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Pneumatic Energy Saving & Efficiency System



Industrial forging is a manufacturing process involving the shaping of metal using localized compressive forces. The blows are delivered with a hammer (often a power hammer) or a die. In a hot forge the metal is heated and used to manufacture parts weighing from less than a kilogram to hundreds of metric tons. In an industrial forge air compressors consume about 60% of the total electricity in the factory. By introducing a pneumatic energy savingsystem an awful lot of this electricity can be reduced Once installed this new system needs to be properly maintained to ensure that it reduces production costs.

System Requirement

The client had several requirements for this project. It was essential that the efficiency of the air compressor would be monitored at all times for its air flow and electricity consumption, and control the demand and supply of compressed air amount through analysis of producing pattern to minimize the waste of energy.
These requirements would be met by monitoring the flow meter, watt-hour meter, pressure sensor, thermos hygrometer, LTE modem through a database.

System Implementation

To implement these system two ACP-4300 servers with Intel Quad Core Processors and monitors had WebAccess installed on them.
Going beyond SCADA, WebAccess 8.x is also a HTML5 Business Intelligent Dashboard which can be opened from anywhere on any HTML5 compatible browser. The Business Intelligent Dashboard analyses data and helps managers make decisions as to what to do and WebAccess 8.x also provides developers with the tools to design their own widgets and applications and the integration of Microsoft Excel reports. Included is a set of Excel templates or users can build their own report templates to generate daily, weekly, monthly and yearly reports to help predict the status of equipment. Through HTML5, a limitless number of users, with varying access levels are able to read information and make changes from wherever they are using either the Internet or Intranet. To monitor this information, not only can it be viewed remotely but also on the FPM-7211W.
To communicate with the data acquisition devices an ACP-4300 was connected via Ethernet to an EKI-2525I-AE-wide temperature 5-port Unmanaged Industrial Ethernet Switch and to connect to the flow meters via a Data Acquisition Device, the system integrator used EKI-6311GN wireless access points.
The EKI-2525 supports a Fast Ethernet solution. The power is a 12 ~ 48 VDC redundant input design, and is secured with a double protection mechanism: Power Polarity Reverse Protect and an Overload Current Resetable Fuse. The former tolerates reverse power wiring while the later secures the system from overload currents. As the power supply turns normal, EKI-2525 will automatically get back to work. Each port of EKI-2525 has 2 LED’s to show the link status transmission speed and collision status. It also provides a relay output for an event alarm. In the event of a power failure, the built-in LED will activate the alarm to notify administrators. Engineers can simply verify the hardware status by checking the LED, and have troubleshooting easy and quick. EKI-2525 comes with compact metal housing that rates IP30 to help against from dusty industrial environments.
The EKI-6311GN is a feature rich wireless AP/CPE which provides a reliable wireless connectivity for industrial environments. The PoE injector enhances flexibility in deployment of this AP/CPE even where the DC power supply is hard to fulfill. As an 802.11n compliant device, EKI-6311GN provides 3 times higher data rates than legacy 802.11g devices. With the support of STP, WMM and IGMP snooping protocols, EKI-6311GN effectively improves the reliability of wireless connectivity, especially in app.

System Diagram


With the combination of powerful industrial hardware designed for harsh environments and software that enables site engineers to watch and analyse Advantech was able to provide the forge with the correct equipment to monitor thepower usage of the most powerconsuming aspects of the factory.