Latest Trends in Pneumatics Systems

 

 

There is a common perception that not much is new in the world of pneumatics but scrape the surface and a different picture emerges.

Pneumatics has long played a significant role in the performance of mechanical work as a technology. It's also being used in the establishment of automation systems. Pneumatic systems are like hydraulic systems but in these systems compressed air is used in place of hydraulic fluid. A pneumatic system is one that transmits and controls energy using compressed air. Pneumatic systems are widely employed in a variety of sectors. Most pneumatic systems rely on a constant supply of air compressed air to make them work. An air compressor is used to provide this. The compressor draws air from the atmosphere and stores it in a receiver, which is a high-pressure tank. Through a network of pipelines and valves, compressed air is delivered to the system.

As the Fourth Industrial Revolution continues to change the face of the manufacturing world, many are questioning the future of pneumatics.

To stay alive, several shark species must swim constantly to keep water flowing over their gills. The same principle holds true for technology: once it stops evolving and progressing, it is on the verge of extinction. New sensing and data communications solutions are making pneumatics smarter and easier to incorporate into the Industrial Internet of Things (IIOT), which is good news for people responsible for building and managing pneumatic systems ubiquitous across industrial environments.

Recently with emerging technology this industry is showing great growth potential, some of which are covered further.

Miniaturization

There is a prevailing trend towards miniaturization. Smaller is better since smaller is lighter and generally costs less in terms of input costs (raw materials, handling, labor, conversion energy...), but the degree of feasible miniaturization varies from application to application. For motive applications using fluid power there is some limit to how far manufacturers can progress along the miniaturization route before cooling and flow rate issues come into play. In other applications like liquid and gas sampling, nanotechnology systems are being implemented that fall within the nanometer range – that is one billionth of a meter.

For off-highway vehicles the greatest motivator for miniaturization has been the phased introduction of emission regulations by the US Environmental Protection Agency (EPA) to drastically reduce carbon and nitrogen oxide emissions. Tier 4 Final will be implemented in 2024, requiring emissions to be as close to zero as possible. In 2025, the EU will implement a similar strategy. The necessity to enhance fuel efficiency is a direct result of these rules, and this has resulted in smaller hydraulic reservoir sizes and circuit capacity in order to minimize vehicle size and weight. More component integration, smaller devices capable of handling larger flow rates, and increased system pressure have been developed in response.

Sauer-recently Danfoss's announced PVG 100 High-Flow valve option (Figure 1), for example, provides a 30% increase in flow capacity in the smallest package on the market.

Fig.1-Sauer-Danfoss’s recently launched PVG 100

 

Pneumatics 4.0

Because of its inherent safety in hazardous applications, simplicity, and reliability, pneumatics is a well-established technology that will continue to be preferred for a wide range of applications. However, despite its many advantages, there is still potential for improvement in terms of energy efficiency, particularly when compared to rival technologies such as hydraulic or electric. Energy efficiency is a critical end-user need, not only because of global government crackdowns on industrial energy usage, but also because energy prices account for a large amount of pneumatic system operating costs. A pneumatic system's major components include valves, actuators, air filter regulators, lubricator units (FRLs), and fittings, in addition to the compressor, which delivers compressed air for use in these systems. While all these components are commodity products, IoT/Industry 4.0 has the greatest impact on valves and actuators, which are the market's main growth engines, as these components have a strong influence on purchasing patterns for other components.

The application of sophisticated technologies has two significant advantages: maintenance and productivity. Pneumatic valves govern air flow in the system; in the effort to decrease energy consumption, OEMs and end users alike will prioritize minimizing air consumption in the pneumatic system. Enhancing the amount of control in pneumatic actuators is another important end-user requirement. The end user can collect operational and performance data like as speed, force, air consumption, and cycle time by adding sensors to the system. This information can assist the end user in identifying inefficiencies that can be corrected to increase productivity. In addition, analyzing the data to discover performance profiles that are indicative of deteriorated performance can help the end user identify component failure in advance. A valve or actuator can be replaced at the next scheduled interval in this manner, reducing machine downtime and increasing operating efficiency.

