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When discussing performance what really matters? Is it air flow and pressure? Is it heat dissipation and sound levels? Is it material deflection and vibration? Is it a blower’s reputation for performance over the years or a company reputation for engineered results over the centauries?
At Gardner Denver, we believe that it is not any one particular thing that matters. We believe everything matters. That is why the IQ pre-engineered packages undergo extensive engineering and testing in all areas to ensure your package is one that can be relied upon every day. |
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Performance
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The IQ has been thoroughly designed and built to meet the variable demands of a dynamic work environment. Every business is unique, as is their operations and subsequent air demands. Even within plants, demand for air can fluctuate over hours, days, weeks and months. With this in mind, Gardner Denver designed multiple package sizes that cover an extensive air (or vacuum) map. Packages can be combined in any way to meet your specific requirements. Individual package sizes range from 7.5hp to 100hp, individual package air flow can go up to 1400 ICFM (vacuum applications go up to 15 Hg”).
All Gardner Denver IQ packages are fitted with an Air Smart controller that amongst another things, allow machines to be turned on and off as air requirements peak and trough throughout the day. In addition to this, the controller can rotate the designated lead machine, equalizing the overall workload and subsequently improving both performance and reliability.
In addition to sequencing machines, the Air Smart controller can also operate our variable speed drives, turning each blower up or down to precisely match air requirements. Even when not feeding air into your system, fixed speed blowers can continue to consume up to 90% of the energy used when running at full capacity. All of this means increased utilities for no real production gains. Variable speed drives combined with Air Smart controllers ensure that air is only ever being produced at the levels you require thus increasing productivity while reducing costs. From a capital investment standpoint, these efficiency gains can mean paybacks in one year or less depending on use.
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IQ, the Product of Robust Engineering Design and Extreme Testing
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Gardner Denver understands that ongoing performance is critical to the ongoing success of your business. The IQ package is a culmination of precision engineering and extensive testing without compromise that ensures your blower package is as robust and as reliable as possible. |
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Virtual Modeling and Testing
All of Gardner Denver’s IQ package design processes begin with 3D virtual modeling and design. This allows our team to look at every aspect of the package from structural rigidity to clearances at the design stage before proving these findings out in testing.
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Finite Element Analysis
Any blower package contains many different parts and complex shapes, some of which are bolted onto the base frame. Understanding where this creates loading stress and flex points in the frame is critical in designing a base that is stable and reduces wear on the blower and the motor. Accurately identifying these stress points can be counter intuitive and cannot really be done without full scale modeling and testing. All of the IQs frame and enclosure design was modeled and FMA tested virtually to ensure the best possible structural support for operational use. The result was using metal gauge in the base that is generally thicker than what is available in most packages today because we believe that details like this extend product life and make a big difference to your business. The base was then constructed in accordance with these analysis results and tested again for material deflection and vibration.
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Heat Dissipation and Thermo Graphic Testing
Any machinery that compresses or pressurizes air will produce heat. Industrial blowers are no different in this regard. Excessive heat levels can potentially cause problems for components that are in close proximity to the blower such as belts, guards, motors, oils etc. The ability to control the internal temperatures is therefore crucial in avoiding downtime and extending the overall life of the package. Gardner Denver has repeatedly tested the IQ with dozens of thermal probes while operating at in high ambient temperatures to ensure that heat dissipation and package cooling surpasses all of the required standards.
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Sound Testing
For many people package noise is a critical factor. On many occasions blowers can be installed on facility floors. This presents safety considerations and sound level regulations are in place to protect people that are in close proximity to industrial machinery. Additionally it is possible in some industries for blowers to be outdoors and beside residential areas creating additional considerations for nuisance ordinances etc. Noise abatement was a key consideration for Gardner Denver when designing the IQ.
Custom sound enclosures were developed for this project along with custom designed air inlet filters and outlet silencers. All of the designed packages are thoroughly tested in our ISO certified sound room to guarantee that the basic sound reduction of over 20 dba providing one of the quietest blower packages available today.
