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.
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.
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.
Table of Contents
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.
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.
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.
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.
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.
Benefits of Implementing Compressor Connectivity
Improved Efficiency:
Remote monitoring using real-time data improves the management of air compressor systems – consequently, the costs of air production decline.
Many features are automated, responding to sensor outputs and other indicators. This reduces direct, continual oversight.
Reduced Downtime:
Unexpected maintenance issues and costly repairs are often preventable. Rather than suffer from a flurry of breakdowns, predictive maintenance systems alert managers to early signs of trouble.
Rapid component replacement or earlier-than-planned maintenance helps avoid extended downtime. Real-time mobile app notifications and cloud system alerts keep maintenance personnel fully apprised. This avoids delays in resolving additional issues before they become more significant problems.
Cost Savings:
Operational expenses are managed by balancing energy usage with air system needs. Fewer system downtime episodes reduce production losses and the need to run faster to compensate.
Also, predictive maintenance catches problems sooner. Costly emergency repairs are largely avoided.
Sustainability:
Using less energy to produce a similar pressurised air output helps the environment. It lowers the carbon footprint, boosting environmentally friendly credentials.
Also, it supports strict environmental regulations that require companies to operate greener.
Compliance and Safety:
Compressor performance is monitored and logged for future analysis. Connected control systems help smart factories and other operations comply with industry standards.
Workplace safety is also important. Enhanced safety mechanisms disable equipment when sensors indicate a serious issue. Operators are immediately alerted, too.
Are you interested in advanced connectivity solutions? Talk with our air system connectivity experts at J LL Leach.
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
Artificial Intelligence (AI) and Machine Learning:
What is next for air system connectivity? AI and advances in machine learning are gaining fast. These will better predict maintenance needs and further improve automated performative system adjustments.
Enhanced IoT Integrations:
Smart factories are becoming cleverer by the day. IoT usage is growing and operators need to take it in their stride. Advanced integration with existing industrial systems improves control and oversight.
Autonomous Maintenance:
Autonomous compressors are almost upon us. Hands-off maintenance and automated performance tweaks are ideal for businesses in remote locations or with limited staffing.
Cloud-Based Analytics:
As time goes on, analytical tools offer sophisticated reporting and more meaningful insights. Cloud technology allows access to this information flow from anywhere. This enhances system performance, reduces energy demands, and minimises potentially burdensome maintenance.
Sustainability Goals:
Expect further strides in connectivity. These aim to reduce industrial waste and improve energy efficiency. This helps businesses meet their sustainability goals.
To learn about future trends, please discuss the possibilities with our team at J LL Leach.
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.
Conclusion
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.
Stay caught up with business connectivity. Save time and resources by upgrading your air system. Please get in touch to learn more.
