The Sigma Air Manager 4.0 is the core component of a blower station and the key technology needed in order to take advantage of the Industrie 4.0 services of the future. It acts as the central mastermind and controls the individual machines with maximum efficiency whilst perfectly adjusting the flow capacity to match flow rate demand. All it needs from the process control system is the desired differential pressure value – the SAM 4.0 then ensures optimal control of all blowers. Partial-load bridging and individual solutions are therefore things of the past, along with complicated setups. Now, all applications are supplied by one central blower station with master a controller that analyses operating data in seconds and simulates various scenarios in order to select the most efficient solution. The result? Previously unimaginable energy efficiency.
All components within the station are optimally matched and controlled to meet the customer’s specific needs. Real-time process monitoring provides valuable operating data, which are forwarded for detailed evaluation. The analysis results help to predict potential faults as early as possible and prevent them by taking timely action.
The SAM 4.0 offers communication in 30 languages whilst the easy-to-operate 12-inch colour touchscreen display shows at a glance whether the station is operating in the “green zone” for optimal energy performance. It’s incredibly easy to display and analyse a wealth of data, such as operating status, pressure curve, flow rate and power, as well as maintenance and any fault messages. And, thanks to a network connection, this can be done not only at the machine itself, but also conveniently from a PC at the office or elsewhere. This powerful capability therefore provides peace of mind and lays the foundation for predictive maintenance; it also enables sophisticated energy management per ISO 50001.
The master controller also makes it possible to take advantage of new options for predictive maintenance of blowers. Previously, maintenance could only be performed on the basis of a regular scheduled service date and repairs would be made only after a fault message had occurred. The SAM 4.0 now makes it possible to initiate maintenance before a fault occurs, thereby avoiding costly downtime and consequential damage.
The sensors and Sigma Control 2 controller integrated into the machine collect process data, which are immediately forwarded to the Sigma Air Manager 4.0. Specialised software is then used to transfer the information to the Kaeser Data Center for real-time analysis. The Kaeser Data Center performs central monitoring and processing of operating messages. Required predictive maintenance measures are then initiated as needed based on this information.
Ultimately this enables maintenance and necessary repairs to be performed at the precise moment they are actually needed. This saves time, minimises costs and ensures reliable blower availability, which in turn benefits all associated downstream processes.
Established in 1919 as a mechanical engineering workshop, Kaeser Kompressoren is a family-owned business and today is one of the world’s leading compressor manufacturers and compressed air systems providers. Kaeser’s production centres are located in Coburg (main plant) and Gera, Germany. The company approximately 7000 employees worldwide.
Kaeser’s comprehensive product range comprises stationary and portable rotary screw compressors, stationary and mobile reciprocating compressors, vacuum pumps, rotary blowers, rotary screw blowers, turbo blowers, filters, dryers, air tools and accessories. Furthermore, Kaeser’s state-of-the-art compressor control systems with advanced IT technology take compressed air efficiency to the next level and beyond. Both users and the environment therefore benefit from the consequent energy-savings.
Subsidiaries and authorised partners in over 140 countries ensure that users are able to enjoy all of the benefits that the very best in compressed air engineering has to offer. Key markets include the EU, the United States, Latin America and the Asia-Pacific region. Kaeser owes its enviable reputation not only to the exceptional efficiency and quality of its products, but also to its reliable field service. More recently, the other industry-leading services offered by the company – such as operator models for compressed air stations, concepts within the framework of Industry 4.0 and predictive maintenance – have increasingly moved to centre stage.
Kaeser’s many years of strong growth and expansion are directly attributable to its passion for innovation and strict quality standards. Both are driven by the hard work and dedication of its employees, whose expertise, combined with ongoing professional development, keep them attuned to the very latest technology. The company’s opening-up of key global markets in recent years has also created many additional jobs and secured existing ones, both in Germany and around the world.
The company is headed by Thomas Kaeser, Dipl.-Wirtsch.-Ing, grandson of the company’s founder, and Tina-Maria Vlantoussi-Kaeser, Dipl.-Wirtsch.-Ing.
Brief company history:
Founded: Coburg 1919
Trade name: Kaeser Kompressoren
Founder: Carl Kaeser senior
Executive management: Thomas Kaeser, Dipl.-Wirtsch.-Ing.,
Tina Maria Vlantoussi-Kaeser, Dipl.-Wirtsch.-Ing.
Products: Reciprocating and rotary screw compressors ranging from 0.18 to 515 kW, portable rotary screw compressors, high-pressure and dry-running compressors, compressor control systems, vacuum pumps, rotary blowers, rotary screw blowers, turbo blowers, air filters and tools, refrigeration & desiccant dryers, as well as compressed air system accessories and services.
Turnover (Kaeser Kompressoren SE): Approximately EUR 1 billion
Employees:
Worldwide: approximately 7000
Apprentices: Approx. 300
Apprentice positions per year (since 2016): 120
Production centres: Coburg (main plant), Gera
Branch offices: 8 regional offices throughout Germany
Worldwide sales partners: Represented in over 140 countries by Kaeser-own branch offices and exclusive authorised partners
KAESER KOMPRESSOREN SE
Carl-Kaeser-Str. 26
96450 Coburg
Telefon: +49 (9561) 640-0
Telefax: +49 (9561) 640-130
http://www.kaeser.com
Telefon: +49 (9561) 640-452
Fax: +49 (9561) 640-129
E-Mail: daniela.koehler@kaeser.com
