COMPRESSORS & AIR TECHNOLOGY

Kaeser celebrates 30 years in Australia: Innovating and investing into the future

Kaeser Compressors is celebrating 30 years in Australia this November. Peter Eckberg, Managing Director of Kaeser Compressors Australia, discussed how the company’s latest innovations can assist users in optimising the availability, reliability and efficiency of compressed air systems, through the current pandemic and beyond.

Kaeser Compressors has been present in the Australian market for 30 years, establishing its head office in Dandenong, Victoria, in 1990. Over the past three decades Kaeser has opened branch offices and developed a dedicated network of distributors that are strategically located to be able to deliver Australia-wide sales and service support. Globally, Kaeser celebrated its 100-year anniversary in 2019. From humble beginnings in Germany, the company has grown to become one of the world’s largest compressed air system providers and compressor manufacturers, today employing in excess of 7,000 people worldwide and represented throughout the world through a network of branches, subsidiary companies and authorised partners. The company remains owned and operated by the Kaeser family, now in their third generation, with all products proudly manufactured in Germany. An innovative spirit An innovative spirit continues to pervade all aspects of Kaeser, as Eckberg explains: “This has resulted in a steady stream of innovations in compressed air technology, and applying equally to hardware, software and services. From the refrigeration dryer to revolutionary controllers (Sigma Air Manager 4.0), from the portable compressor through to digitalisation and Industry 4.0, Kaeser still blazes a trail in the industry for the cost-effective, reliable, efficient generation and use of compressed air, thanks to its innovative, topquality products and services.” The COVID-19 pandemic has led Kaeser to develop a number of initiatives, including contactless service, to ensure that compressed air users could continue to operate reliable and efficient compressed air systems. The company has remained open for business throughout the pandemic, ensuring that essential manufacturers have been able to continue to access high-quality, German-made compressed air equipment, local service support, and genuine essential spare parts. One of the company’s most recent innovations brings many benefits to the end user in terms of complete lifecycle efficiency, and most importantly right now, the ability to view – remotely and in real time – key information and diagnostics, for maximum reliability. Complete connectivity “Every part of a compressed air station, whether it be the compressors, compressed air treatment components or distribution system, should operate as efficiently as possible for its own sake,” says Eckberg. “Modern compressors and compressed air treatment components are therefore equipped with internal controllers based on industrial PC technology. But these components are not individual players – they must act together as a team, and a team works best when it is perfectly co-ordinated. A sophisticated compressed air management system is therefore required to perform this particular function.” The Sigma Air Manager 4.0 (SAM 4.0) from Kaeser is an example of a progressive, Industry 4.0-ready compressed air management system that binds all individual components into a complete team, monitoring and controlling them so that the required volume of compressed air is available at all times, at the required quality. Advanced management systems must successfully meet some highly demanding challenges. Not least, they must be capable

Kaeser Compressors Australia’s head office. Construction of a new larger facility is due to start any day.

The SAM 4.0 compressed air management system binds individual components into a complete team, monitoring and controlling them so that the required volume of compressed air is available at all times, at the required quality.

of predictive compressor control, taking into account a range of contributing factors, such as switching losses, control losses, and so on. However, modern master controllers are now expected to do far more than optimise compressor operation according to current demand. Efficiency is playing an ever-increasing role. Here, through the development of a patented, simulation-based optimisation process, the SAM 4.0 is meeting these requirements by predictively selecting the most efficient switching operations based on compressed air consumption profile analysis and equipment and system behaviour, in relation to the prevailing technical operating conditions. Decisions are no longer dictated by a narrow pressure range. Instead, the key is to achieve the lowest possible compressed air production costs through intelligent, energy-saving switching strategies. Predicting service requirements The SAM 4.0 also allows for varying levels of involvement by external service providers. The end user can still perform all of the maintenance, evaluation and servicing of the system themselves (the SAM 4.0 will send notifications when service is required). Alternatively, the end user can choose a predictive maintenance service model with remote diagnostics. Here, the physical meets the virtual world within the framework of a structural model such as Kaeser’s Sigma Smart Air, in which the specific compressed air system – configured according to the operator’s requirements – is represented virtually by a digital twin. Operating data from the compressed air station is securely transmitted to the Kaeser Data Center, where it is analysed in real time. Such real-time availability of operating data makes it possible to monitor the ‘health’ of a compressed air station. This means maintenance is carried out precisely as needed and potential faults can be detected in advance and appropriate maintenance

Peter Eckberg, Managing Director of Kaeser Compressors Australia.

measures automatically initiated at the right time. Ultimately, the end user benefits from significantly reduced compressed air production and operating costs, as well as improved compressed air availability. The combination of remote diagnostics and demand-oriented predictive maintenance ensures maximum compressed air supply availability and complete system effectiveness – preventing unplanned downtime, increasing energy efficiency, reducing service costs by up to 30% and delivering demand optimised compressed air system control throughout the system’s entire life cycle. Remote and real-time monitoring Probably one of the greatest advantages of such advanced compressed air technology in the current pandemic – where many facilities still have staff working remotely, where the number of people in a facility may have been reduced, and where many facilities are still limiting access to suppliers – is the ability to remotely monitor a compressed air system in real-time. From a PC, laptop, tablet or smartphone, the SAM 4.0’s integrated web server provides a visual display of all compressed air system data in the form of HTML pages. All operational and energy consumption data, as well as cost information, can therefore be called up on any network-compatible device – anytime, anywhere. In addition, the end user can choose to configure the system so they receive alarm and maintenance messages for individual components, as well as timely warnings or service requirement notifications via email or text message. When the end user integrates an advanced compressed air management system with a service model such as Kaeser Sigma Smart Air, they have the added peace of mind that a team of compressed air experts are also monitoring the real-time data and acting accordingly. At the best of times a fully networked compressed air system offers the end user numerous benefits. However, many of these benefits – from remote monitoring and diagnostics, to achieving the lowest possible compressed air production costs through intelligent, energy-saving switching strategies – are even more advantageous in the current climate. After all as an essential utility to industry, many businesses rely on their compressed air system and will now more than ever demand maximum compressed air supply reliability.’ Investing in the future Construction is due to start any day at Kaeser’s Australian head office of a brand new factory. This will double the size of the existing facility – increasing the warehousing, workshop and office capacity. While COVID-19 may have slowed down proceedings it has not stopped the company’s reinvestment plans. “Kaeser Compressors has always reinvested heavily into the business,” says Eckberg. “The current pandemic has not halted those efforts. When we finally come out the other end, the company will be in an even stronger position to continue to support its customers.” www.kaeser.com.au

