Compressors play a crucial role in a variety of manufacturing environments. Manufacturers’ Monthly investigates the seven most important compressor demands, and why Atlas Copco variable speed drive (VSD) machines meet all of them.
Atlas Copco offers both variable speed drive (VSD) and fixed speed compressors because each types offer advantages in specific circumstances.
As the name suggests, a fixed-speed air compressor operates at the same speed whenever it’s running. By design, it always draws the amount of power needed to meet the maximum compressed air demand, even if demand is less than maximum.
Because the speed of the motor can’t change, whenever the demand for air changes, an air inlet valve adjusts to allow either more or less air to flow out.
In contrast, a VSD air compressor can operate anywhere in the range between its minimum and maximum speed, and it automatically adjusts the speed so production of compressed air matches demand in real time. When demand increases, the motor speeds up. When demand decreases, the motor slows down.
The first VSD range of compressors were first made in 1994, manufactured in Atlas Copco’s Belgium factory. The latest VSD ranges are made in multiple factories around the world.
The variable speed drive adjusts the compressor’s speed (RPM) by means of an inverter. Instead of sending all the power directly into a traditional AC motor that runs at full capacity, the inverter provides the VSD compressor only with the specific frequency required to meet the current demand.
Gabriela Harris, Atlas Copco communications manager, said this capability saves energy because the compressor don’t have to run at full capacity whenever it’s on.
“You can think of VSD like the accelerator in a car, which allows you to vary the car’s speed according to road conditions, level of traffic and whether you’re in a hurry,” she noted.
The ability to adapt motor speed to the fluctuations in air demand means VSD air compressors can be the best choice for a huge range of industries.
Some manufacturers offer retrofitted fixed-speed compressors with an add-on inverter as VSD units. These compressors should come with a disclaimer. According to Harris, to get the most out of VSD technology, a compressor must be designed, built and tested as a VSD compressor. All components, not just the inverter, must work together to deliver the maximum energy savings and a reliable operation.
“That is why Atlas Copco VSD compressors clearly outperform the pretend ones,” she said.
“Because only a dedicated design and custom-built, quality components will get the most out of the VSD technology. There is indeed a growing demand for VSD units, especially where energy costs are increasing, and demand of air consumption is not consistent. VSD give an attractive Return on Investments (ROI), which can be easily quantified and calculated with our data loggers. Contact us to know how much energy can be saved. We carry significant local stock of VSD, right from 7-90kW range and focus on increasing it to align with the future demands.”
On board innovations
In order to continually innovate and create the most specific solutions for manufacturers, Atlas Copco invests heavily in research and development.
“Significant investment in research and development helps develop new solutions that improve our customers’ performance, providing energy efficient compressed air solutions,” Harris said. “Continuous interactions with customers, connectivity and data-driven insights are key to understanding the customer’s requirements.”
Atlas Copco VSDS machines come equipped with a new element, a Ferrite-Assisted Synchronous Reluctance (FASR) motor, a Neos Next Inverter, and Smart Temperature Control (STC) System.
The Neos Next Inverter provides IP54 dirt protection and combines the functionality of one electrical cubicle into a compact unit. Lastly, the STC ensures ideal injection temperature control.
With all these components included, the GA VSDS air compressor is a powerful machine that adapts its performance to its operational environment – and to your needs. Also, with optional Energy Recovery, these machines can re-use up to 80 per cent of heat generated.
“Benefits offered by the FASR motor include IE5 efficiency (which is the most premium motor on the market), and the way they’re constructed without rare earth metals reduces your carbon footprint and saves on unsustainable rare earth metals.”
For maximum connectivity, the VSDS are equipped with SMARTLINK technology and OPC UA. SMARTLINK provides real-time data, insights, and analytics to help maximise performance. OPC UA helps you integrate our VSDS seamlessly into your smart factory.
The 7 most important air compressor demands
1. Tailored to different needs
Each company has different compressed air needs, which is why it can be hard to decide on the best air compressor. Atlas Copco says manufacturers don’t need a standard solution, they need the compressor that is just right for you.
