The filtration of airborne contaminants is critical in keeping manufacturing technology free from debris and operating in optimal condition.
Without fume extraction, the performance of advanced and costly equipment such as lasers, risks being compromised by particle emissions, potentially leading to equipment breakdown and a degradation of product quality.
Effective filtration is particularly important in end-to-end automated manufacturing systems, which rely on multiple, connected elements to contribute to the greater goal of enhanced productivity. Increasingly, this also depends upon the capture, interpretation, and actions linked to performance data covering each component. For fume extraction, the development and roll-out of Donaldson BOFA’s Pro OS operating platform – thought to be the world’s first Industry 4.0-enabled system of its type – has the potential to be a game changer.
Pro OS delivers numerous benefits to industries. Here are just five of the most valuable:
- Two-Way Data Stream for Better Control
Pro OS is a fully connected solution that provides a two-way live data stream configured to integrate with established automated production processes. It provides a data feed accessible either via an intuitive customer interface onboard the extraction system or by streaming data automatically with a remote centralized workstation to support a holistic monitoring of an entire production process.
These options provide factories with real-time visibility of fume extraction performance in granular detail. In the case of remote monitoring, data is streamed through Donaldson BOFA’s integrated Connect module, which feeds real-time information to either a local area network or a cloud-enabled global monitoring station covering multiple sites.
Pro OS can plug huge volumes of valuable data into a centralized factory dashboard, enabling manufacturers to see multiple extraction performance read-outs, for say filter condition. This has the potential to make a significant contribution to operational efficiency, human resource allocation, energy savings, atmosphere management, and productivity. It’s also possible to download performance logs covering 12 months for a deep dive into historical trends.
- Smart, Multi-Language, Interface for Ease of Operation
Operatives tasked with the physical monitoring of fume extraction systems benefit from Pro OS’s high-resolution 5” color touchscreen, which provides easy access to extraction system navigation and monitoring. This is made simpler through the onboard availability of multiple local language options, while onscreen icons enable technicians not only to see immediate filter condition status, but at the touch of a button to access granular information about incremental percentage saturation for the pre-filter and HEPA filter stages. A VOC sensor is also incorporated to monitor the use of carbon in the combined filter.
- Enhanced Filter Condition Monitoring to Safeguard Uptime
Whether via the digital display or through centralized data integration, Pro OS outputs help end users optimize filter life by providing data that supports better filter replacement forecasting. This helps operators schedule filter exchanges and maintenance regimes in step with production plans, so avoiding costly unplanned downtime.
- Configurable Alarms for Optimal System Performance
Pro OS extraction systems incorporate five configurable relays that can group a number of condition alarms linked to core system components and processes. This allows alerts to be programmed to flag when any thresholds outside normal parameters are exceeded. For example, this could include a warning about a filter nearing saturation, low system airflow, or an elevated system operating temperature. Having these alerts both configurable to local manufacturing requirements and visible via two-way data connectivity, removes the need for ‘eyes-on’ physical system monitoring, thereby improving overall efficiency.
- ‘No Tool’ Serviceability for Faster Reinstatement
Although not directly a benefit of the Pro OS operating platform, Donaldson BOFA has taken the opportunity to redesign certain servicing and maintenance logistics in Pro OS enabled systems.
For example, in the AD Oracle Pro OS Connect extraction system, the PCB and filter compartments have been separated so that technicians gain easier access to the PCB without being exposed to the filter housing. In addition, maintenance is made simpler by the adoption of finger-tight fixings, which in effect create a ‘no tool’ servicing and maintenance environment.
In short, the development of Pro OS has the potential to deliver significant operational benefits to manufacturers by contributing to enhanced automated production processes in step with the vision for Industry 4.0.
Pro OS is currently available in the AD Oracle Pro OS Connect and AD 1000 Pro OS Connect for laser applications, with further releases across Donaldson BOFA’s system line-up due later this year.
