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Monitoring and saving compressed air
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Compressed air is considered one of the most expensive industrial commodities. The cost of producing it and its widespread use in industrial plants make it a significant expense for most companies. The current volatility of energy prices is forcing companies to look for savings more seriously than ever before.
Monitoring the most expensive industrial medium
Automated monitoring of machines and applications brings undeniable benefits in terms of reliability and predictive maintenance. To this end, Balluff has developed a device called the CMTK - Condition Monitoring Tool Kit. Today we will introduce you to the CMTK's implementation capabilities for monitoring and savings in the usage of compressed air.
Growing importance of IO-Link
The primary interface through which the CMTK communicates with sensors and actuators is IO-Link. Its advantages, such as ease of wiring and configuration, allow the fast and easy installation of devices that would have to be handled by PLCs and programmers with conventional technologies.
A recent trend that further underscores the value of IO-Link is multifunction sensors. The relatively large amount of data that IO-Link can transmit opens the door to the development of sensors that provide comprehensive information about the process or medium being measured.
An example of such a sensor for monitoring compressed air is the SMC PF3A8 flow sensor. It combines the functions of a flow, pressure and temperature sensor. It can provide up-to-date information on all relevant quantities of the measured medium, and in combination with a CMTK, also provide insight into event history and trend analysis important for predictive maintenance.
When connected to the IT infrastructure, such versatile sensors become an extremely valuable tool for monitoring the condition of the entire industrial environment.
From condition monitoring to implementing cost savings
Knowing the condition of a process is key to identifying and evaluating savings potential. However, monitoring is only the first step on the road to real savings, and process intervention is usually required to achieve them.
Practice shows that routine tasks, such as shutting down or putting machines to sleep during downtime, are often neglected by operators. For this reason, automating these activities can save significant resources.
CMTK is mainly designed for data collection and analysis, but also includes options for custom software development. With this option, compressed air circuits can be controlled based on measurement data.
Balluff Slovakia, in cooperation with leading manufacturer in the tyre industry and SMC, has tested and implemented the first joint project for flow control and pressure management of machines during idle time. This makes their operation both environmentally and economically less demanding and thus more cost-effective.
Summary
CMTK is a tool for data collection, storage, display and analysis. It supports modern multifunction sensors with an IO-Link communication interface. CMTK can operate independently or as part of a distributed data acquisition and processing system.
The ability to develop custom software allows the CMTK's functionality to be freely extended, for example, with an advanced reporting or control module. Balluff and SMC have developed solutions for CMTK implementation in compressed air monitoring and energy saving that can be easily applied to existing machines or production lines.
Keywords
- Industrial automation
- Efficient production
- Smart Factory
- Innovations
- Smart sensors
Author
We have been active on the Polish market for more than 25 years. We serve our customers from Pomerania to the Tatra Mountains, providing first-class service and technical support. We are also present online, where we share our knowledge about the latest implementations, industry trends, events or technical aspects of our solutions.
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