Abstract:
Systems and methods for monitoring the efficiency characteristics and performance statistics of an air compressor system, comprising, an air compressor system, an air compressor system monitoring module operable for receiving input data and sending results data, the monitoring module having an analyzer for analyzing input data relating to air compressor system operation and generating output data relating to air compressor system performance and efficiency, and a communications network operably coupled to the air compressor system and air compressor system monitoring module, the communications network operable for acquiring the air compressor system data and for communicating the air compressor system data to the air compressor system monitoring module.

Description:
BACKGROUND OF INVENTION  
         [0001]    The present invention relates generally to computerized systems and methods for monitoring the usage and efficiency of industrial equipment and, more specifically, to computerized systems and methods for monitoring the usage, efficiency, and productivity of air compressors.  
           [0002]    Compressed air is used in everything from automotive repair shops, to house painting applications, to industrial manufacturing facilities. Compressed air powers the tools that are used to build homes and paint automobiles. Compressed air is used in the cleaning of facilities and equipment, and as a carrier of materials and products.  
           [0003]    The costs and energy associated with using compressed air are often overlooked. Despite the fact that the natural resource component of a compressed air system is free to anyone who wishes to use it, there are still costs associated with using air for certain purposes. While compressed air usage may be a significant operating cost, the fourth highest utility cost after electricity, natural gas, and water, most industries simply consider compressed air usage as a fixed cost. However, compressed air costs may be monitored and reduced just as the costs associated with, for example, recycling, raw material usage, and energy usage, may be monitored and reduced.  
           [0004]    Compressed air&#39;s costs come with producing it in a compressor. Compressors require electricity to run them, tanks to hold the compressed air, hoses and valves, and a distribution system to move the air. By reducing the number of leaks in a compressor system, energy costs may be reduced while efficiency, performance, and productivity may be increased.  
         SUMMARY OF INVENTION  
         [0005]    There is, accordingly, a need for systems and methods for monitoring compressed air usage, predicting compressed air usage, and for quickly gathering, formatting, and reporting compressed air usage data of a facility in order to optimize compressor efficiency. Efficiency is a measure of actual compressed air delivered to the system and the amount of horsepower required to deliver it. Productivity is measured as effective operation as measured by a comparison of production with cost, where cost is measured in terms of energy, time, and money. Productivity is defined as yielding results, benefits, or profits. The present invention meets these needs by implementing computerized systems and methods that allow a company to easily input production data and individual compressor related data and quickly obtain performance analysis results in order to maximize efficiency and reduce the costs associated with compressed air usage.  
           [0006]    The present invention provides systems and methods for measuring the efficiency of compressed air systems in order to optimize that efficiency. The systems and methods of the present invention may be used by plant managers, engineers, etc. to measure the current state of their facilities&#39; air compressor systems. The present invention analyzes data, calculates compressor efficiencies, analyzes facility and shift productivity, and analyzes variance in the air compressor systems. The present invention ranks compressors for overhaul, provides strategies for optimizing distribution systems, and calculates potential savings based on decreasing variance in the systems and optimizing compressor efficiency and overall plant productivity.  
           [0007]    The present invention provides systems and methods for monitoring the efficiency characteristics and performance statistics of an air compressor system, comprising, an air compressor system, an air compressor system monitoring module operable for receiving input data and sending results data, the monitoring module having an analyzer for analyzing input data relating to air compressor system operation and generating output data relating to air compressor system performance and efficiency, and a communications network operably coupled to the air compressor system and air compressor system monitoring module, the communications network operable for acquiring the air compressor system data and for communicating the air compressor system data to the air compressor system monitoring module. 
       
    
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0008]    [0008]FIG. 1 is a functional block diagram of a compressed air system monitoring module residing in a computer system;  
         [0009]    [0009]FIG. 2 is a functional block diagram of a communications network further representing an operating environment for the air compressor monitoring module of FIG. 1;  
         [0010]    [0010]FIG. 3 is a functional block diagram of one embodiment of the air compressor monitoring module of the present invention;  
         [0011]    [0011]FIG. 4 is a flowchart of a method for acquiring air compressor data over a communications network; and  
         [0012]    [0012]FIG. 5 is a functional block diagram of a plurality of data sheets stored in a database that are components of the air compressor monitoring module. 
