Project idea: Mutli-air-compressor air controller

[rquackenbush]

I’m interested in building an open-source controller that coordinates multiple air compressors.

Why?

• I’m a nerd. I like embedded control systems.
• Controlling multiple air compressors appears to be deceptively difficult to do well.
• I want more CFM in my shop (I currently have one single-stage compressor on a 60 gallon tank). It technically keeps up with my plasma cutter, but I’d like more headroom.
• I like the idea of multiple compressors rather than one single point of failure.

Disclaimers:

• In my case, it would be waaay cheaper to just buy a bigger compressor.
• There are commercial versions available (though they’re ****** expensive).
• I’m not a compressed air expert. Like at all.

Goals:

• Integrate a base load / peak load option where at least one compressor is run via a VFD to allow for dynamic load.
• Support an optional air flow sensor.
• Support multiple configurations:
  • One centralized compressor bank
  • Distributed compressors for large buildings.
• Integration with:
  • Home Assistant (for residential setups)
  • OPC (for industrial applications)

Would anyone be interested in a system like this?

 

[cvairwerks]

Really just need a lead-lag controller and some check valves... or you offset the cut in and cut out pressures between the compressors.

We run an automated compressor control system at work, but then we have probably a dozen or more 500+ SCFM screw units, a couple hundred thousand gallons of storage and more than 100 miles of 1/2" to 12" air piping in the facility. I haven't been in the tank room for years, but it used to look like we had 8 or 10 railcars standing on end for air storage. Used to have a pair of CP 24" diameter single cylinder compressors for pressure boosting between a couple of the hangars I worked in. Long gone now and the screws cover it all.