For pneumatic systems to move machinery, equipment, and tools, they require compressed air, a few basic parts, and a piping configuration. Pneumatic systems are increasingly engineers’ preferred choice for automation projects because of their simple, inexpensive, and eco-friendly power source. A wide range of industries employs pneumatic systems in a multitude of applications. In this article, we will examine the reasons behind the widespread use of pneumatic systems and examine 4 practical uses that highlight their versatility.
1. Several benefits of using pneumatic systems in automation projects
Pneumatic systems depend on several parts to regulate and sustain airflow, providing devices with a steady supply of power. An air compressor in the system draws in outside air and compresses it to a smaller volume. After that, the compressed air is sent through a filtering system and, if present, an air drier to remove moisture and impurities.
Once the compressed air reaches the system actuator, which powers connected devices such as air-powered tools, robot end-of-arm tooling, or automated machinery, the treated air is distributed through a series of valves that regulate, maintain, and direct the airflow through the distribution system of pipes and tubing. Common pneumatic system motion profiles include pushing, pulling, closing, lifting, and holding.
- Reliability: Pneumatic systems are often quite dependable when in operation since they have simple components, are unaffected by temperature changes, and can withstand shock and vibration. Because air is readily available, pneumatic systems also provide a reliable power supply.
- Cost-Effectiveness: Pneumatic systems are inexpensive to build, have few moving parts, and require little upkeep. Furthermore, ambient air can be freely extracted from the environment. Pneumatic systems are among the least expensive power solutions because of these considerations.
- Safety: Pneumatic systems minimize the risk of fire or explosion in situations where it may be problematic, since they power equipment with air rather than sparks.
- Flexibility: Pneumatics are an effective way to power various devices, as a single pneumatic system can precisely and consistently control multiple components or applications. This eliminates the need for additional power sources. Furthermore, pneumatic systems can be easily customized for a variety of applications, from small, delicate robots to heavy-duty equipment.
- Cleanliness: Pneumatic systems offer a cleaner power source than hydraulic systems, which are infamous for fluid leaks. A pneumatic system may leak, but any air loss will return to the atmosphere. Additionally, treated air that meets strict criteria in sterile sectors, such as food and pharmaceutical processing, may be produced using specialist oil-free or oil-less air compressors and appropriate filtering systems.
2. Applications of Pneumatic Systems in real life
Given all the benefits that pneumatic systems provide, it’s hardly surprising that they’re employed in a broad range of automated applications, such as material handling, packing, conveying, and filling machinery, in sectors like general manufacturing, the automotive industry, and the food and beverage processing industry. Here are four real-world instances of pneumatic systems in use that demonstrate their adaptability.
2.1 Equipment for processing food
Equipment for chopping, cutting, slicing, and dicing is one use for pneumatic systems in the food industry. Pneumatic cylinders in these machines precisely control pressure and motion, minimizing food item damage. To chop, dice, or slice delicate things like cheese and baked products before packing, or fruits and vegetables in preparation for canning or freezing, consider using air-driven saws, knives, blades, and mandolins.
Pneumatic-based cutting systems are sufficiently accurate to promote uniformity and are easily adaptable to process a wide range of sizes, thicknesses, and angles.
2.2 Industrial robotic arms
Pneumatically operated end-of-arm tooling (EOAT) is a technology that robotic arms use for a variety of industrial jobs. These operations include material handling, machine tending, assembly, and pick and place. Pneumatic systems are frequently employed to run robotic EOATs because of advancements in vacuum and pneumatics that enable more fluid movement and accurate speed and motion control.
Pneumatic systems, including vacuum EOAT, can be precise and repeatable, providing fluid motion that prevents damage to delicate products. Additionally, because of their lightweight, simple design, pneumatic systems are easier to use, often less expensive, and require less maintenance than electronic systems. Finally, because pneumatics perform well across both hot and cold temperature extremes, they are ideal for applications that require extreme temperature performance.
2.3 Making PET bottles
Pneumatics are being used in automated equipment as more and more plastic firms are switching to stretch blow molding methods for the creation of PET bottles. This is because pneumatics provide an affordable, adaptable, accurate, and repeatable motion profile. PET preforms are put on cores and sent through an oven in stretch blow molding machines to soften them.
After that, high-pressure air is blasted on them to solidify the form and start the cooling process, and they are placed into molds that shape them into bottles. Pneumatic control valves are utilized during the expansion blowing process in this application, and pneumatics regulate the cores as they pass through the heating, stretching, and blowing processes.
2.4 Automotive Painting
Pneumatics is used in numerous processes in the automotive production industry, but painting and finishing is one of the most crucial ones. Bare automobiles are cleaned with dry, oil- and contaminant-free compressed air before painting to get rid of any contaminants that could have stuck during production. After washing, the paint is mixed and prepared using oil-free, clean, dry compressed air to guarantee uniform pigment dispersion.
Lastly, the paint is sprayed onto the prepared automobile body using guns, robots, or paint sprayers, powered by compressed air. To assist in producing a smooth and even manufacturing finish, the pneumatic system supplies high-quality, moisture-free compressed air during these processes.
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3. Other reference robot accessories:
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