Improvement of operating conditions of pneumatic systems and minimizing energy consumption

Pneumatic systems are used in many areas of industry. This scope of work; Applicable saving methods of pneumatic systems in the automotive industry have been investigated. For this purpose, the effects of leaks in compressed air lines on efficiency, the pressure coming from the central compressor room to the production lines with minimum loss, and the energy efficiency and gains as a result of reducing losses by reducing air pressure in periods when there is no production, were evaluated. Concrete improvement values were determined based on the measurements made in the automotive facility where the analyzes were carried out. In this regard, an energy audit was conducted in the compressed air lines of the facility, leakage rates and unnecessary energy consumption values were determined, and the necessary precautions were determined. In this experimental study, six sigma (advanced) problem solving techniques and advanced mathematical modeling method were used methodically in the calculations and detected nonconformities. As a result, the compressor outlet pressure was reduced from 8.0 bar to 7.7 bar, and with the addition of proportional valves, the air pressure going to the lines was reduced on a relevant production unit basis, resulting in a 20% decrease in the amount of compressed air consumption. Energy efficiency was increased by saving 16% in consumed electrical energy. In addition, improvements in connection elements and air filters, removal of unnecessary connection elements from the system, changing filter designs and updating maintenance periods contributed to energy efficiency