August 9, 2020
Why do you need central control system?
Estimated reading time: 5 minutes
When you have a compressed air system that comprises of multiple compressor /dryer units, it can be difficult to determine which machine to run when. Compressed air consumption is seldom constant, therefore many compressor installations have a flexible design, using a combination of compressors with different capacities and speed-controlled motors. If the system isn’t properly managed, there is a risk of producing too much air, which translates into higher operating costs. Using a modern central control system can help the compressors run optimally for different operating situations while enhancing safety and availability. Selecting the right regulation method encourages energy savings through lower system pressure and a better degree of utilization, which is optimized for each machine in the installation. The control system also balances the work load between different machines enusirng increased availability and reducing risk of unplanned downtime. Besides, central control allows programming for automatic pressure reduction in the entire system during operation at night and on weekends.
The central control system
Central control in association with compressors usually signifies relatively intelligent control systems. The basic demand is to be able to maintain a predetermined pressure within tight limits to provide economic operation of the installation. To achieve this, the system must be capable of predicting demand, while at the same time sensing the load on the compressor. The system senses how quickly the pressure changes either increase or drop in pressure (i.e. the time-derived pressure). Using these values, the system performs calculations that make it possible to predict the air demand and , either load/off-load or start/stop the connected compressors. In a correctly dimensioned installation, the pressure fluctuation will be kept within ± 0.2 bar. The modern intelligent controllers focus on operational efficiency and selects the most economical compressor or compressor combination, if compressors of different capacities make up the system. The central controller will ensure the compressors run continuously loaded, thereby minimizing idling periods and providing optimal economy. It is generally possible to connect older machines to these systems and therefore modernize the entire compressor installation in a relatively easy manner. Operations become more economic and availability is increased.
Optimizer 4.0 central controller
Benefits that matter:
Efficiency
Adapting to the 4th Industrial Revolution or the Industry 4.0, which pertains to Internet of Things (IoT), Optimizer 4.0 can gather data, store and analyse information that can be available in the cloud to be used to further improve an existing process or system. A perfect fit for “Smart Factories”. With the Optimizer 4.0 Central Controller, multiple compressor installation runs within optimum pressure band while prioritizing more efficient units. Furthermore, the Optimizer 4.0 automatically shuts down machines during “non-production” times such as nights, weekends and holidays, reducing running hours and service costs further.
Reliability & Uptime
For multiple compressors Optimizer 4.0, distributes load thereby equalizing running hours and ensuring preventive maintenance can be better planned.
Connectivity
Optimizer 4.0 is also a way of connecting your compressors and dryers through Local Area Network (LAN) or via cloud-based monitoring system to get valuable real time data and inputs on the state of your compressors as well as the energy consumption of your compressed air plant.
