Tech Briefs Magazine - June 2022 - MD-5

Application
kWh savings
from
decreasing
leaks
Parts Handling 3,910
Clamping
Engine Parts
Machining
18,719
220
Tons of CO2
saved from
decreased
leaks
3.01
14.6
.17
saved = 1,299 kWh avoided EPA Greenhouse Gas Equivalencies Calculator
kWh savings
from smart
design
25,136
120,222
1,286
* Calculations based on 250 working days per year, 16 hours per day, 6 bar (90 psi) operation pressure
1 ton of CO2
Average of 7.3 cents per kWh in U.S. for industrial users January 2022. Average price of electricity U.S.
Figure 1: Estimated annual energy savings from leakage vs. smart design.*
part machining. Energy savings and carbon
dioxide (CO2
) emissions reduction
through leakage eradication alone is
compared to energy savings from leakage
eradication combined with seven
other smart design concepts. The additional
energy conservation tactics are
reduced pressure, correct sizing, reduced
tubing lengths, reduced pressure
loss, recovered energy, remove power
when the machine is idle, and air saving
circuits. The total savings are up to six
times greater with combined smart design
concepts than through leakage
eradication alone.
An important conclusion from Figure
1 is that air intensive applications, such
as clamping, offer greater energy savings
potential than others such as parts
machining. In a strategy of smart design,
renovations focus on those big
potential wins first and work back from
there. Another important fact to be
gleaned from Figure 1 is the potentially
significant carbon footprint reduction
in terms of less CO2
. Every corporate
sustainability effort will applaud these
reductions.
When designing or renovating pneumatics
on a machine or in a cell based
on smart design concepts, the system
becomes more sustainable on every
level, including higher performance
and less downtime. The reasons are:
Use air saving circuits -
60% savings
Reduced pressure level -
22% savings
Reduced friction -
15% savings
Reduced pressure loss -
6% savings
Figure 2: Best-case savings from smart design strategies.
Motion Design, June 2022
* Less friction in the system
* Fewer stress points and more efficient
movement of actuators
* Optimum control, including shutting
off the system when not in use
* Better diagnostics that contribute to
higher uptime
* Optimization of vacuum and high-pressure
zones
* Cleaner air, which extends the life of
pneumatic valves and actuators
* Optimized safety systems
* Smaller and lighter components for
reduced footprint and less force required
for movement
Smart Design strategies
Similar to air intensive applications,
some concepts offer higher energy conservation
than others. Figure 2 shows
some of the top smart design concepts
and the potential best-case savings. The
idea in smart design is to incorporate
those strategies that make sense for the
application - not to apply all of them
every time.
The following are factors to consider
when using smart design concepts.
The tips can raise awareness and generate
interest in these concepts so that
while using new automated design
tools, an engineer has a fundamental
understanding of the basic intent of
those tools.
Correctly sized components -
35% savings
Reduced leakages -
20% savings
Recover energy -
10% savings
Reduced tubing length -
25% savings
Reduced weight -
18% savings
Switch off power -
10% savings
Tons of CO2
saved from
smart
design
19.6
93.9
.99
Pneumatic Cylinders
Oversized actuators drag down system
efficiency through higher weight, friction,
and energy consumption. If there
is one strategy to apply at every opportunity,
it is to correctly size pneumatic
components. Reduction to the next
smaller size actuators, for example, decreases
energy consumption by roughly
35 percent.
In locating cylinder and valves, look
for ways of keeping tubing lengths to the
various cylinders as short as possible,
because shorter tubes can be up to 25
percent more energy efficient than longer
ones. Shorter tubing also promotes
faster actuation and higher performance,
as shown in Figure 3. This is an
example of the congruence of energy
savings and higher performance.
Valve and Valve Terminals
Valves function as switching and control
components in pneumatic systems.
The drive connected to a valve can only
be operated efficiently if the valve is correctly
sized and actuated.
In many applications, full force is only
required in one direction. In these instances,
pressure may be cut in half for
the return stroke for up to 20 percent
energy savings. Valve terminals with vertical-stacking
regulators can easily make
these kinds of force adjustments.
A next generation of valve terminals
have an " eco " app that saves energy by
setting several pressure levels. The user
sets pressure for a range of selected movements
at reduced levels. Additionally,
these intelligent terminals can control
speed with a flow control valve setting.
Whenever possible, machine mount a
valve terminal as close to the actuators as
possible. Machine mounting shortens
the length of tubes, which as noted, improves
reaction time and energy conservation.
Machine mounting of valves and
terminals can also reduce the space required
in a control cabinet or even eliminate
the need for a cabinet altogether,
creating savings and a smaller footprint.
Considering that many valve terminals
can offer IP65 or even higher degrees of
protection, this can be implemented
quite often.
Consider the use of proportional
valves with pilot control based on piezo
valve technology to control pressure levels
and flow rates. This reduces energy
consumption considerably as does speci5
MD
Motion Control Feature 0622_1.indd 5
Cov
ToC
5/18/22 10:04 AM
http://info.hotims.com/82322-850

Tech Briefs Magazine - June 2022

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