Improving Swissomation’s Pneumatic System: Identifying Leaks, Mapping, & Increasing Efficiency

The authors of this paper undertook the broad design objective of analyzing and improving the existing air compression system at a small parts manufacturer, called Swissomation Virginia. Swissomation uses an air compressor system as part of their machining process. The client wished to improve the overall system efficiency and address specific system issues. To better define the problem within the client’s needs, the work was divided into three subprojects: 1) Detecting and locating leaks. There are two types of leaks that are of concern: large blow-out leaks and small pin-hole leaks, also known as whisper-leaks. To address the first, a prototype alert system will have been developed, so plant management could be alerted to system failures during non-working hours. To address the second, a prototype of a leak detection system, telltales, will have been designed, tested, and given to the client to replicate for future use. 2) Creating a detailed map of the air compressor system. Initial hand-drawn sketches of the system were created, which were subsequently used to develop a comprehensive schematic, using mapping software with the goal of delivering the client a detailed schematic of the air compressor system. 3) Enhancing the system’s efficiency. The combined outcomes of the first two subprojects will be analyzed under the lens of efficiency with the goal of providing the client an analysis of the resulting enhancements and cost savings.