     
    
     DETAILED DESCRIPTION  
       [0013]    The term “six sigma” is used in and forms the background for the present application. The term “six sigma” defines an optimum measurement of quality: 3.4 defects per million events. The Greek letter sigma (σ) is a mathematical term that represents a measure of variation, the distribution or spread of data around the mean or average of any process or procedure in manufacturing, engineering, services, or transactions. The sigma value, or standard deviation, indicates how well a given process is performing. The higher the value, the fewer the defects per million opportunities. Six sigma is the application of statistical problem-solving tools that identifies where wasteful costs are located and points towards steps for improvement.  
         [0014]    The present invention provides systems and methods for measuring the efficiency of an air compressor system. Efficiency is defined as effective operation as measured by a comparison of production with cost, where cost is measured in terms of energy, time, and money. In one embodiment of the present invention, the systems and methods for monitoring an air compressor system include an air compressor monitoring module including a plurality of predefined data files which are accessed via, for example, a webpage. For instance, such information may be obtained by a remote computer accessing a web server via the Internet. The web server may employ a plurality of data files displayed as a webpage layout and an active server page program to create a webpage that displays information. In an alternative embodiment of the present invention, the plurality of predefined data files may be included in a software application residing in a computer system.  
         [0015]    [0015]FIGS. 1 and 2, in one embodiment, depict a computer system  10  and an operating environment used for measuring the efficiency of a facility&#39;s air compressor system in order to optimize the productivity of that air compressor system. Productivity is a measure of effective operation as measured by a comparison of production with cost. Cost may be measured in terms of energy, time, and money. Efficiency is a measure of the actual air delivered compared to the energy required to produce it.  
         [0016]    The computer system  10  acquires air compressor system information and predicts air compressor efficiency. As those skilled in the art of computer programming recognize, computer programs are depicted as processes and symbolic representations of computer operations. Computer components, such as a central processor, memory devices, and display devices, execute these computer operations. The computer operations include the manipulation of data bits by the central processor, and the memory devices maintain the data bits in data structures. The processes and symbolic representations are understood, by those skilled in the art of computer programming, to convey the discoveries in the art.  
         [0017]    [0017]FIG. 1 is a functional block diagram showing one possible embodiment of the present invention, in which an air compressor monitoring module  12  resides within a computer system  10 . The air compressor monitoring module  12  may be stored within a system memory device  14 . The computer system  10  also includes a central processor  16  executing on an operating system  18 . The operating system  18  also resides within the system memory device  14 . The operating system  18  includes a set of instructions that control the internal functions of the computer system  10 . A system bus  20  communicates signals, such as data signals, control signals, and address signals, between the central processor  16 , the system memory device  14 , and at least one peripheral port  22 . Those of ordinary skill in the art understand that the program, processes, methods, and systems described in this application are not limited to any particular computer system or computer hardware.  
         [0018]    Those skilled in the art also understand that the central processor  16  is typically a microprocessor. Advanced Micro Devices, Inc., for example, manufactures a full line of ATHLON™ microprocessors (ATHLON® is a trademark of Advanced Micro Devices, Inc., One AMD Place, P.O. Box 3453, Sunnyvale, Calif. 94088-3453, 408.732.2400, 800.538.8450, www.amd.com). Intel Corporation also manufactures a family of X86 and P86 microprocessors (Intel Corporation, 2200 Mission College Blvd., Santa Clara, Calif. 95052-8119, 408.765.8080, www.intel.com). Other microprocessor manufacturers include Motorola, Inc. (1303 East Algonquin Road, P.O. Box A3309 Schaumburg, Ill. 60196, www.Motorola.com), International Business Machines Corp. (New Orchard Road, Armonk, N.Y. 10504, (914) 499-1900, www.ibm.com), and Transmeta Corp. (3940 Freedom Circle, Santa Clara, Calif. 95054, www.transmeta.com). While only one microprocessor is shown, those skilled in the art also recognize that multiple processors may be utilized. Those skilled in the art further understand that the program, processes, methods, and systems described in this application are not limited to any particular manufacturer&#39;s central processor.  
         [0019]    The system memory  14  further contains an application program  24  and a Basic Input/Output System (BIOS) program  26 . The application program  24  cooperates with the operating system  18  and with the at least one peripheral port  22  to provide a Graphical User Interface (GUI)  28 . The Graphical User Interface  28  is typically a combination of signals communicated along a keyboard port  30 , a monitor port  32 , a mouse port  34 , and one or more drive ports  36 . The Basic Input/Output System  26 , as is well known in the art, interprets requests from the operating system  18 . The Basic Input/Output System  26  then interfaces with the keyboard port  30 , the monitor port  32 , the mouse port  34 , and the drive ports  36  to execute the request.  
