CNC Factory Implements Smart Air Quality Management System

Successful Story | CNC Factory

1. Project Background

During CNC machining processes, metal dust and oil mist are often generated. If not properly managed, these contaminants can not only shorten equipment lifespan but also pose health risks to workers.

Originally, the factory relied on handheld detectors for routine inspections; however, this method could not be integrated with the exhaust control system.

To enhance both environmental quality and energy efficiency across the facility, the CNC factory adopted Sysinno Technology’s iAeris2 Air Quality Monitoring System, integrated with an industrial-grade computer software platform and a KR03 controller.

This setup enables intelligent control of the variable-frequency drives (VFDs) for large-scale exhaust systems, creating a smart and visualized air quality management environment.

2. System Architecture and Operation Process

The entire system consists of three core components:

1. iAeris2 Air Quality Sensor

   • Continuously monitors PM2.5 concentration in each factory zone.

   • Transmits real-time data to the central industrial computer for analysis.

   • Provides instant air quality index (AQI) visualization.

2. Industrial-Grade Computer with Sysinno’s Custom Software

   • Displays real-time air quality status for all factory zones in a rotating slideshow view.

   • Automatically records PM2.5 log data and supports historical data review and trend analysis.

   • Offers flexible configuration and analytical functions, including:

     • Zone selection: Display data by specific areas within the factory.

     • Time scheduling: Automatically switch display content based on time periods.

     • Display factor selection: Customize displayed metrics such as PM2.5, PM10, temperature, and humidity.

     • Averaging logic settings: Choose between real-time or averaged data display.

     • Historical trend visualization: Clearly illustrate long-term data trends and variations.

   • The software allows switching between “Automatic Control Mode” (linked to the KR03 controller) and “Manual Exhaust Mode.”

3. KR03 Controller

   • Automatically adjusts exhaust fan speed based on PM2.5 concentration levels.

   • Supports a four-stage intelligent control mechanism:

     • Stage 1: PM 0–15.4 → Low-speed operation

     • Stage 2: PM 15.5–35.4 → Medium-speed operation

     • Stage 3: PM 35.5–54.4 → High-speed operation

     • Stage 4: PM ≥ 54.5 → Full-speed operation

   • Each stage’s exhaust activation threshold can be individually configured.

3. System Features

• Real-Time Visual Monitoring: Large display screens provide instant visualization of air quality data across different factory zones.

• Smart Linked Control: The system automatically adjusts exhaust fan frequency to maintain optimal air quality while balancing energy consumption.

• Long-Term Data Logging: Continuous PM2.5 data recording enables future performance tracking and improvement analysis.

• Multifunctional Software Interface: Offers flexible configuration options for zone, time, and display factors, along with historical trend analysis for comprehensive monitoring.

• Flexible Operation Modes: Supports both automatic frequency control and manual exhaust operation, allowing users to switch according to factory needs.

• Stable and Reliable: Built with industrial-grade hardware to ensure long-term operational stability and reliability.

4. Implementation Benefits

After the system was implemented, the CNC factory achieved significant improvements in air quality across its work areas, effectively reducing oil mist contamination and metal dust issues while minimizing energy waste.

Factory managers can now monitor real-time air quality data across the entire facility through the system’s interface, greatly enhancing both operational efficiency and employee health and safety.

By integrating the iAeris2 sensors, KR03 controller, and industrial-grade computer platform, Sysinno Technology enables manufacturing clients to realize “Smart Monitoring + Intelligent Control” — an automated environmental management solution that creates a cleaner, healthier, and more energy-efficient workspace.

If you have any questions about air quality solutions or would like a consultation, feel free to reach out to us. We are happy to offer expert advice and assistance.

e-mail: service@sysinnotec.com 

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