Intelligent Transformation Project for Air Compressor Systems of Greek Industrial Enterprises
To address the challenges of low energy efficiency (comprehensive energy consumption 15% above industry standards) and lagging monitoring in a Greek industrial enterprise's air compressor system, we delivered a customized solution using Inovance Technology, resolving long-standing pain points of high energy consumption, slow fault response (average over 2 hours), and elevated maintenance costs.
Core Solutions
Full-Parameter Smart Monitoring
Equipped with the H2U-8A91G-XP air compressor-specific PLC, the system integrates multi-type sensors to real-time collect 12 key parameters, including:
- Exhaust pressure (0.1–1.6MPa)
- Air end temperature (0–120℃)
- Oil/air filter blockage status (contact signal feedback)
Fault response: Abnormal states trigger audio-visual alarms and upload cloud-stored fault codes within 0.5 seconds, enabling remote diagnosis via mobile devices.
Efficient Drive & Closed-Loop Control
Variable frequency drive: MD380/MD500 series converters achieve constant-pressure gas supply via built-in PID algorithm:
Pressure fluctuation ≤±0.02MPa (30% better than industry standards) No-load energy consumption reduced by 45% (sleep-wake function)
Motor optimization: Vector control tailored for permanent magnet synchronous motors boosts: Efficiency by 12% (vs. traditional asynchronous motors) Power factor to 0.98
Smart HMI & System Integration
The IT5060T industrial human-machine interface enables:
Real-time visualization: Pressure, temperature, current, and 24-hour operation trend curves
Intelligent maintenance: Auto-calculated filter replacement cycles and proactive maintenance reminders
Seamless connectivity: MODBUS protocol support for integration with the client’s SCADA system, allowing remote export of key data to Excel reports
Project Value
Energy efficiency: System-wide efficiency improved by 22%, saving over €180,000 annually for three 250kW units
Maintenance optimization: Filter replacement cycles extended by 20%, Unplanned downtime reduced by 60%
Reliability upgrade: Phase sequence protection eliminates motor reverse damage risk Temperature monitoring prevents air end overheating, extending key component lifespan by 30% This transformation achieves a holistic upgrade in safety, efficiency, and digital management, setting a benchmark for intelligent retrofitting in industrial air compression systems.
