power usage by 10–15% after implementation.
The system identifies pressure drops between shifts and adjusts output accordingly.
Less Downtime
Breakdown prevention comes through the early detection of problems. Sensors pick up issues like bearing vibration or temperature changes before they cause stoppages.
A Birmingham metals firm avoided a three-day production halt when their system flagged excessive motor temperature two weeks before their scheduled maintenance. The repair took just four hours during a planned weekend break.
Practical Maintenance
Service intervals become based on actual usage rather than calendar dates. For many sites, this means fewer unnecessary filter changes and more attention to genuinely worn components.
Engineers carry service records on tablets, with access to the machine’s complete history. Most systems store data for at least five years, making HSE inspections more straightforward.
Cost Reductions
For mid-sized compressors, energy savings typically range from £2,000–£8,000 annually. The payback period for retrofit sensors and basic connectivity packages averages 18 months.
Retrofit options work on most machines built after 2005. Depending on complexity, these often cost between £600 and £1,500 per compressor.
Environmental Benefits
Lower energy use means reduced carbon emissions. For a typical 90 kW compressor running 60 hours weekly, connectivity improvements can cut CO2 output by around 12 tonnes yearly.
Heat recovery systems linked to connected controls can redirect waste heat to building warming during winter months.
Safety and Compliance
Automatic logging makes F-Gas compliance and pressure equipment regulations easier to manage. Systems can set operating parameters that prevent machines from exceeding safe limits.
Automated shutdown triggers activate when unsafe conditions occur. Most installations link to plant management systems that provide oversight across multiple pieces of equipment.
Use Cases and Applications
Manufacturing:
Manufacturing plants often run 24/7. Connected compressors within a compressed air system must operate with minimal downtime.
Using predictive maintenance, industries such as electronics, automotive, and food processors keep the production line humming.
Healthcare:
Patient safety is a critical factor for healthcare facilities. Medical labs and hospitals depend on compressed air to maintain operations. Service continuity is vital.
In these sensitive environments, monitoring systems also ensure continued regulatory compliance.
Oil and Gas:
The oil and gas industry benefits from monitoring software to verify performance at remote locations.
Ongoing performance is improved through real-time monitoring. Downtime is incredibly expensive in this industry. Alerts notify managers and maintenance teams about what needs fixing fast.
Construction:
The construction industry is fond of portability. Smaller, portable air compressors are often used on work sites.
Remote monitoring, adjusting performance parameters for energy savings, and early notification of maintenance issues are invaluable.
How to Choose a Connectivity Solution
Compatibility:
Any compressor connectivity system must be compatible with existing equipment. This applies to compressors, monitoring platforms, and advanced control systems.
Atlas Copco’s SMARTLINK system is compatible with numerous control systems to facilitate improved oversight, monitoring, and control.
Scalability:
Modern connected systems must be able to grow with the business. Busy companies add new systems yearly. Connected systems must be adaptive, not restrictive.
Cost:
Two cost-related aspects are relevant to choosing a connected system:
- The initial cost of deploying the connectivity features.
- Subsequent cost savings from reduced maintenance expenses, downtime losses, and energy savings.
Service Providers:
Not all service providers offer the same deal. A provider must support both the supplied software and hardware. They must have experience with connected compressor monitor systems, IoT, and cloud solutions.
Ease of Use:
Overly complex systems cause difficulties for compressor operations. Systems must be easy to configure and use. An understandable interface allows managers to learn it quickly and best use all the features.
Cybersecurity:
Be aware of cybersecurity. All connected systems must be protected from the spectre of potential cyberattacks.
Future Trends in Compressor Connectivity
Predictive Analysis Systems
Machine learning tools are beginning to appear in compressor management. These systems spot patterns in operational data that humans might miss. A Yorkshire textile mill recently installed sensors that detected a 0.2°C rise in bearing temperature over three weeks – a small change signalling an alignment problem.
Most current models require a manual response to alerts. Next-generation systems from manufacturers like Atlas Copco and CompAir will adjust settings automatically when minor issues arise. The technology relies on thousands of data points from similar machines across different sites.
Cross-Platform Compatibility
Compressor controls now work with standard factory systems. Many operators need their air system to communicate with other equipment through common protocols like Modbus or OPC UA.
