Pneumatics market adapting Industry 4.0 with IoT-enabled compressors

By Staff Report November 30, 2024 6:17 pm IST

 Manufacturers should consider several factors, including good performance, energy efficiency, and sustainability, when selecting pneumatic systems. Danish Shaikh, National Sales Manager – OEM (Industrial Air) of Chicago Pneumatic Compressors-India, gives a breakdown of key aspects relevant to Chicago Pneumatic Oil Injected Screw Air Compressors and the general trends in pneumatic technology.

What pneumatic systems should manufacturers consider when selecting the machines?

Screw air compressors are the heart of every pneumatic system and manufacturers should consider air requirements, working pressure, power efficiency, and environmental impact while considering an ideal compressor. Our compressors are designed to deliver consistent, reliable performance across diverse applications.

For variable demand, the VFD adjusts speed based on consumption, reducing energy costs and increasing efficiency. The required air quality for the application can be achieved through condensate treatment systems offering dual-stage filtration, which achieves high water purity and meets environmental standards. These features make our compressors a sustainable and efficient choice for industrial use.

How have technology advancements, such as IoT and automation, influenced the design and operation of your pneumatic systems?

We walk with time and keep ourselves ahead with technological advancements. We adapted IoT in the early times. ICONS is one such advancement, where users get real-time monitoring and analytics for critical compressor data, including air pressure and energy use. These factors are essential for optimising maintenance schedules and minimising downtime. ICONS is a cloud-based platform that allows for predictive maintenance, and it automatically flags potential issues before they lead to costly disruptions, thereby aligning well with Industry 4.0 standards.

The EControlsystem is another feather in the cap. It enhances operational flexibility by enabling centralised control over multiple compressors. This system adjusts compressor outputs based on real-time demand, ensuring energy efficiency while maintaining optimal air pressure across various applications. Together, ICONS and EControl offer great data visibility, streamlined energy management, and reduced operational costs, all while supporting a connected manufacturing environment.

What are the key considerations for the maintenance and safety of pneumatic systems? How do you mitigate risks associated with these systems?

At Chicago Pneumatic, we emphasise regular maintenance and safety checks for our pneumatic system performance and risk management. We optimally change air filters, inspect for leaks, and ensure components like pressure valves and safety vents always function correctly. Positioning compressors in clean, ventilated areas prevents moisture damage and fire hazards, while using grounded electrical connections adds further protection.

I advise users to check compressor hoses and fittings before each use and wear protective gear. Maintenance routines are also helpful for preventing issues like overheating and clogging and improving system longevity and reliability. When anyone uses our system, they also get centralised control options for streamlining management, allowing operators to adjust settings based on real-time needs and further reduce risk. These guidelines help maintain safe, efficient operations, ultimately protecting personnel and extending equipment life.

How do you foresee the future of pneumatics evolving in the context of Industry 4.0 and smart manufacturing environments?

As Industry 4.0 continues to shape manufacturing, the role of pneumatics will evolve with increasing automation, connectivity, and data integration and a vision to safeguard environmental impact. Our vision for the future includes developing more intelligent and efficient compressors powered by technologies that reduce energy consumption and improve system flexibility. The company’s adoption of smart, interconnected systems positions them well within the smart manufacturing landscape, where compressor systems will be integral for saving energy generated by the compressor and wasted as hot air to the surrounding environment. This heat can further be utilised to charge water temperatures for industrial applications. Similarly, there are versatile products, and the features offered by CP compressors fit well in the context of Industry 4.0.

How do you focus on tropical-ready designs and advanced technologies?

Since 1901, Chicago Pneumatic Compressors has built a legacy of innovation in industrial equipment and is known for high-quality and reliable pneumatic technology. With pressurised canopy design, we design compressors for tropical conditions to withstand high ambient and dusty environments, a unique feature that reduces power consumption and carbon footprint. Compressors are equipped with advanced connectivity systems with cloud-based remote monitoring from any device, enabling greater flexibility and reduced downtime. Variable Frequency Drive (VFD) and interior Permanent Magnet (iPM) motors are an additional advantage for saving substantial energy with a faster return on investment.