FAQ Energy efficiency

Energy efficiency

What pneumatic actuator has the least amount of leakage?

Membrane-based system, such as the pneumatic muscle MAS, bellows cylinder EB and the clamping components EV can be described as being "absolutely" leak-tight, due to the nature of the system. With these products, there are no dynamic sealing points (piston rods/lip seal ring).

How can constantly changing pressure ranges be realized energy efficiently?

Often, the required system pressure is set on the last element of the control chain. Before that, the entire system is fed with the maximum expected pressure. This means that the high pressure level is controlled down at many points with lower pressure levels. At these points, you could say the energy is being 'destroyed'. If the different pressure levels are already controlled at the valve terminal, the losses up to the consumer are lower. If proportional valves VPPM are used as pressure zone controllers on a valve terminal MPA, the pressure levels can be optimally set, conveniently and nearly constantly, via the bus.

What energy-saving potential does our new servo controller of type CMMD-AS have to offer?

Often, handling tasks are solved with XY or XZ kinematics. For these 2-axis solutions, there is now the compact servo controller CMMD-AS for actuating 2 independent axes.

Especially the function for using the braking energy of one axis to accelerate the other one underscores the consistent component design with regard to optimal electrical energy utilization with this controller.

How can vacuum suction grippers connected in parallel be shut off when one or more suction points are no longer needed?

If one or several suction points of a vacuum line section are not 'occupied', vacuum is wasted unnecessarily. If each suction point is provided with a vacuum valve ISV, this component does not block the used suction point.

What must be taken into account when designing pneumatic circuits with optimal use of compressed air?

The right dimensioning with regard to the required drive force, the associated nominal size of the fittings and hoses and the right valve size.

The various design tools from Festo also help.

How can a higher operating pressure be generated for individual consumers?

What options are there if a higher pressure is required on individual consumers than the available system pressure?

In order not to have to supply the entire compressed air network with the higher pressure, a pressure booster DPA would make sense. With this booster, the higher pressure can be targeted at the right place.

How can a pneumatic drive be sensibly dampened?

For one thing, vibrations can be reduced with rigid designs. This often means more material must be used or higher-quality material. How can a pneumatic drive be 'dampened' without having to invest in complex mechanics/frames/cushioning elements?

Similar to a controlled servo motor, a cylinder can be moved extremely softly into its end positions with the pneumatic Soft Stop SPC11 without any mechanical design elements having to be added.

How can using a vacuum gripper be made more efficient?

The trick is to keep the volume to be evacuated as low as possible. With bellows grippers in particular, this is not necessarily the case. The porous inlay OASI, which also has a support function for very thin workpieces (e.g. foils).

How can the energy efficiency of a classical 2D gantry handling system be streamlined?

In addition to using controlled drives, the most energy-saving potential lies in the weight, here. Particularly with handling systems, the weight being moved by a Y or Z axis is the decisive parameter when sizing the drives. Weight which is not moved must thus not ever be accelerated/braked.

With the new H-gantry kinematics, the moved masses of the Y direction of movement could be drastically reduced compared to a conventional X/Y handling system. Just the fact that the Y motor does not have to be moved reduces the necessary drive energy.

Are rodless drives energy efficient?

Anything that has to be sealed represents a potential source of leakage. In the case of a rodless cylinder, the critical leakage point is the slotted barrel with sealing strip. For the DGC series, Festo was able to notably reduce the risk of leakage. Compared to the previous model, the sealing strip is not only laid around the cylinder barrel, but is securely clipped into place and thus provides a more effective seal.

How can compressed air costs be lowered in the vacuum range?

Realizing gripping functions using suction grippers often involves high air consumption to generate the vacuum. This air consumption can be very easily reduced by only activating the vacuum when it is needed.

Also, for 'holding' a workpiece, the generated vacuum level is constantly measured with the vacuum suction nozzles OVEM. If it is sufficient, the vacuum generation stops. Compressed air costs are thus reduced to the minimum required level.

What does integrated current reduction do beyond reducing the current requirement of a solenoid coil?

• Built-in freewheel circuit for fast switch-off (freewheel voltage=Vp+25V)
• Protection against short-circuits helps guard electronics
• Undervoltage and undercurrent identification ensures operational reliability
• Monitoring of armature movement of coil ensures operational reliability

 

How much air does a system consume?

The answer to the question of "how much air a system consumes" relates to the actual consuming device.

It is also essential to clarify the theoretical level of consumption of the system. Our calculation tool will help you do that. Air consumption of cylinders.

The actual air consumption is measured using a flow sensor . Continuous monitoring of the consumption ensures you have the necessary overview.

What alternatives are there to a controlled servo motor?

The new EMMS-ST stepper motor generation combined with the CMMS-ST motor controller provides efficient control of the stepper motor. This enables the motion profile to be optimised for the specific requirements, thus saving energy costs.

Advantages:

Generally speaking, closed-loop controlled systems should always be used with electrical systems as they only utilise the amount of power actually required. Previously, this was solely the preserve of servo motors.

With the encoder EMMS-ST and the motor controller CMMS-ST, stepper motors can now be efficiently controlled, thus saving energy costs.

How can the return stroke of a pneumatic cylinder be implemented with reduced pressure?

When using Festo valve terminals, it is possible to provide each drive with the individual pressure level required for the forward and return stroke. This is done by fitting an intermediate plate with pressure regulator (preferably a reversible regulator) on the relevant valve position.

The reversible regulator splits the supply air (duct 1) and regulates the pressure before the valve in 3 and 5. This operates the valve in reversible mode. Port 3 routes the air to 2 and port 5 to 4.

During the exhaust process, air is exhausted in the valve from 2 or 4 to 1 and the air is returned to 3 and 5 via the intermediate plate.

Benefits:

- Different pressures possible at 2 and 4, resulting in lower compressed air consumption.

- Exhausting is not carried out by the pressure regulator and is therefore faster (up to 50%).

- "Ducted" quick exhaust function via valve terminal is virtually integrated

- The pressure regulator can always be adjusted (with the AB regulator the valve must be switched to do this)

 

Note: Not every application allows a pneumatic cylinder to be operated with reduced pressure on the return stroke.

It is not possible to use 2x3/2-way valves in combination with ducted exhaust 82/84, as reversible pressure is present at the valve interface.

Are there any pneumatic drives that are particularly lightweight?

Moving weight costs energy and therefore money.

When pneumatic cylinders have to be moved, we recommend cylinders with high-performance polymer bearing and end caps. Depending on the size, this brings weight savings of up to 25%.

For round cylinders, the DSNUP series is ideal, and for compact cylinders ADNP

 

How can a service unit optimise compressed air consumption?

Prompt disconnection of the compressed air supply to a system (e.g. at night) prevents individual leaks from adding up. The electric on-off valves enable this to be done conveniently and selectively from a central location.

The golden rule of compressed air consumption

Experience shows that compressed air costs are not only generated during operation but also, and to a considerable extent, during system standstill.

The classic energy saver is mundane but highly effective. Ensuring that compressed air is only consumed where work is actually performed.
We will be happy to support you in this area. Energy Saving Services

Does Festo provide products for clean room applications?

All regular Festo products correspond to at least clean room class 10 000 as defined by the Federal Standard 209 F Airborne Particulate Cleanliness Classes (US FED-STD-209). Some standard products even correspond to class 100, while components up to class 0 are available as part of customised solutions.

What does clean room classification in accordance with US FED-STD-209 specify?

Example: class 100 permits up to 100 airborne particles with a diameter of more than 0.5 µm per cft (cubic foot) of air (1 cft corresponds to 28.3 litres).