Mechanical Technology January 2016

⎪ Innovative engineering ⎪

Hybrid automation and efficient pneumatics and hydraulics

In this article, Kevin Lombard (right), general manager of Tectra Automation, a Hytec Group company, talks about the integration and hybridisation of pneumatic, hydraulic, and electric motion systems, driven by IT connectivity and Industry 4.0 technology innovations.

I n the current technological environ- ment where there are increasing demands on higher energy efficiency and, in apparent contrast, lower costs, most manufacturers do not rely only on machinery and automation to decrease cycle times. Instead, they now pursue solutions that are easy to set up, provide a simple operator interface and reduced downtime. Using electric, hydraulic or pneumatic motion systems is a choice that has the potential to affect costs, performance, flexibility, reliability, ease of use and maintenance. It is there- fore important that customers get appro- priate advice before selecting a solution. One modern option is to opt for a hybrid automation solution, a technol- ogy that has made rapid in-roads in our technologically advanced environ- ment. This is especially relevant in the automation sector, which has already entered the new reality of Industry 4.0 – the fourth industrial revolution. Among other aspects, Industry 4.0 centres on the increasing integration of all areas of industry, which has been made possible by information technology. In the history of change in the indus- try, never before has IT brought such potential for increased collaboration, through quickened communication and real-time data exchange. For those with the foresight and expertise to quickly integrate Industry 4.0’s offerings, exciting opportunities are on the cards. There are six design principles in Industry 4.0 that support companies in identifying and implementing Industry 4.0 scenarios: interoperability, virtualisation, decen- tralisation, real-time capability, service orientation and modularity. Engineering companies that embrace combination electric, hydraulic and pneu- matic motion technologies are in a better position to give the most suitable advice. They can help customers achieve the best solution for performance and price. They

s hou l d ha v e strong product

portfolios in all three disciplines, and sig- nificant expertise in integrating electric, hydraulic and pneumatic technologies into an overall solution. Hydraulics Hydraulics is the choice for heavy loads when immediate motion is required. Hydraulics allows full velocity to be achieved quickly. Forces are by far the highest of the three technologies – up- wards of 100 tons. Hydraulic systems have become smart – they are inher- ently powerful and combine hydraulic actuators with integrated digital control electronics. This combination allows functions to shift to the software. The hydraulic standard functions are pre- defined in Bosch Rexroth control, drive and power units – all the user needs to do is define the parameters. The software and intelligent control algorithms, developed specifically for hydraulic requirements, automatically equalise the non-linearities inherent in fluid technology. For example, in the Bosch Rexroth Sytronix series, the soft- ware combines the best from both elec- trical and hydraulic systems. Essentially, operations that used to be performed by valve controls made of steel and iron are now handled by decentralised intelligence in the electronically controlled device. Bosch Rexroth has integrated all of its electro-hydraulics expertise into the IndraMotion MLC control solution soft- ware. This allows for the special charac- teristics inherent in fluid technology and can, in most instances, replace elaborate programming with parameterisation. This reduces engineering expenditure for machinery manufacturers and, depend- ing on performance requirements, can execute both electrical and hydraulic movements without major changes in the machine control.

Expertise in integrating electric, hydraulic and pneumatic technologies into an overall solution can help customers to optimise solutions for performance, efficiency and price. Pneumatics Commonly powered by compressed air or compressed inert gases, pneumatics finds wide application in machining ap- plications by offering fine performance and simple application. Most pneumatic systems operate at pressures of about 6.9 bar (100 psi) or less. Because pneu- matic pressures are lower, components can be made of thinner and lighter weight materials. Factory automation is the largest sector for pneumatic technology, which is widely used for manipulating products in manufacturing, processing and packaging operations. Pneumatics is used when speed and force need to be easily and continu- ously controllable over a wide range. This technology is also functionally reliable under adverse operating conditions and is insensitive to external influences such as high and low temperatures, dirt, mechanical vibration, moisture, and electrical noise. In addition, pneumatics is fundamentally safe. Aventics has integrated electronics into its current pneumatic range, such as the ED series electro-pneumatic pressure regulators or AES modular electronics for the AV Advanced Valve generation. This product range provides the functions required for machine networking and the Internet of Things, making Aventics’ pneu- matic components ‘Industry 4.0 ready’. Aventics AV valves are a valve tech- nology innovation that is pushing the boundaries of electric/pneumatic hybrid products in terms of space and energy efficiency. With their diagonal arrange- ment of the valve spool, the valve size is reduced by half. This means these valves

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Mechanical Technology — January 2016