Martin Engineering has launched a digital system that unlocks opportunities to maximize the efficiency, reliability and performance of industrial air cannons.
The N2 Air Cannon Intelligence (ACI) System gives operators of cement plants and other large-scale, high-temperature facilities unprecedented insight into how their air cannons are performing.
Part of Martin’s N2 Enhanced remote monitoring portfolio, ACI represents the biggest technological advancement since air cannons were first introduced by Martin Engineering over half a century ago to improve material flow through raw mills, preheaters, kiln feeds, coolers, silos, chutes and other process vessels.
Developed at Martin’s Center for Innovation in Neponset, Ill., N2 ACI has been refined during two years of real-world trials with leading cement producers in the United States as well as Brazil, France, Turkey and the UK. These test installations have helped Martin’s R&D team to fine-tune the platform’s monitoring algorithms, ensuring useability and demonstrable operational benefits in the most demanding industrial settings.
In major bulk-processing plants, arrays of air cannons provide carefully sequenced blasts of compressed air to dislodge material clinging to the inner walls of process vessels, especially important for fine, sticky, moisture-rich feedstocks and fuels.
With N2, ACI operators have access to continuous monitoring and detailed performance analytics through a secure web-based dashboard and mobile interface. Fitted to each air cannon on a plant, the ACI sensor measures firing characteristics from which underlying problems can be diagnosed. That means maintenance issues can be fixed before they result in unscheduled downtime and, crucially, air cannon arrays can be modified for optimum performance.
“Air cannons have been around for more than 50 years, but until now there has been no reliable way for plant operators to understand how effectively they are actually performing as a sequence,” said Brad Pronschinske, global air cannon product manager for Martin Engineering. “With ACI, we’re not just trying to tell plant operators whether a cannon fired or not. We’re helping them operate more efficiently by interpreting data from the sensors so they can improve system performance, for example by adjusting firing sequences and improving installation positioning, as well as better manage preventive maintenance. Potential problems can be identified earlier, reducing unnecessary downtime and helping maintenance teams make smart decisions to optimize their systems.”
Traditional air cannon inspection methods often require maintenance personnel to manually trigger systems while visually observing pressure gauges. However, partial nozzle blockages and performance degradation can go unnoticed for long periods, resulting in reduced effectiveness, excessive compressed air and energy consumption, and increased risk of production interruptions.
By reducing the need for manual inspections and emergency cleanout procedures, the system helps minimize worker exposure to hazardous environments, confined spaces and high-temperature process areas. Reports from customer evaluations also highlighted reductions in manual water jetting, fewer emergency interventions and improved understanding of when maintenance is genuinely required.
The system operates through wireless battery-powered nodes mounted directly to air cannons, communicating via long-range radio frequency to a single cellular gateway capable of supporting more than 1,000 sensors across a site. Because ACI operates independently of plant Wi-fi or control networks, installation can typically be completed without requiring a plant shutdown.
Martin said the platform is also designed to support long-term reliability and optimization strategies by maintaining detailed historical records for every monitored cannon, including service events, firing trends and component performance data.
“Many customers simply don’t have the time or resources to continuously monitor air cannon performance,” Pronschinske said. “ACI gives them actionable information automatically, helping maintenance teams focus attention where it’s actually needed to keep critical material flow systems operating reliably. By turning traditional air cannons into intelligent, connected assets, plants can move from reactive maintenance to proactive performance management.
“ACI also gives maintenance teams early visibility into cannon performance, allowing them to identify inefficiencies, improve firing sequences and address possible problems before they impact production. The technology helps facilities operate more reliably and efficiently, while reducing wasted labor, compressed air consumption and unnecessary wear on critical equipment across demanding bulk material handling applications. Ultimately ACI helps optimize process flow, reduce costly unplanned downtime and improve workplace safety by limiting the need for manual inspections.”
www.martin-eng.com/content/product/22097/n2-air-cannon-intelligence-system
