The Far-Reaching Influence of IIoT

How can pneumatic systems be influenced by IIoT implementation?

It is easy to become swept up into the torrent of the Industrial Internet of Things (IIoT), especially as Industry 4.0 spreads across the manufacturing and automation world. But IIoT is more than a trend that will fade in time. To truly understand why, one only has to consider the myriad of practical influences it holds for everyday plant operations. From monitoring and preventative diagnostics to process optimisation and cost savings, successful IIoT implementation can influence every aspect of your business.

When it comes to pneumatic systems, the benefits of IIoT seem almost endless. The implementation of smart air compression systems will not only ensure increased production time, but also promises to be a more cost-effective solution over time. Once a pneumatic system is maximised, system reliability increases and energy costs are reduced along with power consumption. The system’s longevity will also be increased due to the fact that maintenance can now be performed as early as possible thanks to early warning notifications. Through smart pneumatic systems, utility costs can be minimised, and planned for adequately due to the creation of a benchmark that can guide future utility requirements.

Figure 1: The cost structure of an optimised air system

When monitoring a compressed air system, the most common method is through pressure sensors that notify the end user through a programmable logic controller when the pressure falls below the required levels, indicating the existence of a problem. In order to investigate and perform the necessary diagnostics, and to take possible corrective actions, the system is shut down and production can only commence once the system’s safety is confirmed again. This means that valuable production time is lost every time a possible leak is suspected, and extensive down-time when a leak indeed does exist and has to be fixed.

But leakages do occur – they are unavoidable. In most cases this is due to the gradual wear that occurs in tools and components that are exposed to high pressures. As this is something that will no doubt have to be addressed when working with a pneumatic system, keeping track of any possible problems is the only way to ensure that leakage is addressed as soon as possible. When leakage is not addressed in time, wasted air puts unnecessary strain on the system and results in unforeseen maintenance and productivity loss.

With IIoT, leakage is kept to a minimum thanks to early detection and continuous monitoring that allows preventative measures to be taken as soon as a problem occurs, no matter how minute it may seem. This keeps necessary downtime to a minimum by addressing the problem before it escalates and causes greater damage.

The measurement of air pressure is only part of the picture; when working with air compression, air flow rates and volumetric consumption are as important.

A major matter that IIoT solutions can address is the fact that system failure is not the only negative outcome. When a system begins to use more air for specific repeated processes, the system is still, technically functioning as it should, just at a slightly greater cost and under slightly greater strain. A minor compromise in the system that does not affect production in any visible way can lead to small additional costs at first, but will, no doubt, lead to greater damage and greater costs if left unattended. But in these cases, where no visible effect is markable, predictive maintenance becomes essential, and can be implemented more efficiently with cumulative data that is gained through IIoT.

The far-reaching influence IIoT implementation can have on compressed air systems is a prime example of just how beneficial IIoT can be to a business. Energy costs can be reduced significantly with the correct monitoring and early warning notifications systems. Cyntech is fully equipped to conduct a study of your pneumatic system and advise you on the most cost-effective strategic way to integrate your system into IIoT and start realising savings and production optimisation immediately.

This is a general information sheet and should not be used or relied on as legal or other professional advice. No liability can be accepted for any errors or omissions nor for any loss or damage arising from reliance upon any information herein. Always contact your legal adviser for specific and detailed advice. Errors and omissions excepted. (E&OE)