At a Norfolk food processing plant, maintenance staff monitor their three Ingersoll Rand compressors from the same screens that display their refrigeration systems. The setup required three days of integration work but eliminated the need for separate monitoring stations.
Remote Access Improvements
Remote monitoring is evolving beyond basic alerts. Technicians at a Glasgow engineering firm use secure access points to change pressure settings across five sites without travel. They adjusted output at three locations during the December freeze, saving approximately £4,300 in energy costs.
Hardware requirements remain modest – most systems run on standard industrial PCs with 8GB RAM and stable internet connections. Backup cellular connections provide redundancy when primary systems fail.
Automated Compressor Management
Compressors are beginning to self-manage within set parameters. A Midlands automotive components factory uses load-sharing controllers that balance output between four units based on air demand, cutting energy use by 17% compared to fixed rotation.
These systems make hourly micro-adjustments that would be impractical for human operators. Most require initial setup periods of 4–6 weeks while they gather baseline performance data.
Energy Monitoring Tools
New regulations are driving better energy tracking. Compressor control systems now feature carbon calculators that report usage for sustainability reporting.
A Manchester printing company uses connected monitors to provide monthly CO2 figures for ISO 14001 compliance. Their system includes basic air leak detection that flags unusual pressure drops during off-hours.
Affordable Upgrades
Retrofit options are improving for older machines. Basic connectivity kits for pre-2010 compressors cost between £800 and £1,200 and include pressure transducers, temperature sensors, and control interfaces.
A Coventry metal fabricator fitted five older compressors with aftermarket monitoring equipment rather than replacing them. The £5,400 investment is expected to extend machine life by 3–5 years while providing most of the benefits of newer models.
Getting Started with Compressor Connectivity
Upgrading to Connected Compressors:
Can existing compressors be upgraded to benefit from connectivity features or are replacement compressors the answer? A proper evaluation is the key.
Initial Setup:
A reliable service provider like J LL Leach can install tracking sensors, data monitoring systems, and upgraded control units to usher compressors into the connected era.
Upgrading existing infrastructure, such as SCADA or the PLC systems, is often possible.
Ongoing Maintenance:
Regular, scheduled system checks are essential. These ensure reliable connectivity and optimal settings and verify whether there are any safety issues.
Troubleshooting:
Troubleshooting is a useful skill. It is required to manage sensor malfunctions, intermittent loss of connectivity, or occasional software glitches. Technical support from a dependable supplier addresses all these potential issues.
Training:
Effective training is necessary to provide staff with a complete understanding of connected compressor systems. Post training, they can understand data analysis reporting and how to troubleshoot smaller problems. Ongoing refresher courses ensure teams stay updated with evolving technologies.
Compressor connectivity delivers remote monitoring capabilities using centralised control systems. Real-time monitoring allows plant managers to improve cost efficiencies while minimising downtime.
Improved notification systems alert managers sooner to problems. Remote monitoring and automated system responses free up operators from being constantly on-call.
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FAQ
What are the main advantages of compressor connectivity for industrial settings?
Connectivity helps control energy use and spot problems early. A Bradford paper mill saved about £12,000 yearly after connecting their Atlas Copco GA75 to monitoring equipment. The system flagged pressure drops during shift changes that wasted air.
Most setups include basic sensors for temperature, pressure, and power draw. These feed into standard industrial computers that cost around £800–£1,200 to install. Data storage typically needs about 5GB per compressor annually.
Can older compressors be upgraded with connected technology?
Yes. Compressors built after 2000 usually accept retrofit equipment. A Newcastle brewery added basic monitoring to their 15-year-old HPC unit for £970 plus installation. The work took a full day and required an additional pressure transducer at the tank.
Older machines with mechanical controls need interface modules to convert analogue signals. These cost about £300–£500 each and connect to standard industry protocols like Modbus RTU.
Is remote compressor connection secure and reliable?
Security varies by system. Most UK installations use standard VPN connections or mobile data with firewalls. A West Midlands engineering firm monitors seven compressors across three sites using a cellular backup when their main connection fails.
Reliability depends partly on hardware quality. Better systems include uninterruptible power supplies for the monitoring equipment. These add about £200–£300 in installation costs but prevent data loss during power fluctuations.
Maintenance staff typically need training sessions of 4–6 hours to understand common dashboard indicators and alerts. Simple password management remains a common weak point in otherwise well-designed systems.
