Industry 4.0 – The future has begun

Configuration, adjustment, individual design – individualism is part of human nature. But how can an entire industry meet this wish for individual serial products?

Industry 4.0

Welcome to the age of the fourth industrial revolution

For the first time ever, digital communication between a workpiece and a machine opens up the potential for individual products that are manufactured within an industrial mass production environment. This development presents completely new challenges, challenges for which Kaeser is already prepared. As your compressed air systems partner, we offer you smart solutions with unprecedented efficiency that can be seamlessly incorporated into your production and energy management system.

KAESER 4.0 – real-time adjustment and predictive maintenance

In ultra flexible industry 4.0 production environments, intelligently networked Kaeser compressed air systems reliably provide the necessary compressed air power and quality according to requirement. Moreover, potential issues within the compressed air network are identified at a very early stage so that appropriate service measures can be taken before a fault even occurs. 

The SIGMA AIR MANAGER 4.0 master controller plays a key role in all of these aspects. As the core of the overall SIGMA NETWORK, the SAM 2 transfers all compressed air system performance parameters to the KAESER DATA CENTER in real-time. Here the parameters are analysed, processed, supplemented with expert Kaeser knowledge and output to various mobile end devices (monitoring cockpits). It is this real-time analysis with Kaeser expertise that makes predictive service possible.

Core technology

SIGMA AIR MANAGER 2 master controller

All details regarding function, equipment and technical capabilities of our master controller can be found here:

Your advantages

  • Variable adjustment of compressed air control for individualised series production.
  • Exceptional efficiency through continuous real-time monitoring and optimisation.
  • Maximum availability through remote diagnosis, predictive maintenance and avoidance of critical states.
  • Future-proof thanks to various interfaces, easy updates and integrated energy management in accordance with ISO 50001.

Questions and answers

How secure is digital networking with KAESER?

  • Compressor performance data are only transmitted via the closed SIGMA NETWORK. Third-party access to your data is not possible. All structures meet the recommendations of the German Federal Office for Information Security (BSI).
  • The automatic fault management of the SIGMA AIR MANAGER 4.0 remains operational even during power failures. Should this occur, the compressors switch to independent regulation.

What are the advantages of Predictive Maintenance?

  • Flexible demands on a compressed air supply system require flexible service. Traditional maintenance that relies on firmly defined service intervals quickly reaches its limits. Furthermore, dynamic maintenance reduces costs in accordance with actual demand.
  • The SIGMA AIR MANAGER 4.0 continuously delivers all operational and environmental parameters to the KAESER DATA CENTER in real-time. Using specially-programmed expert tools, irregularities are detected at an early stage and costly downtime can be prevented as a result.

What does ongoing analysis of performance data mean for system effectiveness?

  • By monitoring key operating parameters, such as airend discharge temperature (ADT), pressure dew point or differential pressure, compressed air system efficiency can be kept in the optimum range at all times.
  • Thanks to real-time transmission and evaluation, data is always as up to date as possible, even in the event of sudden adjustments to production.
  • You will always be made aware in good time of what may cause a malfunction; necessary countermeasures can then be taken.