         [0020]    The operating system  18  may be WINDOWS® (WINDOWS® is a registered trademark of Microsoft Corporation, One Microsoft Way, Redmond Wash. 98052-6399, 425.882.8080, www.Microsoft.com). WINDOWS® is typically preinstalled in the system memory device  14 . Those of ordinary skill in the art also recognize that many other operating systems are suitable, such as UNIX® (UNIX® is a registered trademark of the Open Source Group, www.opensource.org), Linux, and Mac® OS (Mac® is a registered trademark of Apple Computer, Inc., 1 Infinite Loop, Cupertino, Calif. 95014, 408.996.1010, www.apple.com). Those skilled in the art again understand that the program, processes, methods, and systems described in this application are not limited to any particular operating system.  
         [0021]    The air compressor monitoring module  12  may be physically embodied on or in a computer-readable medium, or may be stored as a web-site that is accessed via the Internet using a web browser Examples of computer-readable medium include: CD-ROM, DVD, tape, cassette, floppy disk, memory card, and a large-capacity disk (such as IOMEGA®, ZIP®, JAZZ®, and other large-capacity memory products) (IOMEGS®, ZIP®, and JAZZ® are registered trademarks of Iomega Corporation, 1821 W. Iomega Way, Roy, Utah 84067, 801.332.1000, www.iomega.com). The computer-readable medium, or media, could be distributed to end-users, licensees, and assignees. These types of computer readable media, and other types not mentioned here but considered within the scope of the present invention, allow the air compressor monitoring module  12  to be easily disseminated. A computer program product for tracking, monitoring, and reporting air compressor efficiency comprises a computer-readable medium and the air compressor monitoring module  12 . The air compressor monitoring module  12  communicates information over a communications network.  
         [0022]    [0022]FIG. 2 is a functional block diagram of a communications network  40 . This communications network  40  further represents an operating environment for the air compressor system monitoring module  12  (FIG. 1). The air compressor monitoring module  12  resides within the memory storage device  14  (FIG. 1) in the computer system  10 . The computer system  10  is shown as a server  42 . The server  42  may communicate with a Local Area Network (LAN)  44  along one or more data communication lines  46 . As those of ordinary skill understand, the Local Area Network  44  is a grid of communication lines through which information is shared between multiple nodes. These multiple nodes are conventionally described as network computers. As those of ordinary skill in the art also recognize, the Local Area Network  44  may itself communicate with a Wide Area Network (WAN)  48  and with a globally-distributed computing network  50 , such as the Internet. The communications network  40  allows the server  42  to request and acquire information from many other computers connected to the Local Area Network  44 , the Wide Area Network  48 , and the globally-distributed computing network  50 .  
         [0023]    Referring to FIG. 2, the server  42  may communicate/acquire information to/from many computers connected to the communications network  40 . The server  42 , for example, may acquire air compressor system information from a predetermined facility A computer  52  monitoring an air compressor system. The server  42  may also acquire air compressor information from a different facility B computer  54  monitoring, for example, a product manufacturing plant or process that requires the use of compressed air to produce a specific manufactured product.  
         [0024]    It is also possible for a user or operator having an interest in the air compressor system to use a remote computer  56  to access the communications network  40  and to remotely access the server  42 , the facility A computer  52 , and the facility B computer  54 . Because many computers may be connected to the communications network  40 , computers and computer users may share and communicate a vast amount of information acquired and processed by the air compressor monitoring module  12  (FIG. 2). The air compressor monitoring module  12  thus permits on-line, real-time air compressor system monitoring.  
         [0025]    [0025]FIG. 3 is a functional block diagram illustrating one embodiment of the air compressor monitoring module  12 . The air compressor monitoring module  12  acquires information from the communications network  40  (FIG. 2), or directly from an air compressor system and uses this information to track and predict air compressor usage and efficiency for, for example, commercial buildings or for industrial facilities. As FIG. 3 illustrates, the air compressor monitoring module  12  acquires air compressor system information  60  and stores this information in a database  62 . The air compressor system information  60 , for example, may relate to an air compressor being used in a product manufacturing plant. The air compressor usage information  60  may also relate to an air compressor used in any portion, area, or machine of an industrial process. The air compressor system information  60 , likewise, may relate to an air compressor being used in a particular room, in similar applications at different facilities for comparison, and in an entire facility as a whole. Further, the air compressor monitoring module  12  may acquire air compressor system information  60  from multiple locations. The air compressor system information may include data such as compressor identification, owner identification, activity logs identifying compressor usage, energy logs identifying energy usage and cost, reference compressor data based on a make or model of a compressor, raw data info (described in more detail below), and combinations of and associations between such data. This air compressor system information  60  may be used by an analyzer  61  to track and predict historical, present, and future air compressor system conditions from those multiple locations. The analyzer  61  may include, for example, software having data analyzing and forecasting capabilities. The air compressor monitoring module  12  supplies air compressor system profiles that help plant operators, owners, and other employees understand the consequences of using inefficient air compressor systems.  
