MILESGO
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Industrial & ManufacturingS38

Compressed Air Monitoring

Bài toán

Compressors run on local pressure switches, leaks and idle running go unnoticed, and nobody knows the energy cost of a cubic metre of compressed air.

Tổng quan giải pháp

MILESGO gateways collect data from air compressor controllers, flow meters, pressure transmitters, dew point sensors, electricity meters over Modbus RTU / Modbus TCP, and deliver it to the energy management system, WEB HMI panels, a cloud platform (MQTT) as MQTT / OPC UA / BACnet/IP. Field equipment keeps its own protocol and control logic; integration is done by configuration and point mapping, not custom code.

Typical scope

  • air compressor controllers
  • flow meters
  • pressure transmitters
  • dew point sensors
  • electricity meters

Protocol path

Modbus RTU / Modbus TCP → MQTT / OPC UA / BACnet/IP

Implementation checklist for the project manager

  • Collect register maps and protocol documents from every equipment vendor early; a missing map is the most common delay.
  • For hard-wired signals, list each DI/DO/AI/AO with its type (dry contact, 4–20 mA, 0–10 V, PT1000) and choose I/O modules accordingly.
  • Record CT ratios, meter IDs and multipliers in the point table; wrong multipliers are the usual cause of billing errors.
  • Agree KPI definitions (for example OEE components or kWh per unit) with operations before building dashboards.
  • Commission in read-only mode first; enable write / control points only after the client approves each one.
  • Hand over configuration backups, point table, IP plan and as-built drawings, with a short operator training.

Project deliverables

  • Signed point table and protocol mapping
  • Gateway configuration files and backups
  • IP address plan and network drawing
  • FAT and SAT test records
  • As-built documentation and operator training

Kiến trúc hệ thống

Field layer: air compressor controllers, flow meters, pressure transmitters, dew point sensors, electricity meters, connected over Modbus RTU / Modbus TCP. Edge and integration layer: MILESGO protocol gateways and edge controllers, mounted on DIN rail in existing panels, polling each device, time-stamping values and buffering them locally. Upper layer: the energy management system, WEB HMI panels, a cloud platform (MQTT), which receives the data as MQTT / OPC UA / BACnet/IP. Remote access for maintenance runs over VPN rather than open internet ports.

Thành phần hệ thống

Field devices
air compressor controllers, flow meters, pressure transmitters, dew point sensors, electricity meters
Edge / integration
MILESGO protocol gateways and edge controllers
Upper systems
the energy management system, WEB HMI panels, a cloud platform (MQTT) (MQTT / OPC UA / BACnet/IP)
Tools and commissioning
Web-based configuration, point table import/export (Excel), off-site simulation and on-site diagnostic tools

Năng lực phần mềm và AI

  • Consumption baseline and deviation alertsThí điểm
  • Anomaly detection on trend dataTrong lộ trình

Các bước triển khai

  1. 1

    Site survey and point list

    Inventory devices, protocols, register maps, panel space, power and network paths.

  2. 2

    Design and point table sign-off

    Map every point to the target protocol and system; agree it with the client and the upper-system contractor.

  3. 3

    Configuration and FAT

    Build the gateway configuration off site, simulate it and test against the signed point table.

  4. 4

    Installation and wiring

    Mount gateways on DIN rail, wire RS-485 / I/O / Ethernet, apply the IP plan.

  5. 5

    SAT and alarm tests

    Verify values against local readings, test every alarm and command end to end.

  6. 6

    Handover and support

    Hand over configuration backups, point table and as-built documents; train operators.

Giá trị cho khách hàng

  • Consumption visible by area, system and time period
  • Abnormal conditions seen early, before they become failures
  • Reliable trend data for optimisation and fault diagnosis
  • Consumption attributable by tenant, department or cost centre

Các giải pháp khác trong Industrial & Manufacturing

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