Allen-Bradley PLC Integration Platform
Our technology backbone leverages Rockwell Automation Allen-Bradley programmable logic controllers to create a unified control and monitoring layer across diverse compressed air assets—regardless of OEM manufacturer.
CompactLogix & ControlLogix Architecture
The PLC continuously polls all connected assets at 1-second intervals, collecting discharge pressure, sump temperature, motor amperage, package status, and fault codes.
How It Works
Real-time data feeds our sequencing algorithm which determines optimal compressor staging based on live demand, minimizing part-load inefficiency and eliminating blow-off waste. The controller manages start/stop commands, load/unload signals, and VFD speed references through hardwired I/O and network communication—ensuring fail-safe operation even during network interruptions.
Native Rockwell protocol for high-speed PLC communication
Universal industrial protocol for legacy device integration
Building automation protocol for BMS integration
Secure, platform-independent data exchange standard
Supported Equipment
Universal OEM Compatibility
Controller & Operator Interface
Allen-Bradley PLC with PanelView HMI display—all components are replaceable and industry-standard. The same familiar interface is used across every compressor type, so staff never have to learn a proprietary system.
Universal Load Sharing
Our controller load-shares any combination of compressor types and control mechanisms in a single unified system.
Graphical Operator Interface
The PanelView gives operators a real-time window into compressor operation with consistent displays across all equipment types.
Connectivity
- Built-in Ethernet connection & web interface
- SCADA & BAS integration via optional interfaces
- Slave panels for multi-location systems over plant network
- Easy connection to existing OEM controllers
Additional Monitoring
Intelligent Sequencing & Analytics
Our analytics engine ingests historical and real-time PLC data to continuously optimize compressor staging decisions, delivering measurable energy savings and operational visibility.
Event-Driven Pre-Staging
The sequencer accepts input signals from production lines or other significant events about to start, pre-staging enough compressor capacity to prevent pressure sag when demand ramps up.
Efficiency Mapping
Each compressor's specific power curve (kW/100 CFM) is modeled across its full operating range to always select the most efficient combination.
Anomaly Detection
Intelligent baseline models flag deviations in discharge temperature, pressure differential, and power consumption—identifying leaks, fouling, and bearing wear before failure.
Run-Hour Equalization
Intelligent rotation algorithms balance cumulative run hours across the fleet while respecting maintenance windows and lead/lag preferences.
Adaptive Sequencing
Machine learning continuously refines sequencing logic based on seasonal patterns, shift schedules, and process demand variability unique to your facility.
Predictive Maintenance
Trending data on temperatures, pressures, and motor currents builds degradation models that predict maintenance needs weeks in advance.
Cloud Analytics Dashboard
All PLC data streams to our cloud analytics platform, delivering KPIs like specific power (kW/100 CFM), system efficiency ratio, leak load percentage, and cost-per-unit metrics. Data-driven insights adapt to each facility's unique demand profile—providing actionable information that drives 15–30% energy reductions with continuous improvement over time.
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