This solution serves for compressor analysis (current/ power measurement), system analysis (current measurement and real flow measurement) and leakage calculation, providing a comprehensive evaluation of compressed air generation and consumption.
For compressor analysis, the energy consumption of every single compressor is measured by means of a clamp-on ammeter. Based on this data, the produced compressed air quantity is calculated by the software on the basis of the performance data of the compressor which have to be calculated. This enables precise monitoring of compressor performance without invasive installation.
In addition, the following parameters are calculated additionally: energy consumption in kWh, load-, unload-, stop time, compressor load in %, and number of load/ unload cycles. These key performance indicators allow detailed assessment of operating efficiency, utilisation, and switching behaviour of each compressor.
The system analysis has the same function like the compressor analysis, but additionally offers the possibility to measure the actually produced resp. used quantity of compressed air by means of the flow sensor. With this real flow measurement, the system provides a direct comparison between generated and consumed compressed air.
Using this data, the leakages and therefore the cost share of the leakages in comparison to the total costs in € can be determined. The leakage calculation is done during the production free time (shutdown, weekend, holidays), when no intentional air consumption takes place.
During this downtime, the flow sensor measures the supplied quantity of air while the compressor delivers compressed air in order to keep a constant pressure. According to statistics even if production is carried out day and night there is at least one short period of time during which all load is switched off. Based on this condition, the software defines a leakage rate and calculates the incurred leakage costs in €, delivering a clear financial evaluation of compressed air losses.