Smart Air Compressor Station Cloud System utilizes wireless communication module IoT technology to transmit all data of the air compressor station wirelessly to the cloud. It provides comprehensive control and energy-saving for the entire station through cloud + edge hybrid technology, and configures a station house display system for customers. Through mobile phones (mobile)End and computerPresented on the web端Provide managers with a clear and real-time view of the entire air compressor station's operation status, enabling complete intelligent remote monitoring.
Smart Air Compressor Station CloudSystem Function Overview:
(1) Centralized and Linked Control
The MSAC-SA air compressor centralized control system can connect and monitor air compressors via CAN, Modbus, or Ethernet, while also expanding peripheral device management. For example, the MSAC-SA8 can support 8 expandable connections for dryers, 8 cooling water flow valves, 2 cooling water pumps, 2 pressure sensors, 8 electricity meters, and 8 flow meters.
(2) Remote MonitoringManagement
The MSAC-SA compressed air compressor centralized control system can be connected to a remote operation terminal via RS485 or Ethernet. The RS485 connection extends up to 250 meters (ensuring reliability), while Ethernet extends up to 150 meters, and Ethernet fiber optic communication extends up to 20,000 meters. Data from the air compressor station can be presented on mobile devices (mobile end) and computers (web end), achieving complete intelligent remote monitoring of the air compressor station.
(3) Data StorageSearch
MSAC-SASystemWe will monitor all machine data, pipeline data, and connected analog inputs derived from measurements and calculations. Through direct Ethernet, analog, or GSM/GPRS The modem uploads all data to any configured monitoring device.PC。Automatically generate operation parameter reports based on requirements, supportsExcel Export Function
(4) Constant Pressure Gas Supply Setting
MSAC-SASystemAdjustable within a narrower user-defined pressure range/UnloadingAir CompressorMachine. If there isVSDPlease provide the Chinese content to be translated.FrequencyThe machine connects to the system, which will adjust towards the pressure setting point of the air pipeline. The adjustment response is quick and will not overshoot or undershoot. To comply with regulations and optimize configuration file requirements, the system can decideAir CompressorThe switch that stops the operation of one or more machines while starting up one or more machines simultaneously. In this case,SystemWill calculateAir CompressorCommand timing to maintain pressure within the pressure band and minimize the impact of switching on pressure.
Directly control the air compressor pipeline pressure without setting stepped pressure.Pressure bands can be reduced to0.1 bar (require sufficient storage and control).
l Every reduction 1 bar (15 psi), reduces energy consumption by 7%，Every reduction1 bar (15 psi), reduces leakage by 13%。
l Without the centralized control system, the loading and unloading sequence of the air compressor is controlled by the settings on the compressor itself.The pressure band is set with a gradient, resulting in a significant fluctuation of system pressure (wide bandwidth) and causing energy waste.。
After implementing the centralized control system, it controls the loading and unloading of air compressors based on the real-time pressure of the system's main pipeline, providing single-point pressure control. This ensures system pressure stability within a narrow pressure range, offering users consistent pressure and energy savings.
(5) Multiple pressure pointsMonitor
For each air pipeline system, multiple pressure transmitters can be utilized. Should a pressure transmitter fail or exhibit excessive deviation from others, the system will generate an alarm but will continue to adjust. If the deviation between the remaining transmitters is too great, the system will send all affected machines in the air pipeline system to local control, ensuring pressure within these pipelines through the machine's and local pressure transmitter's local control algorithms.
(6) Multiple Pressure Control Sets
For each air pipeline, different pressure zones and set points can be defined. Settings to be applied can be manually selected or automatically triggered, or selected by external inputs such as digital signals. The system can adjust each air pipe network to the pressure band and set points.
(7) Optimized ConfigurationOperation
MSAC-SASystemAdjust each air network through the following optimized configuration file:
Energy-saving optimization：MSAC-SASystemWe will select machines capable of meeting the requested flow rate with reasonable energy costs.
SequenceArrangement:MSAC-SASystemThe machine's startup and shutdown will be triggered in sequence.
Balanced WearMSAC-SASystemWillMaintain operating hours for various machines within a set range.
(8) Rotary Operation Control
When there are multipleAir CompressorAnd when it comes to dryers.MSAC-SASystemCustomizableAir CompressorRun the dryer in alternating cycles.For instance, sequence1 for 1-2-3；Sequential Order2 for 2-3-1... When the system pressure is below the set lower limit of the target pressure, if the current sequence is 1, the system will load the corresponding air compressor in the order of 1, 2, 3; when the system pressure exceeds the set upper limit, the corresponding air compressors will be unloaded or stopped in the reverse order of 3, 2, 1, thereby keeping the system pressure within the set range.
(9) Intelligent Analysis Forecast
Analyze operational data of the equipment to calculate the usage rate and load rate of each air compressor, and provide certain alert functions based on the system's safe operating status for timely understanding of the air compressor station's operation. Through real data analysis, evaluate the specific energy efficiency of individual air compressor units, plot operation curves, analyze the overall gas-to-electricity ratio and unit gas production cost in real-time, and calculate the unit energy consumption of gas usage over specific time periods for accurate cost analysis in production.
(10) Fault Alarm Handling
Upon detection of a compressor fault, the control system will automatically retrieve the current operating sequence and activate the nearest standby air compressor. The comprehensive alarm and fault status of the air compressor will be displayed in real-time on the touch monitoring interface of the MSAC-SA system and the supervisory interface of the upper computer.
Smart Air Compressor Station CloudSystem Interface Reference:
