Air Pressure Monitoring
Measure discharge and suction pressure to ensure proper operation.
Detect pressure drops that may indicate leaks or restrictions.
Verify system setpoints for compressor loading and unloading cycles.
Ensure consistent air supply to production lines.
Monitor receiver tank pressure for storage and stability control.
Air Flow Monitoring
Measure total air output and system demand.
Identify air leaks or excessive air usage.
Verify compressor performance and efficiency.
Balance flow across multiple compressors or zones.
Support energy optimization and system tuning.
Temperature Monitoring
Monitor discharge air temperature to detect overheating.
Track bearing and motor temperature for early fault detection.
Monitor oil or coolant temperature in lubricated compressors.
Detect abnormal temperature rise in aftercoolers or intercoolers.
Prevent thermal shutdowns or excessive wear.
Humidity / Moisture Monitoring
Measure moisture content in compressed air lines.
Verify dryer system performance (refrigerated or desiccant dryers).
Prevent water accumulation in air receivers or distribution lines.
Protect air tools and pneumatic devices from corrosion or damage.
Ensure compressed air meets quality standards (ISO 8573).
Vibration Monitoring
Detect imbalance or misalignment in motor and compressor shafts.
Identify bearing wear or mechanical looseness.
Track vibration trends for predictive maintenance.
Prevent costly mechanical breakdowns and unplanned downtime.
Correlate with temperature and power data for deeper insights.
Electrical / Power Monitoring
Measure compressor power consumption and energy efficiency.
Detect abnormal current draw or phase imbalance.
Monitor startup load, idle running, and load/unload cycles.
Identify electrical faults or overload conditions.
Support energy management and cost tracking.
Oil Level & Quality Monitoring (Lubricated Compressors)
Ensure proper oil level to prevent mechanical wear.
Detect oil degradation or contamination.
Monitor oil temperature for overheating conditions.
Schedule timely oil changes and maintenance.
Prevent compressor damage from lubrication failure.
Filter & Separator Condition Monitoring
Detect pressure drop across air filters or oil separators.
Identify clogged or dirty filters before performance loss.
Maintain efficient air delivery and reduce energy waste.
Extend component lifespan through timely filter changes.
Ensure clean air quality for downstream systems.
Air Tank / Receiver Monitoring
Monitor air pressure stability in receiver tanks.
Detect temperature rise due to high loading cycles.
Check condensate levels to prevent overflow or moisture buildup.
Track tank fill and discharge cycles for performance optimization.
Support automated condensate drain control.
Ambient Environment Monitoring
Track ambient temperature for compressor cooling efficiency.
Detect high humidity or dust that can affect air intake quality.
Monitor ventilation effectiveness in compressor rooms.
Prevent overheating due to poor environmental conditions.
Optimize operating environment for energy efficiency.
Leak Detection
Identify air leaks in pipelines or fittings.
Quantify leak rate to estimate energy loss.
Support proactive maintenance to reduce waste.
Improve compressor utilization and energy savings.
Maintain system efficiency and safety.
System Performance & Analytics
Calculate compressor efficiency (kW per cfm).
Monitor duty cycles and runtime hours.
Compare performance across multiple compressors.
Optimize sequencing and load sharing in multi-unit systems.
Generate maintenance alerts and performance reports.