An air preparation unit is a specialised unit that is solely responsible for delivering high-quality compressed air to integrated pneumatic systems. It contains various parts, each with a different function. In this detailed blog post, we will explore the function of each part, how the unit works, and where this unit is required most. Keep reading!
A] What is an Air Preparation Unit?
The air preparation unit (APU) is a central unit of the air compressor that contains FRL (Filter, Regulator, Lubrication). This unit is responsible for providing pneumatic systems with smooth, dry, and lubricated air. The APU is known as the ‘lung’ of the pneumatic system, ensuring only high-quality compressed air enters the system. It ensures that downstream systems receive the required air supply and maintain their performance and lifespan.
B] Functions of an Air Preparation Unit
The air preparation unit has several parts. The following are the parts with their names and functions:
1. Filtration
The air preparation unit (ALU) contains the filtration system, which effectively removes dust, dirt, and moisture from the compressed air. It uses centrifugal force to separate moisture and a mesh to sideline the minute particles from the compressed air. Consequently, the filtration system saves the downstream components from corrosion, damage, and wear.
2. Regulation
Regulation is another important system of the ALU that controls the pressure of the compressed air to keep it consistent throughout the system. It has a spring-loaded diaphragm that maintains the pressure under the preset level. It also prevents pneumatic systems from damage by controlling over- and underpressures and maintains the component’s performance and lifespan.
3. Lubrication
The next part is lubrication, which sprays the oil mist into the compressed air to make it slightly moist. The moisturised air makes the moving part smoother, maintaining efficiency, controlling wear and tear, and boosting the performance of the connected pneumatic systems.
4. Monitoring
The monitoring system, typically comprising sensors and gauges, effectively measures the quality of compressed air. It ensures the delivered compressed air meets the requirements and is free from contamination and impurities.
C] How an Air Preparation Unit Works
The air compressor’s air preparation unit works in four simple stages:
- Compressed Air Enters: The ALU working starts with sucking compressed air into the system. The air sucked in is dirty and moisture-laden before entering the filter.
- Filtration Stage: In this second stage, uncleaned compressed air is cleaned through centrifugal force and mesh. This stage completely removes contaminated particles and condensates.
- Regulation Stage: In this working stage, a spring-loaded diaphragm is used to monitor the quality of the compressed air and ensure requirements are fulfilled as per the predefined criteria.
- Lubrication Stage: This stage infuses oil mist into the compressed air to ensure that downstream systems run smoothly.
All stages of the pneumatic air preparation unit work together and save pneumatic tools, valves, and actuators by filtering out contaminants, regulating air pressure, and maintaining lubrication.
D] Key Parts of an Air Preparation Unit
The air preparation unit contains several essential parts that work in tandem to deliver clean, contamination-free, and high-quality compressed air to the downstream systems. Below are the key parts of an air preparation unit:
- Air Filter: Air filters in ALU are responsible for removing impurities from compressed air. It is located at the inlet of the air compressor with a regulator and lubricator, since air filters require strategic placement to ensure performance.
- Pressure Regulator: The pressure regulator is a crucial component of the ALU, controlling and maintaining the quality of air. It is located between the air filter and the lubricator and stabilises the air to the desired level.
- Lubricator: As discussed, the lubricator injects a gentle oil mist into the compressed air to ensure the downstream systems run smoothly and stay efficient without any friction. It is located below the air filter and regulator.
- Drain Valve: The drain valve is a component of the ALU, which collects the accumulated water and contamination particles and releases them at the designated place. It is located at the bottom of the condensate collection bowl.
- Pressure Gauge: The pressure gauge measures the existing pressure of the system and allows operators to adjust the pressure as per requirements.
- Mounting Accessories/Brackets: Mounting accessories and brackets are basically used to attach the components of filtration, regularisation, and lubrication. These accessories can be found throughout the air preparation unit.
E] Applications and Industry Use Cases
The air preparation unit is widely used in industries that require high-quality and contamination-free air for their downstream systems. Below are the applications and industry use cases of the air preparation unit:
- Pharmaceuticals and Healthcare: As clean and sterile air is needed for pharmaceutical and healthcare facilities, ALU ensures air meets the requirements by providing high-quality compressed air.
- Food and Beverage: ALU is used in powering packaging equipment in the food and beverage industry. It also delivers high-quality air to bottling machines and pneumatic conveying systems, maintaining product integrity and food safety.
- Electronics and Semiconductors: Electronics and semiconductor manufacturing industries require clean air for manufacturing microchips and electronic components. ALU provides the required high-quality air by filtering air through its integrated air filtration system.
- Automotive: The automotive industry uses high-quality air for painting, coating, and operating air tools. The ALU empowers the assembly line equipment by providing clean compressed air.
- Aerospace & Defence: Clean air is necessary for aerospace tasks, like aircraft maintenance, pneumatic weapons controls, and powering air start systems for jet engines.
Conclusion
The air preparation unit (ALU) plays a highly significant role in cleaning the compressed air. The filtration, regulator, and lubricator work in tandem to deliver high-quality compressed air and meet the requirements. When buying ALU, always ensure you select only a FESTO partner to ensure you get only reliable products.
Bimpex is a trusted FESTO authorised distributor in India, selling top FESTO products at a cost-effective price. Also, we are the number one air compressor supplier, offering heavy-duty and long-lasting air compressors for different industrial and standalone uses. Contact us today!