FEATURE COMPRESSED AIR
INDUSTRY 4.0-READY COMPRESSED AIR SYSTEMS
a large number of networked features that enable one machine to act as the master for a wider network while coordinating the operation of multiple machines via a fieldbus. Meanwhile, built-in Internet links allow operations and maintenance staff to monitor overall system performance remotely using a web browser or mobile app. These features are provided as standard in all BOGE air compressor control systems, but for larger, more complex systems, next generation networked controllers called airtelligence provis 2.0 continually and automatically monitors a compressed air system, anticipates changes in demand and operates proactively to activate the optimum combination of compressors and other components to fulfil that demand. The system can also monitor the running hours of different system elements and adjust their usage to extend the time required between maintenance intervals. The German drinks manufacturer,
today, enabling those that aspire to this ‘brave new world’ of manufacturing to grasp the opportunities. Mark Whitmore, from BOGE, describes how existing compressed air technology can be integrated into the Industry 4.0 manufacturing environment...
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In a recent survey of its customers, one UK industrial services company found that there is a clear differentiation between believing in the potential of Industry 4.0 and actually implementing it. Where emerging technology is concerned, a gap in know-how is understandable, but with established technology this is somewhat of a surprise. In compressed air, users can easily take advantage of modern system management and control to meet the requirements of the smart factory.
NETWORKED MACHINES Take the example of a system comprising one large, fixed-speed compressor to provide the factory’s base-load, alongside a smaller variable-speed machine that is brought online to meet peaks in demand. For such multiple compressor installations to work efficiently, they need to be networked. Modern compressor control systems have
12 DECEMBER/JANUARY 2018 | FACTORY EQUIPMENT
he smart factory may be a far-off hope for many manufacturers but the technologies are here
Nordbrand Nordhausen, is currently using this system on three frequency- controlled type SF 60 BLUEKAT catalytic compressors. It does so to determine its total network volume and trends, initiating appropriate machine start-ups ahead of predicted demand peaks. This enables the company to maximise efficiency and, therefore, reduce its energy consumption.
THE IMPORTANCE OF DATA SHARING Today, many BOGE compressor installations have a secure Internet link that allows them to share operating data with the company’s analytics centre in Germany. The links send around 70 data points a second on pressure, temperatures, motor speeds and energy consumption collected from sensors around the machine. This data is assessed by ‘learning’ algorithms that establish the plant’s normal operating conditions and send alerts to the analytics centre staff if there is an excursion from that norm – enabling appropriate action to be taken to correct any issues. Significantly, this monitoring is a two-
way process. As it builds its understanding of machine performance, the algorithm can update parameters set within the machine controller; the machine is then able to alert on-site
operators to conditions that might suggest a developing problem. BOGE is also making use of augmented reality spectacles that provide onsite maintenance staff with the virtual support of remote experts who are able to view what a maintenance technician is seeing in real time and provide guidance as appropriate.
THE PROMISE OF INDUSTRY 4.0 Industry 4.0 uses a wide range of monitoring and reporting tools, allowing system operators to see and understand energy consumption, system reliability and available capacity at the touch of a button. Machines connected to BOGE’s analysis system, for example, are given an annual report detailing the cost of compressed air system production, how demand varies over time and how the operating efficiency of the system is influenced by those demand variations. The data from these reports shows how changes to system design or configuration might deliver efficiency or performance improvements, particularly as usage patterns change. Industry 4.0 technologies can also use these sets of data to drive continuous improvements in the machines themselves. Online monitoring builds a detailed picture of the user’s real-world usage; feeding data into a simulation application enables the potential impact of changes in machine operation to be determined, as well as suggesting mitigating actions. BOGE is currently using smart
technologies in its own manufacturing operation to improve its product customisation capabilities. The use of 3D printing, for example, enables redesigned components to be rapidly manufactured for specific customer requirements based on that customer’s usage data and system performance simulations. The approaches described here are not
tomorrow’s technology - they are real product and service offerings, driven by Industry 4.0, and are now available. With that in mind, it is time to embrace Industry 4.0 and build it into manufacturing operations to achieve significant benefits that have previously been beyond reach for most businesses.
BOGE
uk.boge.com/en
/ FACTORYEQUIPMENT
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