Compressed Air Monitoring
Last updated
Last updated
Understanding the usage of compressed air within certain manufacturing processes can be critical to determining the performance and efficiency of that operation.
When integrating machines that use compressed air as part of their process, we have 3 methods of acquiring data signals:
By monitoring the signal to the pneumatic valve, we are able to determine when compressed air is being commanded by the PLC and therefore the productive status of the machine.
By using the typical flow rate at each value, we can estimate the amount of compressed air used.
When using this option, we recommend it is used in conjunction with method 3.
Pros: Simple to implement.
Cons: The amount of compressed air used can only be approximated using this method.
What's required: It is normally quite straightforward to find the actuation signal inside the control cabinet of the machine, however a electrical schematic can be helpful in this process. No additional hardware is required for this option.
It is possible to measure the flow of compressed air through the machine using accurate and dedicated metering devices (e.g. ).
Pros: Detailed information on the amount of air consumed at short, detailed time intervals.
Cons: More effort is required to implement compressed air meters on each machine.
What's required: If not already in the machine, a compressed air meter is required for each machine being monitored in this way. The typical flow rate and fitting type used is required to determine the correct compressed air meter to use.
By using an energy meter on the compressor itself, we are able to determine when it is running and the exact amount of energy consumed when providing the compressed air.
Pros: Information on exact amount of energy consumed in the deliver of compressed air to assets.
Cons: The compressor is normally shared between several machine and, because of the air receiver tank, its operation does not relate exactly to when a downstream machine is consuming air. Therefore does not give exact information on machine productivity.
What's required: A can be used for this option. The maximum current draw and number of phases used by the machine is required to determine the correct energy meter to use.
