world of industries 3/2017 (EN)

02 Real-time data monitoring is performed in the service centre
availability of modern databases and enormous improvements in
sensor technology, that real-time monitoring and predictive maintenance
have become a reality.
Tailor-made solutions
Customer needs vary widely. Kaeser has a diverse range of service
packages geared to specific requirements. One model, the Sigma
Air Utility, is based on the existing contracting models, which leave
nothing for the customer to take care of. Kaeser assumes full responsibility.
Similar to the electricity or water supply, customers
pay only for the compressed air that they use. This leaves them with
more liquid assets on hand for their core business activities.
Another model, Sigma Smart Air, is designed for customers who
own their compressed air stations. As regards service and availability,
however, they are just as care-free as those who opt for a contracting
solution – because Kaeser handles everything. According
to Kaeser’s estimates and the initial experiences, this model can
save up to 30 percent in service costs for customers.
Whether the compressed air station is owned by the customer or
Kaeser, the basic requirement for using predictive maintenance is
the Sigma Air Manager 4.0. This core control technology was developed
by Kaeser – as were the analysis tools behind it. The master
control system itself is the core element of a compressed air station
and is essential for utilising everything Industry 4.0 has to offer.
It functions as a central brain for the controlling tasks and data
streaming to the data (service) centre, which performs continual
monitoring and analysis. When potential faults are detected, a
process is initiated to ensure the problem never reaches the point
where components stop functioning. Along with fault analysis, the
control system determines when maintenance is actually needed,
as opposed to following a fixed schedule. This switch to needsbased
maintenance also saves costs.
01 The Sigma Air Manager 4.0 (SAM 4.0) master controller
functions as a management system for the compressed air
components and as a central node for secure data exchanges
Infrastructure, expertise and intelligent services
are essential
A system operator planning to introduce predictive maintenance
will need an excellent compressed air system infrastructure like
that provided by the Sigma Network. Real-time monitoring is possible
only if the system components are equipped with sensors that
enable the master control system to monitor activity, retrieve data,
and transfer it instantly. Naturally the vast quantities of raw, unfiltered
data are of little use on their own. Appropriate analysis processes
must be developed to extract useful information and predict
events. This requires human input – just like the steps that follow.
The global service network needs to be just as extensive and effective
as the data network to ensure a prompt and cost-effective response
when action is needed. The right combination of infrastructure,
expertise and intelligent services is essential for exploiting the
full benefits of predictive maintenance.
www.kaeser.com
The cornerstone: knowledge and
experience
Essential for the development of such predictive maintenance
concepts is the extensive knowledge, accumulated
over many years, on the processes, interrelationships,
vulnerabilities and challenges involved in producing and
using compressed air. It is this knowledge on the part of
Kaeser’s specialists – combined with the latest technologies
– that makes it possible to rapidly analyse and evaluate
the status of a station and to promptly initiate any
steps that may be needed.
WORLD OF INDUSTRIES 55