A variable speed drive (VSD) machine delivers exactly this flexibility. If compressed air flow changes throughout the day, this equipment will match those needs. Designed for various applications, including heavy industry, woodwork, textiles, recycling, pulp & paper, chemical & petrochemical, and general manufacturing, an Atlas Copco VSD compressor offers lots of options for a custom compressed air solution.
“If you work across different applications requiring varying levels of air flow, a VSD air compressor will definitely be the right choice. In some instances, they provide an all-in-one solution.”
2. Reliability
Reliability is a crucial factor with any air compressor setup, especially when downtime adds unexpected operating cost expenses. To maximise performance and efficiency, you’ll want a machine that is versatile, connected, and easy to install, maintain, and monitor. The Atlas Copco variable speed drive GA VSDS air compressors come with the latest innovations to keep your factory operating smoothly. With their Neos Next inverter, Boost Flow and Limp Modes, and Smart Temperature Control (STC) System, they’re well- equipped to help avoid downtime.
When maintaining any machine, you’ll want to invest in OEM replacement parts and a service plan with certified technicians. With proper care, Atlas Copco air compressors
are built to operate for a long time. By following the recommendations below, your equipment should keep going for years to come.
Although generic non-branded parts are cheaper upfront, they could increase your company’s overall operating costs and expenses. By using generic parts for your machine, you increase the risk of breakdowns, downtime, and loss of air flow and supply. These unforeseen issues could lead to additional business expenses and cut into potential revenue.
If you use more than one air compressor, you might want to add an Equalizer 4.0 central control system. This connected technology helps you operate multiple compressors efficiently while minimizing individual wear.
3. Efficiency
With stricter emissions regulations, and increasing gas and fuel prices, it’s now more important than ever to reduce electricity consumption wherever possible. Depending on your country, you may need to act quickly.
Electricity consumption makes up more than 80 per cent of the cost of owning and operating an air compressor. Atlas Copco’s VSDS air compressors produce maximum air flow with the lowest possible electricity usage.
With features including a state-of-the art drive train, the Neos Next inverter, and a Smart Temperature Control (STC) system, they can reduce energy consumption by up to 60 per cent.
Although it may not seem cost- effective to replace old machines, doing so could save on wasted energy consumption.
4. Connectivity
When choosing an air compressor to work with your smart factory, you’ll likely want features like remote monitoring, and seamless connectivity, in addition to other innovations. The VSD model comes 6. with features like SMARTLINK and OPC UA for maximum control and integration.
operational status of compressed air installation
It also has unique innovations like Boost Flow and Limp Mode, and a Smart Temperature Control (STC) System.
Adding SMARTLINK monitoring technology to any air compressor puts you in charge. This feature from Atlas Copco provides real-time air system status updates and monitors energy use. SMARTLINK also comes with an easy-to-use mobile application.
In addition, you can opt for an Elektronikon Touch 4.3-inch display for access to customisable timers and controls.
With OPC UA, you can connect all your production equipment in one system. This integration includes machines beyond air compressors. When combining OPC UA and
SMARTLINK data technologies, you’ll tap into secure, efficient connectivity to keep your smart factory running.
5. Compact and quiet
If you have your compressor on the production floor, rather than in a separate utility room, you’ll want a quiet solution. Industrial compressors don’t always have to be loud, especially the latest models. Since VSD air compressors only deliver the amount of air flow needed, they tend to be less noisy than fixed speed models.
6. The right size
Industrial air compressors come in a variety of sizes to meet different industrial application needs. When deciding between a large or small air compressor, it’s important to consider your pressure requirements.
If you need to push or move heavy objects, a big machine with lots of force is likely the solution. To determine size, you’ll also need to calculate how much air flow you’ll need on a daily basis.
Although it might seem smart to plan for future expansion, investing in a machine that’s too big for your needs could be wasteful. As always, our team is here to help evaluate your air flow needs and guide you through the process.
7.Sustainability
Low emissions will be mandatory for businesses in the future and are quickly becoming the norm. If you use industrial compressors in your operations, chances are you could benefit from the latest energy efficient equipment to meet today’s and tomorrow standards.
The best way to begin achieving low emissions is with a comprehensive energy and emissions assessment of your operations.