         [0026]    The air compressor monitoring module  12  may also report air compressor system data to suppliers, manufacturers, or maintainers  66  of air compressor systems. As FIG. 3 illustrates, the air compressor system monitoring module  12  may communicate with a supplier, manufacturer, or maintainer  66  of the air compressor system to send and receive statements, usage reports, dry air quality reports, and other air compressor related information. The air compressor monitoring module  12  may communicate formatted air compressor system data  64  along the communications network, in real-time and on-line, to an air compressor system supplier, manufacturer, or maintainer. The air compressor system monitoring module  12  may include a plurality of sensors connected to the air compressor system, the plurality of sensors operable for directly inputting data into the air compressor monitoring module  12 . The air compressor monitoring module  12  may further accept manually-entered data  68  from plant operators, engineers, and others with access to the database  62  or with access to the network. The air compressor monitoring module  12  thus reduces, and may even eliminate, the need for plant personnel to monitor and report air compressor system information. The reporting of system data to manufacturers and suppliers of the systems may facilitate the repair and service of air compressor systems that are not running at optimum efficiencies. The reported results may lead to pulling an air compressor off-line or possibly changing its mode of operation.  
         [0027]    FIG. 4  is a flowchart of a method for acquiring air compressor information over a communications network. Air compressor data may be acquired in real-time or at a later time, over the communications network from a computer, automatically or by manual entry (Block  70 ). The air compressor information may be displayed via a user interface on the computer (Block  72 ). Historical air compressor efficiency (Block  74 ) and predicted air compressor efficiency (Block  76 ) for the facility may be displayed via the user interface. A comparison between an air compressor used at a given facility and an air compressor used at a different facility may also be displayed (Block  78 ), or a comparison of a single air compressor used at a single facility during different shifts (Block  78 ) may also be displayed. Average air compressor efficiency for the facility may also be displayed (Block  80 ). The methods and systems of the present invention may also dynamically update the acquired air compressor information in real-time, independent of any intervention by a human user (Block  82 ). A user may also request an update of air compressor efficiency information in real-time (Block  84 ). It should be noted that the systems and methods described herein may be utilized to generate and output any user-defined manipulation of the compressor system information.  
         [0028]    Referring to FIG. 5, the air compressor module  12  (FIGS. 1 and 2) includes a plurality of data files  90  that include input data or results data used to analyze an air compressor system. The data may be manually gathered and input into the system, such as though using a data-recording sheet, or the data may be automatically transmitted through the network. The input files contain efficiency characteristics and production information necessary to collect data, analyze data, and calculate results. The results data contains suggested optimization processes, such as air compressor system maintenance, replacement, usage, etc., for the air compressor system that is being analyzed. The results data further include optimization suggestions which lead to increased efficiency of a given system and potential savings. The data files  90  include instructions for completion, spaces for inputting data, and tabs for selecting features, as described in more detail below.  
         [0029]    In one embodiment, input data for the module  12  may include: site information, financials, name plate information, gauge repeatability and reproducibility (R&amp;R), raw data, production data, and supply/demand data. Results data for the module may include: six sigma metrics, overhaul options, stable operating conditions, and reports. All input data and results data may be stored in a database for further queries. The module also may allow for multiple compressor records to be input.  
         [0030]    The site information input data  91  may include contact and reference information regarding a given site and the audit, such as site location, address, date of audit, site contact, phone numbers, e-mail addresses, auditor contact, auditor contact phone number, and the auditor contact&#39;s e-mail address. This information may also be used as a cover sheet for a final report.  
