Compressed air consumption measurement using IO-Link
Flow meters connect directly to ITS Edge Cabinet over IO-Link, providing continuous flow monitoring and aggregated consumption in 15-minute, hourly and daily intervals. The example configuration below includes eight measurement points and can be expanded with additional points.
Four reasons to choose this solution
Direct IO-Link connection
The flow meters are wired directly to the cabinet, with no intermediate wireless connection in the measurement path.
8 points in one cabinet
The ITS Edge Cabinet IO-Link variant shown supports eight independent flow meters simultaneously.
Raw and aggregated data
Continuous flow visibility and consumption aggregated into 15-minute, hourly and daily intervals.
Rapid identification of losses
Comparison across lines identifies sections with unusual consumption that should be checked for leaks.
What the solution includes
- IO-Link compressed air flow meters (8 units)
Installed in the compressed air system and connected to the cabinet using IO-Link cables. The model, diameter and measurement range are selected for the specific installation.
- ITS Edge Cabinet — IO-Link variant View ITS Edge Cabinet →
A prefabricated cabinet with an ITS platform instance and eight IO-Link communication channels. It receives and stores data from the flow meters and provides an on-site dashboard.
The configuration shown includes eight measurement points as an example. Larger installations can use additional compatible channels and ITS Edge Cabinets, with all data presented in a shared view.
How it works
Eight flow meters installed in the system measure flow and transmit data over wired IO-Link, to ITS Edge Cabinet in the IO-Link variant. The cabinet runs a local ITS platform instance, processing data and making it available on site.
The dashboard shows current flow at each point and, depending on the configuration, aggregates consumption into 15-minute, hourly and daily intervals.
| Point | Flow | Status |
|---|---|---|
| Point 1 | 98 Nl/min | online |
| Point 2 | 112 Nl/min | online |
| Point 3 | 94 Nl/min | online |
| Point 4 | 121 Nl/min | online |
| Point 5 | 87 Nl/min | online |
| Point 6 | 103 Nl/min | online |
| Point 7 | 115 Nl/min | online |
| Point 8 | 112 Nl/min | online |
Example Grafana dashboard showing live flow, selectable 15-minute, hourly and daily aggregation, and the status of all eight points.
Where it works best
Production facilities
Compressed air consumption monitoring across individual production lines.
Automotive industry
Air consumption monitoring for pneumatic tools and assembly stations.
Food industry
Monitoring pneumatic systems used in packaging and production processes.
Workshops and service facilities
Air consumption monitoring at tool stations.
Extensive compressed air networks
Consumption comparison across buildings and distribution network sections.
Energy audits
Input data for analysing losses and optimising compressed air costs.
See exactly where compressed air is being lost
- One central meter for the entire system
- No information about which line consumes the most
- Leaks discovered by chance or during inspections
- Manual consumption summaries in spreadsheets
- No consumption comparison between periods
- 8 independent measurement points monitored simultaneously
- Clear consumption comparison across lines
- Unusual consumption increases visible on the dashboard
- Automatic 15-minute, hourly and daily aggregation
- Data ready for trend analysis and audits
ITS is the starting point, not the endpoint
Flow, consumption, aggregation and point status can remain in the ITS dashboard or, depending on the deployment scope, be forwarded to systems already operating at the facility.
The diagram shows example ITS platform integration paths. The protocol, data scope and exchange frequency are defined separately for each deployment.
Access to dashboards and configuration can be granted according to user roles.
Deployments requiring remote connectivity can use the built-in VPN server.
Data can remain in Edge Cabinet or be consolidated from multiple facilities.
Describe the installation and measurement points.
For an initial discussion, the number of points, pipe diameters, available installation sections, medium type and required dashboard location are sufficient.