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The Blower and Package Components
Gardner Denver is one of the oldest and most respected industrial blower manufacturers in the world. This experience, know how and reputation for innovation goes into every product we make. The HeliFlow blower used in the IQ is the 2008 plant engineering product of the year. Every component in the IQ has been proven out through years of service or has been tested extensively for performance. Many components have been designed explicitly for the IQ package. These components have been extensively bench tested to validate performance and tested again as part of the total IQ package. All of this is driven by the desire to deliver the highest possible quality and reliability standards
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Installation and Turn Key Capability
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The singular aim for Gardner Denver with regard to installation is simplicity and a belief that anyone that uses the IQ package should be able to install and operate the unit with minimum fuss. In response to this aim, we feel that we produced genuine plug and play system that saves our customers from any additional hidden complications and or costs.
| Feature |
Problem Solved |
| Fully programmed VFD |
The VFD comes pre-programmed eliminating the need to program on site at the time of installation. |
| VFD integrated inside IQ frame |
Because the IQ VFD comes inside the existing enclosure, there is no extra space required to wall mount any drives and no need for external wiring between the package and the drive. |
| Integrated wiring |
The VFD, controller and motor are pre-wired and set eliminating the need to wire between systems. |
| Vibration Isolators |
The IQ comes with vibration isolators negating the need for any special housing pads or bolting to the floor. The IQ simply requires a flat surface that will bear its weight. |
| Structural rigidity |
The strengthened base and frame reduce the risk of damage with placing the blower package in a facility. |
Pre-wired, pre-engineered, pre-programmed features mean much faster cheaper and simpler installation without needing extra space, wiring or additional manpower to complete the installation.
The IQ is pre-programmed upfront. Should anything arise, you don’t need to deal with multiple vendors; your Gardner Denver distributor should be able to take care of it all.
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Smart Made Simple: Easy Access Maintenance and Monitoring
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The goal of the maintenance group is to ensure that equipment runs as efficiently as possible for as long as possible. At different stages this will involve routine checks, minor maintenance (changing air filters etc) and scheduled maintenance or larger service work. One of the goals with the IQ blower package was to carefully design a package that would to allow easy monitoring in conjunction with fast and easy access to all of its internal components. The end result is a package that is as service friendly as possible.
Some of the key features for fast easy access include:
- Auto self tensioning belt to optimize belt load, reduce belt wear, regulate overhung loads and minimize bearing wear.
- Multiple internal monitoring sensors regulating internal heat, pressures, oil levels and run times allows the service person to easily monitor what is happening at all times.
- Data can be sent through the web to your computer allowing you to monitor performance remotely without having to constantly visit the package.
- Vibration isolators, no need for special construction pads. The installation surface needs only to be level and to bear the weight of the package.
- All performance data being recorded in the controller providing one easy access point for monitoring and negating the need to crawl in and around the package to monitor it.
- Setting advisory thresholds and receiving notices ahead of problems occurring. This allows for proactive intervention rather than shutdown.
- All the enclosure panels are easily removable with quarter turn fasteners making all components accessible very quickly and easily.
- The IQ package has a hinged lid (like a car bonnet) allowing instant visibility to all the internal components.
- Easy access oil fill reservoirs and oil drain system
- All minor components (filters, thermometers, sensors) are all easily access and can be replaced in a few minutes.
- Inspecting the IQ does not require a lot of tools. A quarter turn fastener key and a screw driver is enough to inspect the whole machine.
- If required, all of the whole blower, motor and components can be removed from the enclosure in one piece to allow total access for major service making access quicker and reducing downtime.
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Manufacturing and Quality Assurance
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Over the last 150 years Gardner Denver has developed an unparalleled reputation in industrial manufacturing. This hard won reputation has been achieved through an ongoing commitment to excellence and continuous improvement over this period. The attention to detail in engineering design is matched by a commitment to quality in manufacturing in assembly. Gardner Denver blowers are proudly manufactured in our ISO 9001: 2008 certified Sedalia, MO facility. The professionals based there have a collective goal to simply make the highest quality product available.
They have built blowers for decades that have developed an exceptional reputation for reliability and performance. This comes down to four factors, extensive training and development, continuous process improvement, industry leading equipment and rigorous quality testing.
Material entering the facility is subjected to a first pass quality inspection. Once the material is approved, it is milled on finest manufacturing equipment available using digital measurement and testing to ensure precision and exact tolerances. The blowers are then assembled and tested again before being passed for use in a package.
The package is assembled and then further tested again for performance standards. Only after every performance specification has been met will a package be approved for shipment.
When purchasing a Gardner Denver blower package, you are not simply getting industrial equipment. You are getting over 150 years of commitment to design, manufacturing, quality, service and delivery that sets Gardner Denver apart as a world class business partner.
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Downloads
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Download the IQ Brochure to see what IQ can do for you! |