Smart Pneumatics 

Old pneumatic processes are being turned into smart pneumatic systems, with data transferred to higher-level controllers and distributed to local networks, thanks to the flow of sensory information in both ways. Continuous position sensors are very useful for process control and optimization in applications that require consistent high quality, speed, and repetition. Position sensors are also appropriate for long-term deployment in difficult situations since they can be customized with features like vibration, shock, chemical exposure, and water ingress resistance.

Pneumatics is already the preferred solution for many of these applications, thanks to its tough character, which allows it to tolerate a wide range of temperature, pressure, and environmental extremes. Material characteristics have improved so much, and production techniques have improved so much, that high-volume manufacturing is becoming more common in the business. This improves overall quality and reliability while also lowering the cost of critical components like pneumatic valves and cylinders. Pneumatics are the natural choice for repetitive, high-volume, "fit and forget" applications since no other technology can operate in such a wide range of situations. 

Overall equipment efficiency is increasing as we gain a better understanding of machine systems and processes, is one of the major concepts driving the future of pneumatics. While the emphasis is on electronic and digital control of automated systems, this does not rule out the possibility of a future for pneumatics, since many material aspects of pneumatic systems can adjust their designs and processes to incorporate IoT factors into their functioning.

 

Fig.2 – Aventics AV03 Valve

Electropneumatic Pressure Regulation

With the incorporation of electropneumatic control capabilities in the valve manifold, advancements in valve performance and versatility took a huge stride ahead. A simple directional control valve is referred to as a basic valve. The air is directed out of a port once an electrical signal is provided to alter the valve spool. Based on the input signals, electropneumatic pressure-regulating valves can give a range of pressures up and down a linear scale. The original analogue versions used an analogue signal scale to change pressure. According to the signal, it gave a linear output pressure to the cylinder. The electropneumatic pressure regulation inside the system is more advanced because to the capabilities provided by digital valves and fieldbus communication. Pneumatics' value and versatility for a wide range of automated systems are enhanced by this advanced level of control. It enables for more precise movement control in the manufacturing process. Diffusion welding operations are optimized with dynamically controlled pressure that may be exactly suited to the application when electropneumatic pressure regulators are paired with an innovative valve manifold with integrated communications bus. Simultaneously, the manifold's intelligence monitors and documents all of the valve's functions, regulating the grippers for improved quality control and process tracking.

Fig. 3-Pressure controller

Lower Downtime, Lower Costs

Even five years ago (a long time in tech terms), an internet study reported that predictive maintenance could reduce costs by as much as 30%, with a corresponding reduction of equipment downtime of up to 70%. With Industry 4.0, this long-term industry goal is finally coming into view. For example, valve terminals are already in use with embedded intelligence which continuously monitors various operational factors and generates data for diagnostic purposes. These factors include the number of run-time hours and switching operations, the condition of the power supply, and more. Pressure, position and flow sensors, designed and equipped with IO-Link capabilities, can deliver advanced data diagnostics and hot-swap capacity, giving manufacturers the ability to predict specific component failures and replacement schedules.

 

Fig. 4-Festo Energy Efficiency Module

Many detractors of pneumatic systems have asserted in the past that the costs of compressed air and the overall costs of pneumatic equipment's life cycle are prohibitive to its economic feasibility. Manufacturers of pneumatics have responded by establishing best engineering practices and more efficient product designs to improve compressed air efficiency.

Festo, for example, has created an energy efficiency module that can monitor the machine's operational condition and immediately shut off compressed air flow while the machine is idle or in sleep mode. The Festo unit not only saves energy but also monitors potential leaks and provides real-time data on air pressure, flow, and consumption. This massive amount of streamed data is subsequently delivered across common connections to an industrial network connection for real-time management control, or to the Cloud for long-term analysis by end users.

The expansion of smart sensing technology will be connected to the future of pneumatics. From connectors, tubing, and hoses to pneumatic cylinders, actuators, and filters, cost-effective sensing and information processing technology is rapidly becoming a part of all forms of fluid power equipment.

The winds of change are surely creating exciting opportunities for growth and a sustainable future for  pneumatic and hydraulic equipment and systems and all those who work with these.