Effortless, effective and ever so smart

It makes sense that you would want to run an energy optimised compressed air system - after all on average, the energy costs of operating a compressor will amount to around 75% of its total lifetime costs. Operating an efficient system will keep these costs to a minimum. And, of course by reducing your electricity usage you are also reducing your carbon footprint. 

For quite a minimal amount of effort, one of the most effective ways to achieve an energy optimised compressed air system is to integrate a sophisticated, intuitive and Industrie 4.0-ready master control system.

So why are the latest generation of Industrie 4.0-ready master compressed air management systems so effective and effortless in optimising compressed air system efficiency? Let’s look at some of the key features of the Sigma Air Manager 4.0 (SAM 4.0) master controller as an example to explain.

1. Identify - in real-time
   
   As the central mastermind of a compressed air system, a master controller such as the SAM 4.0 can control the entire compressed air supply system. It collects, and then via IoT (the Internet of Things), transmits process data in real-time to a centralised application.
   
   
2. Analyse - in real-time
   
   With help from specialised algorithms, the continuous analysis of the transmitted data is subsequently performed.
   The algorithms in the Adaptive 3-D^advanced Control orchestrate the interplay between all components and equipment within a compressed air system. The result - just the right amount of compressed air power is provided to meet the specific needs of the application. This in turn assures maximum efficiency at all times.
   The innovative and unique Adaptive 3-D^advanced Control, continuously analyses the relationship between various parameters (e.g. switching and control efficiency), and proactively calculates the optimum combination from a range of many in order to achieve optimum efficiency. Not only are starts and stops taken into consideration, but so too are idling and frequency converter losses, along with pressure flexibility. Moreover, the compressed air system’s pressure performance value is optimised and average pressure is reduced.
   
   
3. React - in real-time
   
   But, today’s master controllers should not only be capable of activating and deactivating compressors according to demand in order to minimise control-related losses - they should also be able to provide comprehensive monitoring and preventive maintenance features.
   
   Implementing a smart master controller like the SAM 4.0, provides the basis for a new era of intuitive predictive maintenance. Through availability of compressed air system process data and the resulting analysis, it is possible to identify the perfect point in the future when your compressed air supply system should be maintained and serviced. This prevents costly periods of downtime, increases energy efficiency (thanks to monitoring of key parameters) and allows compressed air system performance to be precisely matched according to demand throughout the entire life-cycle of the system. This combination of remote diagnostics and demand-oriented preventative maintenance ensures maximum availability and potentially reduces service costs by up to 30%.
   The combination of remote diagnostics and needs-based, preventative maintenance also helps assure maximum compressed air supply dependability.

One of the great benefits of such smart technologies like the SAM 4.0, is the ability to access, control and manage your compressed air system from anywhere and at any time. Whether it be your smart smartphone, tablet, laptop or PC - any network capable end device can be used to access, control and manage your system. Quite simply this means that you don't have to physically be standing in front of the SAM 4.0 master controller to access important data as well as control and manage your compressed air system. 

What’s more you can see your entire system live in a P&I (pipework and instrumentation flow) diagram. This provides a number of key pieces of information, including real-time alarms and maintenance messages for individual components. 

The SAM 4.0 is also a comprehensive solution because it allows you to store and analyse all relevant, energy-related data from your compressed air supply. You can then create specific energy reports on-demand.

When such permanent energy management is implemented together with centralised compressed air system monitoring (for predictive maintenance), minimal effort is required on your part for maximum effectiveness and efficiency of your compressed air supply system throughout its entire life-cycle.