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The digital gas manifold system

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Industry 4.0/ IIoT

SAVING RESOURCES AND SAFETY IN SUPPLY
The Gas supply in the Smart Factory

When talking about an uninterrupted supply of technical gases, the entire process from the supplier to the consumer must be considered. Increasing digitalisation under the heading of Industry 4.0/ IIoT offers a wide range of possibilities for making processes transparent and simplifying them in the future.

This already results in many added values which can be supplemented with further applications in the future. In order to create the conditions for networking, the assets (machines and plants) must first be digitised.

In order to ensure the gas supply to the manufacturing processes, basic requirements must be met. The gas manifold systems and gas tapping points must be designed to suit the machines and plants which are to be supplied, and they must be installed and maintained according to the technical rules. Possible failures of the supply systems should be detected and prevented at an early stage. The gas demand in the planning horizon should be known and it should be possible to compare it with the gas stocks. Automatic, semi-automatic or also manual changeover systems can ensure an uninterrupted gas supply to the manufacturing processes. The digitalisation and networking of gas manifold system in the smart factory in terms of Industry 4.0/ IIoT offers decisive prerequisites for ensuring the gas supply and creating corresponding added value.

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Halle Smart Factory
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1Manual double-sided auto-change gas manifold Argon

Manuelle zweiseitige Umschaltung, Argon

IBEDA gas manifold systems for oxygen and highly compressed gases are assembled ready for operation on stainless steel mounting plates. All safety-relevant components are BAM tested and certified. The consistent modular design of the individual assemblies ensures that the customer has a gas supply system that is optimally designed to meet his needs (without using of special parts). The modular system covers gas manifold systems with capacities up to 320 m³/h and cylinder/bundle pressures up to 300 bar.

Data exchange

  • The filling pressure of both gas sources is transmitted to the GCU by means of a pressure transmitter
  • The minimum filling pressure of the gas sources is set in GCU
  • The set line pressure is transmitted to the GCU by means of a pressure transmitter
  • If the actual line pressure deviates from the set line pressure, a warning message is sent by the GCU
  • If the filling pressure of the gas source falls below the set minimum, the GCU sends a message:
    • An employee is notified (alarm message by e-mail) and can manually switch to the 2nd gas source
    • The gas supplier receives a requisition note
Manuelle zweiseitige Umschaltung, Argon
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2Single-sided gas manifold acetylene

Einseitige Anlage. Acetylen

IBEDA gas manifold systems for acetylene according to DIN EN 14114 and TRAC 204, 206 and 208 are assembled ready for operation on stainless steel mounting plates. All safety-relevant components are BAM tested and certified. The consistent modular design of the individual assemblies ensures that the customer has a gas supply system that is optimally designed to meet his needs. The modular system covers gas manifold systems with capacities up to 150 m³/h.

IBEDA gas manifold systems for acetylene according to DIN EN 14114 up to an operating pressure of 2,5 bar are used for special applications, e.g. high-speed flame spraying systems. All safety-relevant components are BAM tested and certified. Modular assemblies are used for these gas manifold systems as well. Main pressure regulators and downstream piping are designed and tested for the special demands.

Data exchange:
  • The filling pressure of the gas source is transmitted to the GCU by means of a pressure transmitter
  • The minimum filling pressure of the gas source is set in GCU
  • The set line pressure is transmitted to the GCU by means of a pressure transmitter 
  • If the actual line pressure deviates from the set line pressure, a warning message is sent by the GCU
  • If the filling pressure of the gas source falls below the set minimum, the GCU sends a message to:
    • An employee is notified (alarm message by e-mail) and can exchange the gas source
    • The gas supplier receives a requisition note
Einseitige Anlage. Acetylen
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3Electronically controlled auto-change manifold helium-mixture

Automatische elektronische Umschaltung, Helium-Gemisch

IBEDA gas manifold systems for oxygen and highly compressed gases are assembled ready for operation on stainless steel mounting plates. All safety-relevant components are BAM tested and certified. The consistent modular design of the individual assemblies ensures that the customer has a gas supply system that is optimally designed to meet his needs (without using of special parts). The modular system covers gas manifold systems with capacities up to 320 m³/h and cylinder/bundle pressures up to 300 bar.

Data exchange

  • The filling pressure of both gas sources is transmitted to the GCU by means of a pressure transmitter
  • The minimum filling pressure of the gas sources is set in GCU
  • The set line pressure is transmitted to the GCU by means of a pressure transmitter
  • If the actual line pressure deviates from the set line pressure, a warning message is sent by the GCU
  • If the filling pressure of the gas source falls below the set minimum, the GCU sends a message:
    • An employee is notified (alarm message by e-mail) and can manually switch to the 2nd gas source
    • The gas supplier receives a requisition note
Automatische elektronische Umschaltung, Helium-Gemisch
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4Gas mixer iMixproVario, welding robot single tapping point CO2/Ar

Entnahmestelle Schweissroboter

Data exchange:

  • Data from the integrated GA300 gas analysis are transmitted to the Smart Factory
  • Process control and logging of the actual mixture
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5Leak test system Helium mixture, single tapping point

Dichtheitsprüfanlage, Helium-Gemisch, 1-fache Entnahmestelle

Data exchange:

  • The leak test system transmits the required test pressure (5-25 bar)
Dichtheitsprüfanlage, Helium-Gemisch, 1-fache Entnahmestelle
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6Heating burner, double tapping point Ace/O2

Wärmbrenner, 2-fache Entnahmestelle, Acetylen/ O2

Data exchange:

  • Monitoring of component’s temperature
  • Monitoring/recording of gas consumption
  • Measuring and control of flow rate
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Wärmbrenner, 2-fache Entnahmestelle, Acetylen/ O2
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7Gas Control Unit: GCU

Gas Control Unit: GCU

Gas Control Unit for controlling and monitoring gas supply systems

Highlights:

  • Future-proof thanks to OPC-UA interface, a standard for data exchange as a platform-independent, service-oriented architecture
  • Simple and intelligent communication with networked machines and plants
  • Control of automatic changeover systems for uninterrupted gas supply
  • Monitoring of manual and semi-automatic gas supply systems
  • Simple integration and monitoring of existing systems RETROFIT
  • Optimal utilisation of gas resources with regeneration of the gas source
  • Reduction of gas and rental cylinder stocks through monitoring
  • Provision and recording of pressure and filling level information
  • Leakage control of the supply and high-pressure manifolds
  • Function monitoring of the pressure regulators, prevention of unintentional discharge of the safety valves
  • Reminder of due maintenance of the gas supply systems
  • Meaningful messages and warnings by email
  • WEB browser-based operation and display
  • LAN connection to the company network
Gas Control Unit: GCU