Project Background

Founded in 2001, Goertek Inc. is a technology innovation company with a global presence. It develops, manufactures, and sells precision components—including acoustic, optical, microelectronic, and precision structural components—as well as products such as virtual reality and augmented reality devices, smart earphones, wearables, smart home devices, and advanced equipment. Goertek operates manufacturing facilities in China, Vietnam, and other locations, with its Vietnam operations serving as a key hub in its global supply chain.

A Goertek manufacturing campus in Vietnam partnered with DeepCtrl to improve the energy efficiency of its compressed air station. Using the next-generation PhyAI energy optimization system, the project supports the transition toward smarter, lower-carbon manufacturing.

Compressed Air Station Upgrade Priorities

• More precise air supply control: Stabilize main header pressure through dynamic pressure adjustment and better match supply to end-use demand.

• Improved equipment efficiency: Establish optimal operating ranges based on the performance characteristics of fixed-speed and variable-speed air compressors.

• Intelligent operations and maintenance: Build an intelligent cooling-water control platform with comprehensive energy performance monitoring and analysis.

The PhyAI Intelligent Control Solution

Built around precise diagnostics and system-wide optimization, the solution introduces a coordinated compressor control and optimization system. It incorporates fault prediction and intelligent operations and maintenance while maintaining operational safety and compressed air quality, improving both the station’s energy performance and management efficiency.

AI-Driven Dynamic Pressure Adjustment and Equipment Combination Optimization

Based on forecasts of end-use compressed air demand, the system keeps supply pressure fluctuations within a range of 0.3 bar. It also models compressor performance, combining flexible adjustment of variable-speed compressors with coordinated control of fixed-speed units to reduce inefficient operation.

Self-Optimizing Cooling System

Using wet-bulb temperature sensors and a monitoring network for cooling-water supply and return conditions, the system analyzes how cooling conditions affect compressor efficiency in real time. It automatically selects operating combinations of pumps and cooling tower fans to reduce cooling energy consumption.

Comprehensive Visual Operations and Maintenance

A PC-based visual platform provides a centralized view of operating parameters for compressors, dryers, pumps, cooling towers, and other equipment. It tracks individual equipment efficiency, overall system efficiency, and early fault warnings in real time, while trend charts and multidimensional reports support continuous optimization.

Project Results and Broader Significance

According to the original article, the intelligent upgrade improved the compressed air station’s energy efficiency by more than 5%. By applying AI and Internet of Things technologies to a conventional manufacturing energy system, the project provides a replicable approach to greener manufacturing in Vietnam and across Southeast Asia.

• Technology: Demonstrates the energy-saving potential of dynamic pressure adjustment, equipment combination optimization, and coordinated cooling system control.

• Management: Consolidates equipment monitoring, early fault warnings, and energy performance analysis on a unified platform.

• Industry: Provides practical experience to support the wider adoption of smart and green manufacturing across Goertek’s global production facilities.