FEATURE COMPRESSED AIR
COMPRESSORS THAT LOOK AFTER THEMSELVES
by Mark Whitmore, general manager at BOGE
Advanced digital controls allow a number of aftermarket service and support offerings
ADAPTING TO CUSTOMER NEEDS Perhaps the most innovative aspect of the new technology is how it allows the performance and efficiency of compressor installations to be improved over time. BOGE is developing a Continuous Improvement Programme (CIP), which uses proprietary simulation tools to evaluate the efficiency of each customer’s system in daily use, and compare it with the best available performance. The customer receives regular reports showing how well their system is working, and outlining any changes in operation or configuration that could deliver further improvements. If the customer’s compressed air
M
odern compressors are more reliable than their predecessors,
thanks to high manufacturing standards and new monitoring and control technologies. Despite this, many compressor installations still require routine maintenance to keep them working at their best, which for companies that simply want a secure supply of clean, compressed air means periodically lubricating, adjusting or replacing compressor components is seen as a necessary evil. Also, because compressed air installations are usually designed to meet specific levels of demand, operators must also accept that they might need to replace their compressors periodically as their usage patterns change. Now, however, these headaches could soon be a thing of the past with the introduction of a new generation of compressor technology, based on an innovative turbo drive system. This provides an oil-free supply of compressed air at continuous operating pressures from two to eight bar. This technology allows the footprint and weight of each compressor to be halved compared with conventional machines. Inside each turbo compressor are two
compact permanent magnet, high-speed motors each having a central rotor suspended on self-establishing air foil bearings. Two precision balanced titanium impellors of different sizes and blade arrangements are mounted at the end of each rotor. At rotational speeds typically in excess of 100,000rpm, air is drawn in
16 JUNE 2018 | FACTORY EQUIPMENT
via an intake funnel and a specially designed spiral casing to be boosted in three stages to reach operating pressures quickly and efficiently, with minimal energy losses thanks to the frictionless air bearing configuration.
REMOTE SUPPORT AND ANALYSIS The inherent simplicity and reliability of the turbo compressor design, combined with advanced digital controls, also allows the introduction of a number of aftermarket service and support offerings. These include smart remote monitoring capabilities, performance reporting, predictive maintenance and, from BOGE, a fast diagnostic and repair service. This approach gives companies real-time
remote access to their entire compressed air installation via a secure web-interface. These systems can be configured to send warning messages directly to a mobile device, and allow site management staff or maintenance teams to access information on the status and performance of the compressor from anywhere. The turbo compressor technology is
also modular. This makes it far simpler to carry out both routine maintenance and emergency repairs. In BOGE’s case, service engineers are equipped with all parts, in flight boxes for easy shipment, that enable work to be carried out on- site quickly. An extension of this service is the use of smart glasses, worn by an engineer on-site but connected to an expert based at BOGE’s technical support centre, to enable problems to be diagnosed and fixed quickly.
demand has changed significantly, the simulation tool will identify the need to modify or exchange compressor components to optimise performance. Similarly, if a more efficient component has become available since the installation of the compressor, the simulation tool will quantify the potential benefit of the upgrade. Where hardware changes are shown to be beneficial, engineers will contact the customer to schedule to replacement operation. This effectively eliminates – or at least reduces – the need to replace existing compressors as each machine can be ungraded as the needs of the end user change over time. This offering is based on series
components, with customers receiving the most suitable parts and modules from a standard range. Work is underway to refine the system by allowing the production of fully customised components, which are engineered to meet the exact usage behaviours of each customer. The alignment of turbo technology, the capture and analysis of data in real time, the advent of remote monitoring and control, plus the ability to custom engineer individual components at competitive unit cost, is driving radical change in the way in which companies meet their compressed air needs, making the process far more efficient, reliable and compliant with the best Industry 4.0 practices.
BOGE
www.uk.boge.com/en T: 0800 318 104
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