Product Solution 04 / 08
Online vibration, temperature & current monitoring for air compressors — early warning of bearing degradation and overtemperature shutdown, reducing unplanned downtime
Online health monitoring for air compressors: collects vibration, temperature & current. AI learns operational baseline to identify bearing degradation and cooling anomalies early, reducing unplanned downtime. No equipment replacement, no line modification — data connected in 30 minutes.
The air compressor is the lifeline of plant utilities. A single unplanned stop not only cuts compressed air supply but brings all pneumatic equipment to a halt — losses of thousands of dollars per hour.
Cooler blockage, lubricant degradation, ambient temperature swings — overtemperature shutdowns look like temperature issues on the surface but have diverse root causes that are hard to pinpoint with manual experience alone.
Consumables replaced by running hours, but bearing wear and screw degradation timelines vary enormously with operating conditions. Fixed-interval maintenance still misses failures.
Monitors bearing housing and casing vibration severity. AI learns normal operating baseline to identify early signs of imbalance, misalignment and bearing wear.
Simultaneously collects discharge temperature, oil temperature and cooling water temperature to assess cooling system efficiency degradation and oil deterioration trends.
Records load/unload frequency, running hours and start-stop counts to identify frequent cycling and extended idle conditions.
Combines vibration spectrum with temperature trends to provide 7-14 day advance warning of screw wear and bearing degradation, with maintenance window recommendations.
Abnormal alerts auto-generate maintenance work orders — dispatch → accept → process → archive with full traceability, building per-machine health records.
Alerts pushed to Web dashboard and WeCom; SMS as optional add-on. Same-type alerts auto-merged for noise reduction.
Yes. Externally mounted vibration-temperature sensors on bearing housings capture the data, and current transformers capture motor current — no compressor data output required. DTU aggregates data and uploads via 4G/Ethernet.
Gradual faults such as bearing degradation and screw wear typically show observable trends 7-14 days ahead. Sudden fractures cannot be predicted — the system must be used alongside routine inspections.
The monitoring approach is brand-agnostic. Whether Atlas Copco, Ingersoll Rand, Sullair or domestic brands — all data is collected via external sensors, 100% compatible.
Sensor installation can be completed while the compressor is running. Surface-mount sensors only need surface cleaning and adhesive attachment — no shutdown required.
