400-005-2939

SOLUTION

Industry Solutions

PHM Solution of Air Compressor

Problems In Air Compressor equipment

In recent years, air compressors have become indispensable power equipment in industrial plants. However, air compressors will inevitably generate a large amount of after-sales maintenance and troubleshooting during long-term use. At present, most companies adopt manual periodic inspection and processing methods, which have poor immediacy and low efficiency. Therefore, air compressor equipment manufacturers hope to solve problems related to after-sales operation and maintenance efficiency, maintenance costs, product market application performance, and on-site air compressor equipment health. The end user hopes to avoid the loss caused by the production line shutdown due to the abnormal failure of the air compressor equipment, understand the operating health of the equipment in real time, effectively carry out the inspection and maintenance, and shorten the troubleshooting time of the air compressor equipment.

Solution Value

According to the problems encountered in the air compressor industry,Witium launched the "air compressor fault prediction solution", which carries out the health status analysis and early warning fault analysis of the air compressor and host equipment for the monitoring of the operation status of the air compressor on the user's site, forms a professional air compressor fault prediction and health diagnosis report, and gives maintenance suggestions. Witium 's air compressor fault prediction solution brings great commercial value to users:

Solution Details

Solution Architecture

  The air compressor fault prediction solution uses the Internet of things high-frequency vibration sensor to collect the equipment vibration waveform samples and surface temperature, and generate the vibration characteristic samples of the air compressor equipment; The edge computing gateway collects the three-phase winding temperature and lubricating oil temperature of the air compressor through the platinum resistance to understand the operating load state of the air compressor. Combined with the vibration characteristics of the sensor, the intelligent mechanism model algorithm is used to analyze the big data of the sampled data, so as to realize the prediction of air compressor equipment faults such as imbalance, misalignment, looseness, gear wear and bearing aging; Then upload the data samples and analysis learning results to the witcloud Internet of things data cloud platform through mqtt; The SaaS business cloud platform of the solution provides users with status monitoring, scene monitoring, fault management, operation and maintenance management, equipment management, customer management, authority management and other functions; It also provides data interface function to facilitate users to import equipment status into intelligent factory operation and maintenance platform system. At the same time, the business cloud platform provides professional users with operation status analysis and early warning fault analysis of air compressor equipment through big data analysis tools, and forms professional air compressor equipment health diagnosis reports and maintenance suggestions.

Solution Software

Solution Web Side Software Diagram

Solution Mobile Software Diagram

Solution Hardware

High frequency vibration sensor

MEMS vibration sensor
Medium and high frequency vibration monitoring
The sampling frequency is up to 20khz
Magnetic suction easy installation

RS485
WTS4VXX

USB
WTS6VXX

BASIC PARAMETER
  • Power Input
    DC4.5V-5.5V
  • Low power function
    support
  • Work Temperature
    -40 ℃-105 ℃
  • Work Humidity
    10%-95%(No condensation)
  • IP Rate
    IP67
  • Installation
    Threaded fixing / magnet fixing
  • Overall dimension
    40*40*15mm/40*40*19mm
  • COM Interface
    RS485/USB
  • COM Protocol
    Modbus-RTU
  • Shell Materials
    Aluminum
TEMPERATURE
SENSOR
  • Temperature Object
    Interface temp
  • Temperature Range
    -40°C~105°C
  • Resolving power
    ±1°C
VIBRATION SENSOR
  • Acceleration(G)
    3 Axis:±8g
  • Sample Duration
    1S/10S
  • Frequency
    4KHz/20KHz
  • Axis
    3 Axis
  • Acquisition accuracy
    1mg/LSB
  • Data Content
    Real-time vibration wave/ Characteristic Value

Edge computing gateway

Edge AI Calculation
Several vibrating channels
Multiple wireless Transmit
Embedded algorithm model

WTG9XXW

WTG9XXF

WIRELESS COMMUNICATION
PARAMETER
  • Communication
    WiFi
    4G(Cat1)
  • Mbps
    3Mbps

    upstream 5Mbps/
    down 10Mbps

  • Work Method
    Sta mode / AP configuration
    -
  • DTE-DTE
    40M
    -
  • communication channel
    802.11b/g/n
    LTE-TDD:B38/B39/B40/B41
MAIN PARAMETER
  • Number of vibration channels
    1-6 Optional Channels
  • Vibration interface
    RS485(ModBus-RTU)
  • Oil Temperature
    1 Pt100 Breakage Detection
  • Three winding temperature
    3 Pt100 Breakage Detection
  • LED
    1 * power light, 1 * sensor communication light, 1 * network status light
  • Firmware update
    Online update, remote update
BASIC PARAMETER
  • Shell Materials
    Industrial plastic shell
  • Overall dimension
    115*70*47mm
  • Installation
    Industrial guide rail / strong magnetic fixing / flange fastening / Strap
  • Power Input
    85-262VAC/12-36VDC
  • Operating temperature
    -30~70°C
  • Storage temperature
    -40~85°C
  • Protection
    Overload protection / output short circuit protection / overheating protection
  • Waterproof grade
    IP67

Solution Hardware Diagram

Site Map Of Successful Cases

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Website records: Shanghai ICP 19015228-1
Police record number: 31011202009248