Project "MASOC KC support for digital product development"

Project Nr.: 2.2.1.3.i.0/1/24/A/CFLA/007

The aim of the project is to increase the level of digitalisation of the air compressor station control in order to increase energy efficiency - energy consumption per unit of material produced (compressed air, nitrogen, oxygen), safety of the production process - possibility to remotely control the production process at any time and operatively manage according to changes in conditions, interoperability and serviceability - use of control teams in Latvian and quality control of produced materials in accordance with the standards.

In order to make the most of compressed air production systems, they need to be loaded at optimum levels in line with changing compressed air consumption. This can be done by improving digital control and process/output control. The project proposes five activities that enable higher efficiency of compressed air systems.

Block control - simultaneous control of several compressor stations.

The main challenges for the simultaneous control of multiple compressor air stations are to ensure equal compressor loads and the simultaneous operation of the required number of compressor stations. This is achieved by the so-called block control function. This is usually pre-programmed in the compressor controllers. Controllers from different manufacturers are not designed to work together, so separate controls are needed to control and monitor all the different stations.

The product package is new for the operator FONONS Ltd. The implementation of the project will allow the Latvian manufacturer Fonons Ltd. to offer improved and competitive products to its customers.

Compressed air production equipment is used in all industries - metalworking, woodworking, food industry, scientific institutes, car repair shops. The target customers are manufacturing companies that need to significantly reduce the amount of electricity consumed per unit of output and downtime losses.

The project is expected to reach TRL7 after implementation.

The activities proposed in the project correspond to the further development of digital control of industrial compressed air compressor stations and their implementation in compressed air compressor stations manufactured by FONONS Ltd. will allow to offer more energy efficient and safer products.

27.12.2024.

Study of the principles of starting electrical industrial equipment, depending on the power of the electric motor. Direct start, star-delta connection, use of variable speed frequency converters. Consideration of frequent starting processes. Consideration of options for solving the problem of heating the electric motor. Studies of the possibility of changing the automated operating mode.

31.01.2025.

Study of various operational protection solutions. Possibilities of embedding in the control unit and displaying on the control panel. Programming options for the control units of the corresponding solution.

Development of an algorithm for starting compressors of various capacities has been initiated.

Equipment control according to the operating pressure. Pressure tracking.

28.02.2025.

Optimization of the algorithm logic and calculation of the possibilities of more efficient use of electricity.

Implementation of various protection options in the algorithm.

Optimal pressure tracking. Ensuring uniform pressure in the system.

1.07.2025.

Development of a multi-device control algorithm will begin. Depending on parameters - for example, pressure, several devices will be controlled. The project plans to demonstrate the operation of the algorithm with three devices.

Three prototypes have been prepared for testing the algorithms.

1.08.2025.

A testing environment is being prepared - depending on pressure changes, device startup and parallel operation. When the pressure decreases, the algorithm should ensure the startup of multiple devices to increase the total capacity.

1.09.2025.

Research has been conducted on the speed of device startup. In the event of a rapid drop in pressure, it is necessary to turn on the devices at a sufficient speed so that pressure pits do not form.

3.11.2025.

The practical research process continues.

31.12.2025.

Logic research was conducted on the control algorithms of several devices by connecting several devices and changing the operating conditions.

During the study, operating settings were changed and connected objects were changed.

Programming control blocks and developing algorithms would be simple if air consumption were uniform and systematic. In a real production situation, air consumption is unpredictable. One example is furniture manufacturing with many workbenches where employees work. Each piece of furniture is manufactured by one or more employees. No two pieces are the same. As a result, the number of manufacturing operations varies. Since the parts are manufactured by employees – people – the time required to perform each operation varies – some are faster, some are slower. The operation produces chips – which must be blown away. As a result, air consumption increases at unpredictable times. 

In most cases, a single compressor with sufficient air capacity for all workplaces and equipment is used to supply the factory with compressed air. Compressors require maintenance, and to do this, they must be shut down for at least an hour. Therefore, factories with a large number of employees and equipment that consume air have at least two compressors installed. It is recommended to have at least two compressors so that there is no downtime in the event of a compressor failure.

In order to use electricity economically and save on compressor operating hours, an algorithm is needed that monitors air consumption and operates one or more compressors.

Currently, the project is researching irregular air consumption and developing a practical algorithm to ensure steady air production.

The supply of compressed air must be continuous and steady, with the minimum pressure required to ensure the operation of the equipment. For example, automated equipment or automated lines require a minimum pressure of 6 bar. If the pressure drops below this level for a moment, the equipment stops – and with it, the entire production line. This causes downtime.

To prevent air pressure drops, it is necessary to switch on the compressor in good time, anticipating the pressure drop and its rate of decline. If one compressor is not enough, then one or more additional compressors must be switched on in time. The compressor start-up speed can be up to several tens of seconds. Since the start-up time is relatively long, the air pressure may fall below the permissible level during consumption. Therefore, it is necessary to create an algorithm that calculates when to switch on an additional compressor, taking into account the rate of air pressure drop, in order to ensure a steady and uninterrupted air pressure in the system.

Currently, the study was conducted with two compressor prototypes – two compressor control prototypes connected to each other.