Compressor
With IoT, compressor maintenance follows actual condition: sensors record current consumption, pressure, temperature and running times. Operators detect creeping damage and unused running time early and cut energy and service costs.
Compressor at a glance
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Verified projects featuring Compressor
IoT monitoring uncovers energy losses and leaks in compressed air
An LTE sensor from achtBytes measures the pressure in the compressed air system and reveals unnecessary compressor run times, excessive operating pressure and leaks, without any connection to company IT. In one case, the compressor started more than 20 minutes earlier than necessary.
Detecting compressor operating states based on current consumption
Retrofit cooling systems digitally and monitor them in real time
Compressed air monitoring in a food plant – 17% lower energy demand
Operating compressed air compressors efficiently with remote monitoring
From compressor to smart product – how data-driven services open new business fields in mechanical engineering
- Evaluating energy data live in the plant – creating visibility without coding
- Detecting unused compressor runtimes and leakages with a scalable IoT platform
- Efficient energy management with intelligent compressed air sensors
- A modular solution for the future of wastewater treatment
- Networking of machines via Modbus RTU
- Automatic detection of pneumatic leaks reduces energy consumption
- Remote monitoring for wastewater treatment plants reduces maintenance costs
- More transparency with energy data management
Compressor maintenance based on condition, not the calendar
In the solution examples, an ifm current transformer measures current consumption, and the moneo IIoT platform uses it to distinguish idle from load operation and count operating hours per working range. Existing compressors with a Modbus interface are retrofitted via gateways such as the PSsystec SMARTbox mini or grandcentrix Modbus Cloud Connect and send pressure, temperature, dew point, flow and operating hours via NB-IoT, LTE-M or LTE to platforms such as Cumulocity. An IO-Link pressure sensor on the ring main reports when a compressor runs outside working hours. One compressor manufacturer also records vibration and energy consumption and analyses the data with machine learning, while at ifm, moneo can trigger maintenance orders directly in SAP.
The examples come from mechanical engineering, the metal and electrical industries, food production and wastewater treatment, typically as condition monitoring, predictive maintenance and energy monitoring. A global compressor manufacturer has connected more than 170 devices with Cumulocity and offers remote monitoring and predictive maintenance as a service instead of sending technicians on monthly scheduled visits. ALMiG Kompressoren connects its compressors to the cloud via NB-IoT using grandcentrix Modbus Cloud Connect. With the achtBytes platform, STEGO Elektrotechnik found that its compressor needs 7 rather than 30 minutes in the morning to reach the required pressure, and cut daily running time by 23 minutes.
Podcast episodes featuring Compressor
Food Production Saves Energy with autinityE3
LoRaWAN® in Practice: Vibration Monitoring and Valve Monitoring in the Oil & Gas Industry
Water crisis 2030 and IoT: Digital solutions to scarce resources and infrastructure
- New LoRaWAN Sensor System – Uncovering Energy Waste in Existing Plants
- From product development to digital service management
- Sustainability as a Market Driver: IoT for ESG (Environmental, Social, Governance) | Software AG
- CO2 & Energy Management with IIoT Software
- Reducing energy costs & downtimes – IoT at Bad Pyrmont wastewater treatment plant
- Commercialization of IIoT business models – support ticket system, external weather data and quality monitoring
- Energy management via load profile analysis, meters, heat maps and Excel spreadsheets – Connectivity and availability of private 5G campus networks
- Wireless Communication and Industrial IoT | What are the possible applications for my IoT project with LTE-M, NB-IoT and 5G? | Eric Scheithauer | Sierra Wireless
Compressor maintenance: frequently asked questions
How can compressor maintenance be planned based on actual use?
Maintenance can be planned based on actual use when the real load on the compressor is measured. Conventional hour meters do not distinguish between idle operation, in which the compressor hardly wears, and load operation. In the ifm solution, a current transformer measures current consumption and moneo counts the hours per working range. Maintenance then happens when it is needed, rather than too early or, with creeping damage, too late.
How do manufacturers provide remote air compressor service?
Manufacturers equip their compressors with sensors and a cellular or network connection and see the condition of every unit on a cloud platform. One global compressor manufacturer has connected more than 170 devices with Cumulocity, with 4.2 million data transmissions per week. Service technicians no longer travel out on a monthly schedule but respond to system warnings. ALMiG uses grandcentrix Modbus Cloud Connect for this, which also allows commands to be sent from the cloud to the device.
How does IoT improve air compressor energy efficiency?
IoT shows when compressors run unnecessarily or at an unfavourable load and provides the basis for better control. At STEGO, an alarm is raised when the compressor runs outside operating hours, for example because the night and weekend shutdown was accidentally disabled after maintenance work. A food plant used in.hub and the SMC Air Management System to optimise the load cycles of its compressors and cut the energy demand of its compressed air generation by 17 percent.
Can older compressors be connected without a new controller?
Yes, older compressors can usually be retrofitted without changing the controller, provided they have a Modbus interface. The PSsystec SMARTbox mini connects up to 32 Modbus devices with a maximum of 400 data points regardless of manufacturer, and configuration is done remotely. grandcentrix Modbus Cloud Connect requires the machine to support Modbus RTU via RS485 and the register assignment to be known. The data is sent to the cloud over the cellular network.
More assets in “Machinery and Equipment”
Pump
Pump monitoring with IoT records vibration, temperature, pressure and energy consumption of running pumps. Operators detect damage and faults before a pump fails and plan maintenance by condition rather than at fixed intervals.
Electric motor
Motor condition monitoring with IoT continuously measures the vibration, temperature and current draw of electric motors. Operators detect imbalance, bearing damage or winding faults early and replace motors based on condition rather than after a failure.
Packaging machine
OEE software automatically records run times, downtime, speed and rejects on packaging machines from the machine signals. Operators see where their lines lose performance, and machine builders use the same data for remote access and digital services.
Refrigeration system
A refrigeration monitoring system makes service plannable: temperatures, refrigerant circuit pressures, compressor status and energy consumption flow into a platform in real time. Operators and service partners detect faults early, avoid unnecessary site visits and reduce excess consumption.
Air conditioning system
Commercial air conditioning systems in offices, retail branches and data centres can be monitored remotely with IoT. Operators see energy consumption, temperatures and faults in one place, detect failing compressors or refrigerant shortages early and plan service visits precisely.
Injection moulding machine
A connected injection moulding machine continuously supplies data on mould cooling, cycle time, electricity and compressed air. Plastics processors use it to cut energy use and scrap, detect faults earlier and bring machines from different makers onto one data basis.
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