SIGMA AIR MANAGER 4.0 master controller - KAESER COMPRESSORS Australia

Compressed air station control - for optimum efficiency

Adaptive, efficient and networked - demand-oriented compressed air management takes on a whole new meaning with the SIGMA AIR MANAGER 4.0.
This advanced compressed air management system choreographs operation of multiple compressors, as well as dryers or filters, with unprecedented efficiency.

The patented, simulation-based optimisation process calculates future demand based on past compressed air consumption. Decisions are no longer dictated by a narrow pressure range, but rather by continuous optimal operation of the compressed air station. Saving energy has never been so easy.

Thanks to networking of all compressed air station components via the intelligent master controller and the secure KAESER SIGMA NETWORK, comprehensive monitoring and energy management, as well as predictive maintenance, are possible. This minimises downtime and maximises productivity.

Your benefits

Demand-oriented compressed air management
Adaptive optimisation of your compressed air station
Greater overview, more control, less downtime

Availability

The SIGMA AIR MANAGER 4.0 makes organisation of service activities simple. Centralised processing of compressed air station operating data ensures a permanent overview of system maintenance status. Service intervals can therefore be planned and optimised from a future-forward perspective.

Monitoring

The SIGMA AIR MANAGER 4.0 enables comprehensive compressed air station monitoring through the recording, archiving and visualisation of operating data. Complete station parameter tracking means that faults can be detected early on and rectified immediately.

Reporting

The SIGMA AIR MANAGER 4.0 records, archives and processes the compressed air station’s operating data and provides active support for energy management activities as per ISO 50001. The required key figures are automatically exported, evaluated and delivered in the form of a report.

Networking

The SIGMA AIR MANAGER 4.0 already enables compressed air station digitalisation. As the central node point, it connects all station components via the secure KAESER SIGMA NETWORK. Operating data are collected centrally and can be integrated into the existing control technology. Communication is performed via Modbus TCP, Ethernet IP, ProfiNet, ProfiBus, Modbus RTU and is also future-proof using OPC UA.

The SIGMA AIR MANAGER 4.0 in detail

Optimisation process

The SIGMA AIR MANAGER 4.0 calculates future demand based on past compressed air consumption profiles. On the basis of this demand projection, the technical conditions of the components and the learned knowledge regarding the system and its behaviour, the patented simulation-based optimisation process is used to anticipate the most efficient switching operations.

SIGMA AIR MANAGER 4.0 master controller from KAESER KOMPRESSOREN.

KAESER SIGMA NETWORK

Industrial applications place special demands on communications technology, particularly in the field of machine-to-machine communication. It must be robust and locally manageable, as well as globally-compatible and also capable of transferring large data volumes quickly and securely. The system must also ensure maximum data integrity and provide the necessary real-time properties required by the process. The KAESER SIGMA NETWORK meets all these requirements and more.

Together with the SIGMA AIR MANAGER 4.0 compressed air management system, the KAESER SIGMA NETWORK creates a perfectly matched secure infrastructure for intelligent services within the advanced scope of Industrie 4.0 operating environments. If required, operating data from the compressed air station can be securely transmitted to the KAESER DATA CENTER via a broadband connection.

The combination of remote diagnostics and demand-oriented predictive maintenance ensures maximum compressed air supply availability and complete system effectiveness.

Prevention of unplanned and planned downtime (malfunctions / maintenance) through evaluation of operating parameters, such as load operating hours and temperatures
Increased energy efficiency through monitoring of key operating parameters such as airend discharge temperature, pressure dew point, differential pressures (filters), leakage rates, pressure and flow rate
Service costs reduced by up to 30% through optimised servicing and avoided repairs
Demand-optimised compressed air system control throughout the system's entire life-cycle