Festo

Air Consumption Analysis
Frequently Asked Questions

 




Why is the energy consumption of a machine so important for OEMs?
For the machine builder, energy consumption is now a real differentiator. As energy costs continue to increase each year consumption figures have become more of an important sales argument for companies that sell machines. Therefore, it is ever increasingly critical for manufacturers to seek out ways to eliminate waste from their processes in order to remain competitive and profitable and to document the energy efficiency of their products. Energy costs are – alongside the statutory requirement to test and provide valid compressed air consumption figures – a major incentive to analyze and improve performance. What is hampering many companies is the lack of our expertise as manufacturer of pneumatic components, appropriate technologies and techniques for the accurate measurement of compressed air consumption and, more importantly the skills to analyze the data and provide effective action plans.


How does the Festo Air Consumption Analysis Service help OEMs?
As compressed air specialists, Festo can help the machine builder first understand and then improve energy consumption at the individual machine level. During a Compressed Air Consumption Analysis Service of Festo new and existing machines are evaluated and precise consumption figures are measured, providing the documentation essential to ISO 14001 compliance. And, of course, giving their customers a valuable benchmark for comparison against competitive equipment. It’s this practical focus, at the most detailed level (down to the seals on the fittings), that defines our Air Service.

What exactly are the benefits of the Festo Air Consumption Analysis Service for OEMs?
The focus of our work with machine builders is first, to improve the accuracy of sizing, to define the optimal compressed air system for a given machine. We then use that information to generate a set of documentation that will give the customer evidence for standards compliance, and underpin an effective total preventive maintenance (TPM) program. The Festo Compressed Air Consumption Analysis Service spans the following steps, all carried out by pneumatic specialists using state of the art, calibrated and tested measuring equipment and advanced analysis software:

  • Inspection and evaluation of the pneumatic system
  • Flow, pressure and air consumption measurement at the machine level during a static test. The static test shows how much air is consumed while the machine is ready to run but not running. Here, the measurement equipment is implemented in the main supply line.
  • Flow, pressure and air consumption measurement at the machine level during a dynamic test. The dynamic test shows how much air is consumed while the machine is running and is used to determine the cost of operating the pneumatic portion of the machine over a customer-specified time period. Here, the measurement equipment is implemented in the main supply line. If the machine requires a more detailed evaluation measurements can be done at different test point locations on subsystem level.
  • Graphical presentation of results, with supporting documentation of values
  • Recommendations for improvements, by technical consultants

Consumption figures for each mode are compiled into a document that acts just like a window sticker on a car. Afterwards, the machine is evaluated on a component by-component basis, and the results are documented in detail.

How do the customers of OEMs benefit from this service?
Since this service can be the last step in a commissioning/quality control process there are several advantages for the customers of OEMs. Machines optimized with Festo Air Consumption Analysis enables EU to operate machines with reduce compressed air costs. The air consumption figures are precisely measured and documented before the machine is handed over to the customer for production. Therefore the compressed air network can be optimized beforehand in order to minimize energy misuse. Also, the measurement and documentation of actual compressed air needs make the pneumatic system of a machine fully analyzable during normal operation, allowing potential problems to be discovered immediately.

What are the basic requirements for project consideration?
The successful conductance of the Compressed Air Consumption Analysis Service requires a little assistance of the customer. Since we measure the compressed air needs of the machine in different operational modes with sensors inserted into the pneumatic lines we need the customer not only for the installation and de-installation of the sensors, but also to run the machine in different modes.

How much downtime is required to install/remove the test equipment?
Experience shows that installation and removal of the test equipment takes approximately 20 - 30 minutes. This does vary from application to application.

Do customers need to use Festo components exclusively?
No, the air consumption analysis can be used on machines with any pneumatic manufacturer’s components.

What if I want Festo to do this service on all my machines on a regular basis?
This is possible as a part of a service contract.
© 2008 Festo Corporation