FEATURE PNEUMATICS & HYDRAULICS KEEPING THE FUTURE AT BAY
Every technology will one day become outdated. However, if it is designed to be continuously upgraded, it will continue to run at maximum energy efficiency each time it is retrofitted with improved components. Mark Whitmore, general manager of compressed air specialist BOGE explains
S
econd-guessing the future direction of technology is hard – and trying to
do it while attempting to predict industry trends is even harder. One constant headache for manufacturers is to wonder how long their new technology will stay that way, and not be superseded by the latest upgrade or competing product. Although suppliers like to describe
their products as future-proof, the phrase is much abused: no system is truly future-proof, and this is especially true of modern electronics, from smartphones to industrial automation. However, while a smartphone can be upgraded every two years, the same cannot be said of industrial devices such as motors or compressors. One way around the problem is to
invest in the latest industrial technology as soon as it becomes available; but this is impractical and can be astronomically expensive. Instead, it makes more sense to use equipment that is designed to be continuously upgraded. Here, the original design is flexible
enough to accommodate updates – rather than needing wholesale replacement – in order to extend operational life, even in the face of changing business requirements over a long period of time.
COMPRESSED ADVANTAGE A good example of this is the latest generation of High Speed Turbo (HST) compressors, which are designed to be continuously upgraded by retrofitting new parts as they become available. This extends the compressor’s operating life, while reducing maintenance intervals. It means that each machine will continue to deliver optimum performance – meeting current business needs and those of the future, such as complying with upcoming regulatory requirements The HST compressor already has an
innovative design: it is oil-free, runs at high speeds, is highly energy efficient
16 AUGUST/SEPTEMBER 2018 | IRISH MANUFACTURING
The BOGE HST compressor features an innovative design: it is oil- free, runs at high speeds, is highly energy efficient and runs extremely quietly, all with minimal need for maintenance
Continuous Improvement Programmes (CIP) tap into the emerging trend of Industry 4.0, where data is gathered, analysed and used to improve performance
and runs extremely quietly, all with minimal need for maintenance. It is based on two compact permanent magnet (PM) high-speed motors, each with a central rotor suspended on self- stabilising air bearings. Two titanium impellors – of different sizes and blade arrangements – are then mounted at each end of each rotor, allowing rotation speeds in excess of 100,000rpm. While this arrangement can slash energy consumption, there may still be room for improvement in future as new technology emerges. This is where the retrofits or upgrades
come in, as part of Continuous Improvement Programme (CIP), which frees owners from the expense, risk and inconvenience of compressor optimisation. Under a CIP, the manufacturer guarantees that, if a more efficient configuration becomes available during the lifetime of the installation, these changes will be made at no cost to the owner. For instance, if a key component – such as the impeller – is later redesigned and upgraded, it will be retrofitted into the turbo compressor to further boost its performance. Right now, CIP is based on series
components. Customers receive the most suitable parts and modules from a standard range. However, BOGE is refining this concept, with the aim of providing fully customised components that are engineered to meet the precise needs of each individual customer – and made using laser metal additive
manufacturing and other agile production techniques at the company’s smart manufacturing facility. The ability to carry out these planned upgrades will help to lengthen the overall working life of each HST compressor. This is a huge bonus for compressor
owners, because compressed air – which is vital to manufacturing – can be expensive (in some industries, air compressors are the largest single consumer of energy). Anything that can improve their efficiency will have a huge effect on the bottom line.
TAPPING INDUSTRY 4.0 CIP taps into the emerging trend of Industry 4.0, where data is gathered, analysed and used to improve performance. Here, CIP uses the internet-connected monitoring and diagnostic capabilities built into the compressor control system. Once installed, the compressor logs its own performance and energy consumption, and sends the information securely to the manufacturer. The company then evaluates the system’s efficiency, compares it with the best available performance, and sends regular reports to the customer, showing how well the system is working, and outlining changes that could boost efficiency. For instance, if the customer’s demand
for compressed air has changed significantly, the manufacturer may recommend upsizing or downsizing components as a way of raising efficiency. Similarly, if the manufacturer has developed a more efficient component since the compressor was installed, it can be retrofitted, if its simulation tools show that this will have a positive effect. While nothing is truly future-proof, the
CIP model of continual upgrades comes as close as possible to ensuring that a large capital investment goes as far as possible, and extends compressor lifetime while continuing to raise its efficiency.
BOGE Compressors
https://uk.boge.com/en / IRISHMANUFACTURING T: 0800 318104
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