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Where tubular linear motors blow away pneumatics

For factory operators looking to save energy and costs, an obvious first place to look is compressed air. Highly useful in many industrial applications, some sites spend up to 30% of their electricity bill generating compressed air.

Pneumatic actuators, which run on compressed air, have been around since World War II. They are wellunderstood, cheap, and suited to harsh environments. However, they also come with their penalties. Obviously, compressed air must be generated to power them. Depending on the expansiveness of a factory, this can mean numerous compressors and/or a complicated reticulation system. A reliable level of pressure must be maintained, or pneumatics will work poorly or not at all. Air leaks can be expensive. According to a leading compressor technology company, one leak in one unit costing 15 cents/kW/hr to operate will represent well over $2,000 a year to a power bill. With a single point of failure – for example air leakage at one location – the air pressure of the whole plant will drop, and operations will be affected. Then there is the noise. “If you are working in or visiting a factory, you will usually hear a lot of noise,” explains Heng Luo, Product Manager, ANCA Motion. “And that’s one big advantage servo-controlled linear motors have against pneumatics.” Linear motors – for example screw-driven and tubular linear kinds – are newer than pneumatic or hydraulic options, but are preferred for certain applications. Instead of a piston in a cylinder – driven by compressed air or an incompressible fluid – tubular linear motors use magnetic flux to create motion. They aren’t as cheap in upfront costs compared to pneumatics, but offer vast benefits in aspects including accuracy, cheaper operating costs, and flexibility. Pneumatics can move quickly and forcefully from one point to The MAP solution aims to assist companies to run their operations efficiently and reliably, regardless of their budget constraints and market volatility. It makes compressed air simple, and allows companies to outsource provision of compressed air to Sullair, allowing for total control over their compressed air without the significant upfront capital outlay. MAP allows companies to save time and money by relying on Sullair’s expertise. Sullair installs the appropriate solution and takes care of all maintenance and servicing over five years. Sullair Australia’s Managing Director, Fred Funnell, explains: “Outsourcing provides the customer with the essential equipment they need, along with a whole-of-life support package and the peace of mind to know the equipment is being closely monitored allowing them to focus on their core business.” After the five-year period, companies have the flexibility to extend their contract, purchase the compressor outright, or end the contract. MAP gives clients the opportunity to buy compressed air on a consumption basis with a single monthly charge including usage, maintenance, and lease of the equipment. MAP is a flexible offering that can work for both large and small companies. Key benefits include: • Maximised reliability and uptime. Sullair’s equipment will be remotely monitored 24 hours a day, 365 days a year. Sullair

another (and hydraulics quicker and more forcefully still, for the same size) but with little positional control along the stroke. ANCA Motion’s LinX M-Series offers 10 micrometre resolution, as well as velocity up to 10m per second and maximum acceleration over 30G. The M-Series comes with an integrated position sensor, with precise positional control. It can also achieve a continuous force of 90-160 Newtons, and a peak force of 1,200 Newtons. An estimated payback period versus pneumatic cylinders – which with their form factor and mounting design, the M-Series is a neat substitute for – is only 18 months. One area of obvious advantage over pneumatics is the ease of reprogramming between jobs. A recent application for a customer’s forming machine substituted LinX motors for pneumatics to move a cutting bed. Changes for different workpiece lengths could take six to eight hours for the painstaking recalibration of air pressure. Such adjustments now are a quick change in servo drive parameters – a matter of seconds. The improved positional control has boosted throughput by 50%, with the massively improved precision allowing the process to be confidently sped up. ANCA Motion’s linear motors were originally developed for sister company ANCA CNC Machines’ FX Linear and MX Linear tool and cutter grinder machines. The LinX M-Series Tubular Linear Motor has a failure rate of less than 0.03%. Robust support is offered through an international network of 125 engineers in strategic

Sullair Australia launches Managed Air Power (MAP)

Sullair Australia has launched new ‘Managed Air Power’ service, a comprehensive outsourced compressed air solution.

locations. www.ancamotion.com

will know if there’s a problem with your machinery before you do, and will act to minimise any downtime. • Easy budget management. Customers will enjoy the convenience of one monthly invoice that covers all equipment parts, maintenance, monitoring and management. • Expedite purchasing of new or replacement equipment. MAP allows clients to treat their compressed air as an operating expense rather than a Capex budget item. • Improved productivity. Funnell says “People should be able to focus on their core business, not whether their compressor is optimised or if it’s missed its routine service”. By outsourcing to Sullair, clients can focus their time and resources entirely on their core business. • Comprehensive monthly reporting. MAP comes with transparent monthly reports including usage, servicing and equipment performance, giving clients clarity and peace of mind. Funnell adds: “Outsourcing options give the customer a chance to stop and reassess their actual air demand. Is it the same as it was 10 years ago when the old compressor was installed? Are we now paying for energy we don’t need?” www.sullair.com.au

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