Over the last decade, industrial machinery the world over has tended towards the distant horizon that is machine automation; a place where manufacturing plants and global supply centers may exist in different cities, states, countries, or even continents. Today’s industrial machines are increasingly interconnected with each other in broad, complex networks that in turn are incorporating internet technology to report things like operational status, key performance indicators, and even process historical trends, with just a few clicks of a mouse. Understanding this trend has guided Haskel Engineers to develop the groundbreaking technology that is within the Q-Drive.
Machine Communication Capabilities
In terms of its ability to interact with other pieces of automation equipment, the Q-Drive features a suite of the latest communications protocols, including OPC UA, Modbus, Bacnet, Allen Bradley ABLogix, and Siemens S7, among others. These communications protocols allow for the efficient transfer of information from one machine to another, via an Ethernet connection. Development is currently under way to allow the Q-drive to be connected to various networks via wifi as well, opening the door to a wider array of applications, as well as simplifying the complexity of its setup and networking to end users. In the event that a simpler communication system is required, the Q-Drive can also be controlled using a 24Volt DC High/Low signal to start, stop, and pause the pump. This allows the system to be easily integrated in to established plant infrastructure.
Remote Monitoring Features
The advent of internet technology has changed the very nature of how factories the world over operate and make goods. Machines, robots, and advanced computational systems have made their way into production floors over the past thirty years and have automated some of the most challenging tasks imaginable. Despite this trend of automation, most of these plants still required the presence of a technician armed with a laptop, connector cables, and programming experience to plug into a physical device and address system performance issues, often times at all hours of the day. As many companies discovered during the pandemic, having to depend on the presence of these technicians often became a significant vulnerability in their ability to produce goods and services in a cost effective manner. To address this, the engineers at Haskel have developed features within the Q-Drive that allow it to be remotely monitored and controlled by properly authorized technicians in a secure manner without them ever having to set foot in the plant.
In the development of these remote access features, Haskel Engineers worked closely with a bevy of customers to identify requirements and functions that they wished to see in their gas compression systems. From this valuable feedback, Haskel was able to create a one-of a kind remote monitoring dashboard that allows authorized users to access important metrics like compressor outlet pressures, temperatures, cycle rate, and even a historical performance trend information that can be used to export data in a variety of formats for traceability and process monitoring purposes.
With the Q-Drive being a ‘smart’ compressor system, it has the ability to actively self-monitor its own performance and advise users on optimal servicing intervals. This is done by employing several key technologies in its design. Using a patented lubricant leak detection system, the Q-Drive is able to detect even the smallest leak within the system’s contained lubricant circuit, and reports a system fault when one is detected. If the leak is found to be severe, the system can shut itself off to prevent damage to the compression piston. In terms of managing the heat generated from compression, the Q-Drive utilizes a coolant circuit that is able to actively monitor system temperatures and can adjust its compression behavior to maintain safe operating temperature and still meet operational requirements. When the time comes to order service parts, users will be able to issue a quote request for these parts right from their Q-Drive remote dashboard, saving the costly, tedious act of regular system inspections.
In the event that the system encounters an error or unexpected problem in normal operation, users will be able view system alarm and fault codes, and acknowledge them remotely in addition to manually clearing them on the Q-Drive’s machine interface. As an added feature of convenience, users can also opt in for email and text notifications of these fault and alarm codes as well.
As with many modern automated systems, the Q-Drive comes standard with the ability to lock out any unauthorized users from making system changes.
Program Functions
The Q-Drive comes standard with three different pre-programmed functions; Compressor, Fill & Pause, and Fill & Stop. Each of these functions as well as function parameters can be accessed from the HMI screen on the unit as well as the remote system dashboard.
Compressor Mode is used for applications where a specified cycle rate and outlet pressure of gas are needed, similar to a more conventional compressor system. In this function, the user can define a desired outlet pressure and specify a dead band with up to 3% accuracy, that is, the when the compressor achieves the desired outlet pressure and stops cycling, how low the downstream pressure will need to drop to before the Q-Drive starts cycling again.
Fill & Pause Mode is used anytime a predefined fill volume and pressure is needed, and the system remains operating until those two conditions are met. Once the conditions are both met, the system pauses operation and enters idle mode, until a qualified user acknowledges that the operation is complete. At which point, the system leaves idle mode and continues operation. One such application where this mode could be used is to fill a pressure tank or bottle rack to a certain outlet pressure, and pause operations once the desired outlet conditions have been achieved, and an operator can then switch out the bottles or tank.
Fill & Stop Mode operates much like the Fil & Pause in that it is used to fill a certain volume to a specified pressure but once the final pressure and volume achieves, the system vents the residual pressure and shuts off.