         [0031]    The financial input data  92  may include costs associated with electricity, water, mode of operation, hours of operation per shift, number of shifts per day, number of days in operation per year, pressure, amperage, cubic feet per minute, temperature, and flow. Pressure, temperature, and amperage are variables that are needed to calculate air compressor system flow. Energy, required in horsepower (HP) or kilowatts (KW), is used to calculate the efficiency of the compressor. The name plate information input data  93  includes the compressor name and number necessary for database queries. This data may include manufacturer rated conditions available on the name plate of a compressor. Also, this data may include the actual or estimated compressor performance under full load test conditions. Measured efficiency of a compressor at full load may be used to determine the efficiency of a compressor and whether or not maintenance may be required. The name plate information input data  93  may be utilized to calculate, compare, and report the rated efficiencies and actual efficiencies of a given compressor. The gauge repeatability and reproducibility input data  94  includes a measure of the variance of the compressor gauges as well as the variance of other devices used to measure the compressor. A data file is used to determine the gauge R&amp;R for each instrument. The data file provides a short description regarding the importance of doing gauge R&amp;R on a compressor and instrument. The gauge R&amp;R data  94  is analyzed by the analyzer  61  to determine whether the instruments are within an acceptable gauge range for the air compressor system. Repeatability is the variation present when one person measures the same part several times with the same instrument. Reproducibility is the variation resulting from different operators measuring the same parts with the same gauge. Gauge error may be caused by an instrument, operator, fixture, instructions, etc. Measurements are used to understand and manage a process, therefore, it is imperative that gauge error be identified and quantified. An inspector/gauging system is not 100% efficient. A variance of the compressor gauges as well as the variance of the auditor instrumentation under 30% is preferred. A variance between about 10% to about 30% is more preferred. A variance below about 10% is even more preferred.  
         [0032]    The raw data input  95  merges electric current and air flow data. To measure the efficiency of an air compressor during actual work conditions, an auditor must measure the electric current and air flow for each compressor. Air flow is calculated from pressure and temperature. To do an efficiency calculation, the files must be combined, matching dates and times. The merged files are then stored on the database for further analysis and queries. The production data  96  is analyzed by the analyzer  61  to calculate productivity (units/KW) and variability in productivity between shifts, lines, days, weeks, etc. using a predetermined standard of acceptability. For each date there may be a plurality of shifts which use the same air compressor system, and for each shift, multiple groups can be added. The total production per shift can be used depending on variations in shifts and lines.  
         [0033]    The supply/demand input data  97  measures the required flow of major users on the distribution side of the air compressor system. The actual flows on the supply side are measured and inputted to determine if there is a deficit or a surplus of compressed air in the system. Distribution systems may be optimized based on supply/demand data. Often, higher pressure is delivered than is actually required, which results in a greater supply than there is a demand for. The air compressor system monitoring module shows what is actually required.  
         [0034]    The analyzer  61  predicts six sigma metrics  98  on compressor efficiencies and productivity. The mean (average efficiency or productivity), standard deviation, Z lt  (sigma long-term), Ppk (measurement for short-term capability), and Cpk (measurement for long-term capability) are calculated for a given compressor&#39;s efficiency and productivity. The overhaul data  99  is analyzed by the analyzer  61  to rank each compressor for overhaul based on Z lt  and variance. The compressor with the highest variance and the smallest Z lt  value is the first to be overhauled. Overhaul options may include repair or replacement of seals, lines, motors, lubricants, nozzles, etc. Voltage, power, and temperature are used in daily efficiency calculations and are needed to recommend an overhaul sequence based on variability during daily operation. Savings based on restoring the compressor to the manufacturers ratings are then calculated and reported. The stable operations data  100  is analyzed by the analyzer  61  to determine savings based on running each air compressor system and work shift at its “best in class”, where “best in class” is a predetermined standard of quality based on air compressor system performance. To determine “best in class” for each shift, daily power consumption, total units produced, and productivity are measured. Optimum power is calculated based on the “best in class” for each shift. Projected savings are calculated based on the shift operating at the “best in class” each day and these savings are rolled up to total savings per year. The reports results data  101  allows for the viewing and printing of each of the printable reports that are created. Results may be displayed for efficiency, productivity, and stable operations. Data from these forms may be recalculated depending on whether modifications were made to input data. A form is recalculated whenever data pertaining to results is edited. Depending on the number of compressors, the amount of data, and the speed of the computer, calculations may take several seconds. However, this data is saved into a database, so subsequent viewings have no time delay. Results are displayed in an easily readable format that relates efficiency to productivity and shows how much each specific product costs to produce.  
         [0035]    The monitoring module of the present invention may also be used to monitor a gas flow distribution system or a water distribution system. These alternative systems operate basically the same way as an air compressor system, the only difference being the material that is being transported.  
         [0036]    While the present invention has been described with respect to various features, aspects, and embodiments, those of ordinary skill in the art, and those unskilled, will recognize the invention is not so limited. Other variations, modifications, and alternative embodiments may be made without departing from the spirit and scope of the present invention.