Bürkert Fluid Control Systems is expanding the control system for its Type 8652 valve terminal to include a diagnostic function for leak monitoring. The software is designed to detect compressed air losses at an early stage, thereby reducing energy and maintenance costs.
In the pharmaceutical and biotechnology industries, as well as in food production, valves are typically actuated using clean compressed air. However, small leaks often occur at pipe connections, both during installation and during ongoing operation. Over time, these leaks lead to significant energy losses and rising operating costs. Bürkert Fluid Control Systems has now developed a new software feature designed to significantly simplify the detection of such leaks.
Compressed air is considered the standard for clean valve control in many industries. However, generating compressed air is energy-intensive and correspondingly costly. Even minor leaks can therefore add up to significant costs over time.
As wear and tear on pipe connections and actuators increases, compressed air consumption in many systems rises gradually. Until now, the search for such leaks has been carried out manually in many companies by employees who regularly inspect the systems. This process is time-consuming and costly.
Continuous monitoring during operation
Bürkert’s new diagnostic function enables continuous monitoring of relevant components in a compressed air valve system during ongoing production. To achieve this, an additional software module has been integrated into the control system of the Type 8652 valve manifold.
During system commissioning, reference values are first determined. To do this, the system measures the time interval on each channel between the switching of the pilot valve and the actuator reaching its end position. If this runtime changes during subsequent operation, a warning message is automatically generated. The messages appear both on the valve island’s display and via the connected bus system.
Software solution that requires no additional hardware
The monitoring function is implemented entirely via software and requires no additional components. This makes the solution relatively cost-effective and easy to install. At the same time, the separate monitoring of individual valve assemblies enables targeted fault localization in the field, allowing problems to be resolved more quickly.
In addition to reducing compressed air losses, continuous monitoring can also indicate other production-related issues. Extended switching times, for example, may indicate seal wear in the actuator. Early warning shortens response times and increases both the cost-effectiveness and safety of production.
According to Bürkert, identified leaks in hoses and fittings in a system with six valve islands and approximately 150 valve functions can yield potential savings of up to 12,355 kWh per year, or approximately 3,706 euros annually, based on an electricity price of 0.30 euros per kilowatt-hour.
