Efficient monitoring: Detecting compressor operating states based on current consumption
Optimal compressor performance for maximum efficiency
Goal of the project
In production, the proper functioning of a compressor is crucial. Its availability affects numerous production-related systems and processes. But how can you ensure that a compressor always operates optimally and that unplanned downtime is avoided? The answer lies in precisely recording the operating hours based on current consumption. As a rule, maintenance is carried out at regular intervals. Thus, progressive damage is detected too late and results in unplanned downtimes and high repair costs.
Targeted monitoring of the compressor’s current consumption, followed by further processing in the IIoT platform moneo, enables a shift from time-based to demand-based maintenance. This not only increases efficiency but also reduces costs. A current transducer is used to measure the current consumption. moneo visualises the different operating states and calculates the operating time spent in each state. This allows you to keep track of your compressor’s wear and react in good time.
Discover how our solution can transform your production processes and benefit from reliable and efficient compressor performance.
Avoid unplanned downtime with |
Prevent costly repairs |
Improve system utilisation |
|
Data-driven decision-making through |
Targeted monitoring of operating |
|
Benefits of compressor monitoring using current data
Monitoring a compressor’s current consumption offers numerous advantages that go far beyond simple operational monitoring. One key benefit is the ability to implement a demand-based maintenance strategy. By measuring the current consumption, the compressor’s operating states can be precisely determined and the operating hours within these states can be determined. This precise data allows maintenance activities to be planned and carried out based on demand, helping to avoid unplanned downtime and costly repairs. Another advantage is the ability to assess system utilisation. The collected current consumption data provides valuable insights into the capacity utilisation of the plant. If production increases, it becomes possible to determine whether the capacity of the existing compressor or compressors is still sufficient. In addition, analysing the available compressed air capacity enables well-founded decisions about potential energy cost savings through the use of different aggregate units.
Comprehensive monitoring and analysis of current consumption not only improves compressor efficiency but also optimises the entire production chain.
Value proposition
|
|
Energy optimisationCurrent consumption as an indicator: How to monitor the condition of your compressor
Compressors can operate in different operating states, with the load varying depending on the operating state of the individual components. In idle mode, the compressor is in a resting state and does not wear out, whereas in load operation it actively compresses air and is subject to greater mechanical stress. Conventional operating-hour tracking cannot distinguish between idle and load operation, which can lead to inaccurate maintenance schedules. The commonly used time-based maintenance approach does not take the actual wear of the wear parts into account. As a result, unnecessary maintenance may be carried out, or, in the worst case, maintenance may be performed too late, after damage has already progressed.
By monitoring the compressor’s current consumption, the actual operating hours within the different operating states can now be measured accurately. This precise data enables demand-based maintenance that reflects the compressor’s real utilisation and ensures that maintenance is performed exactly when it is required. As a result, the service life of compressor components is maximised while costs and energy consumption are reduced.
Automated transfer of your compressor data
ifm offers numerous interfaces for automated data transfer – from the sensor level to ERP or cloud systems. This allows the data to be securely collected and analysed in systems such as moneo. In moneo, it can be defined whether warnings or alarms automatically trigger an email notification or – via the SFI interface – directly initiate an order or a maintenance order in SAP. For applications where maintenance measures are necessary, it is advisable to plan the service call in good time.
System structure
- Current transducer (ZJF056)
- Signal converter for analogue 4...20 mA to IO-Link (DP2200)
- IO-Link master (AL1350)
How to install current monitoring for your compressor
For targeted monitoring of your compressor’s current consumption, ifm offers a wide range of automation components. You can use the IIoT solution moneo directly in the moneo Cloud.
The IO-Link masters connected to your system are linked to the server via an internal VLAN. The ZJF056 current transducer and the DP2200 evaluation system and display for analogue signals were chosen for this application.
The current transducer is used for any phase of the three-phase supply line to the compressor. The measured value from the transducer is available at the signal output as a 4...20mA analogue signal. This value is converted from 4...20 mA to an IO-Link signal via the DP2200. It is important to ensure that the internal load of DP2200 is activated. The data is provided to moneo via an IO-Link master of the AL1352 series.
To obtain useful process values, the measured value of the current transducer must be converted into the actual current value of the transducer (4 mA ≙ 0 A, 20 mA ≙ 50 A*). This is done in moneo using the “Calculated values” function.
In the analysis, the calculated current value is then used to recognise the respective operating range of the compressor.
* Factory setting of ZJF056 = 100 A. To increase the measuring accuracy, the measuring range was adjusted to 50 A via the DIP switch on the transducer.
Operating state: off / current consumption in A: <1
Operating state: idle / current consumption in A: 1 – 40
Operating state: load operation / current consumption in A: >40