Compressed air is an integral component in many industries and is often considered to be the fourth utility. It is used to drive and control machinery serves as a source of power, and has been in use for a long time. It is used in manufacturing, automotive industries, food and beverage industries, and even in mining and construction.
But they’re also highly complicated and are often the least energy efficient systems in industries. With IoT and remote monitoring, companies can make these more efficient and reduce their cost of operation. They can also use IoT-based air quality monitoring systems to ensure that the end product of these systems is up to the required standards. In this article, we are exploring how the internet of things can change and improve the way compressed air management systems are used in industries.
What is IoT and Industry 4.0?
IoT or the Internet of Things is a system of sensors and actuators connected to the internet; it is a technology with which you can connect everything and anything to the internet. It uses components that collect data (sensors) and make changes in the environment (sensors) to allow granular control over industrial processes. The technology powers industrial automation, cutting-edge analytics, to artificial intelligence.
Internet of Things represents a radical shift in how processes are controlled; it offers a level of data and visibility that was previously not available. And this shift is referred to as the fourth industrial revolution or Industry 4.0. Like the first industrial revolution powered by the invention of the steam engine, Industry 4.0 represents a change in how various industries manages their processes and workflows.
Industry 4.0 is about automation, AI, machine learning, and smart and interconnected devices. The internet of things and the visibility it offers allow stakeholders and managers to make data-driven decisions. It pushes for a digital transformation of industries and creates smart factories and organizations.
And the same force can improve how compressed air management systems work in industries making those systems more efficient, long-lasting, and cost-efficient.
How can you use IoT for compressed air management systems?
Compressed Air Management systems are complex with many components and with lots of variables affecting the output. In a compressed air system, the air is first collected by an inlet and then compressed by a compressor. The compressed air is then dried and stored in tanks. The air is further distributed through pipes to reach the final location where it is used. Depending on the specific application, each of these components is carefully chosen; for example, the food and beverage industry uses air compressors without oil so as to not contaminate the end product.
By using IoT sensors and actuators, the operating personnel gets more insights and visibility into the system. Operators can monitor the temperature of the air, its moisture levels, and the condition of filters, compressors, and distribution lines remotely. If the air quality monitoring systems show issues, maybe the quality of air is not up to the required standards, the operators can look at the equipment data to figure out where the issue is. Operators get data from the entire set of machinery in real-time and can in turn control them without being physically present near them.
Connected devices can also be further automated to a large extent. If any of the parameters go out of the allowed range, the system can automatically correct itself, or if required, alert the operators. For example, if the moisture levels go above a threshold, the filters may have to be changed or if the system is not delivering the required pressure, there may be a leak somewhere. In these situations, the system can be configured to automatically alert the operators.
IoT remote monitoring also empowers organizations to shift from reactive and preventive maintenance and move to predictive maintenance strategies. The data from the connected device regarding the vibrations, the sound, or the heat it produces can predict when a piece of equipment may need maintenance. And organizations can reduce unnecessary preventive maintenance without the risk of unpredictable downtimes.
What are the advantages of IoT remote monitoring in compressed air management systems?
- IoT remote monitoring offers more visibility into compressed air management systems: Earlier, even the most skilled operators could only know so much about the state of their equipment. If the machinery failed or was not producing the desired output, in most situations technicians would have to go through section by section to diagnose the cause. But with IoT remote monitoring, the sensor data offers a previously unavailable view into these systems. Organizations have a better picture of the status of their equipment and plan their budget for maintenance, repairs, and upgrades through the compressed air monitoring systems.
- Remote monitoring reduces the cost of operation for compressed air management systems: Without remote monitoring and the data it offers, most organizations are reliant on preventive maintenance strategies. And this means conducting repairs and maintenance at regular intervals even when the machines appeared to be fine. The other choice was to run the machines till they break and then fix it. But with remote monitoring and predictive maintenance, organizations have the best of two worlds and the cost savings associated with it.
- Remote monitoring improves employee safety: Compressed air management systems can present unknown safety risks. There are many components of air compressor systems which if they fail can cause injury to operating personnel. But with remote machine monitoring, organizations can mitigate this risk significantly
- IoT remote monitoring reduces the possibility of unscheduled downtime: Unscheduled downtime can be costly; it leads to loss of productivity, delayed deliveries, not to mention repair costs. As discussed earlier, preventive maintenance with Industrial IoT remote monitoring can reduce the possibility of unscheduled downtime.
Interested in IoT remote monitoring for your compressed air management systems?
Bridgera is a world leader in IoT remote monitoring for industrial systems. We have worked with organizations all over the globe to improve their processes with the internet of things. Reach out to us for a free consultation on how remote monitoring can improve your compressed air systems.
