IoT for air compressor manufacturers
Compressed air is the utility a factory notices only when the pressure drops. A controller on each compressor reports pressure, load and temperature to you and to the service partner who maintains it.
Compressed air is the utility a factory notices only when the pressure drops. A controller on each compressor reports pressure, load and temperature to you and to the service partner who maintains it.
Receiver pressure through a working day shows whether the compressor keeps up with demand, and when it does not.
Time loaded against time unloaded is the conversation about sizing and about leaks. It comes straight from the motor current.
Service by hours run, not by the date on a sticker, is only possible when the hours are reported.
A starting list, not a fixed kit. The ports are set from the dashboard, so the same controller takes a different mix of sensors on a different model.
| Signal | How it is read | What it tells you |
|---|---|---|
| Receiver pressure | Analogue pressure transducer | Whether supply keeps up with demand |
| Motor current | Clamp-on current sensor over RS485 | Loaded, unloaded and stopped time |
| Discharge temperature | PT1000 probe | Overheating before it becomes a trip |
| Fault contact | Dry contact on a digital input | A trip, the moment it happens |
| Compressor controller | RS485 Modbus RTU, from your register map | Hours, service counters and alarm codes |
| Room temperature | 1-Wire probe | A compressor room that is too hot to run in |
Four ports on one controller, and RS485 devices share a bus, so most of this list fits on a single unit.
One machine reporting is a gadget. Every machine you have shipped reporting to the same place is a service business.
Each machine reports to the same cloud. Your service desk sees which units are running, which are in alarm and which have gone quiet, before the customer calls.
Accounts nest: you sit above your dealers, and each dealer above its customers. A parent account cannot grant more than it holds, and a unit can be shared with a service company without handing over a login.
Readings and events are stored with their time and export to Excel, for a warranty claim, a service report or a disagreement about what happened and when.
A REST API with scoped tokens covers what the dashboard covers, so fleet data can feed your service system, your ERP or your customer portal directly.
The controller takes 6 to 32 V DC, so it runs from a 12 or 24 V supply already on the machine. Its internal rechargeable battery keeps it reporting after the machine loses power, which is when the reading matters most.
It connects over 4G-LTE from wherever the machine is installed. There are no Wi-Fi credentials to collect and no IT department to convince at each customer.
If the machine already has a controller with an RS485 Modbus RTU port, give us its register map and we add it as a supported device. Its values and alarms then arrive alongside the sensor readings.
The web dashboard is served on your domain with your name, logo and colours, and the iOS and Android apps are published under your own developer accounts. Your customers log in to your product.
Readings are held on the device while the network is down and sent in order when it returns, so the record has no gap where the incident was.
From the motor current, yes. The two states draw clearly different current, so the record shows the time spent in each. Where the compressor controller exposes its own counters over Modbus, those are read directly.
Yes. A unit belongs to one account and can be shared with another, so the owner and the service partner both see it without sharing a login, and the partner sees nothing else.
Either. Every controller comes with OmniCloud included, and the REST API does what the dashboard does if you would rather build your own front end on top of it.
The supply voltage available on the machine, the signals you want reported, the register map if the machine has a Modbus controller, and how your dealers and customers should be separated. A first batch on machines already in the field is the usual way to begin.
Over the air, by cellular. Where there is no network at all, the unit raises its own Wi-Fi access point and takes the update from a phone or laptop beside it.
What it is, what you want it to report, and who needs to see which units. We come back with how the controller wires in and how the accounts would be laid out.
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