Energy savings in the automotive industry with flow meters

With the introduction of compressed air, the automotive industry has been significantly improved in terms of workers’ safety and overall plant efficiency. Nowadays you will find compressed air in almost all aspects of the car manufacturing process, like vehicle assembly, conveying, painting and cleaning. As such, compressed air is a vital utility, critical to production but also a major contributor to energy costs. Measuring and monitoring compressed air consumption with a flow meter enables manufacturers to gain insight into system performance, detect inefficiencies, and reduce energy waste. By using a flow meter, companies can identify leaks, optimize air usage, and achieve substantial energy savings across the entire plant.

Compressed air usage examples in car plants:

• Compressed air is found in the painting process. The car bodies are cleaned with dry oil-free compressed air and low-pressure air is used to operate the spray guns. Air quality is vital here, as any contaminants in the air supply will cause costly re-work or even production losses.
• Heavy lifting is eased by the compressed air conveyer system. They use clean dry air to create a thin film of air between the worktable and the floor, allowing parts and the (assembled) car bodies to be send through the production line. Furthermore, robotic machinery use compressed air to lift, transport and to place heavy components.
• With compressed air, the metal forming machines turn the sheets of metal into vehicle components.
• There are many air-powered tools in the factory for e.g. fastening and screwing of components in their place, and removing bolts and nuts. Air-powered saws are used for grinding and cutting of metal.

Compressed air measurement and monitoring

Reduce your maintenance costs, monitor air quality, and prevent expensive production losses. Continuous compressed air measurement and monitoring is essential. By measuring your compressed air system, you gain valuable insights to optimize usage and achieve significant energy savings. For example, compressed air flow measurement helps detect and repair leakages, determine the optimal pressure and flow levels for production, and evaluate the potential for switching to low-pressure air in specific processes. Check out how one car manufacturer in the USA saves $600,000 annually through compressed air system measurement and optimization.

Argon

Compressed air is not the only utility that presents an energy savings possibility. In the automotive industry you will also find argon, e.g. as protection gas for welding robots. Investment in one flow meter can already show a significant savings potential, as this car manufacturer in Tennessee, USA, uncovered: