Whether standard pneumatics suffices or a controlled solution is necessary depends on the actual process requirements. This guide shows which criteria are crucial for the selection process and when a deeper assessment of Controlled Pneumatics is worthwhile.
Standard pneumatics are suitable for simple, stable applications with clear end positions and constant conditions.
1. Simple switching and motion tasks
It is usually sufficient when defined end positions are adequate, pressure remains constant, no ongoing adjustments are required, and processes are simple and repeatable.
2. Stable process conditions
Fixed settings are often sufficient for consistent workpieces, minimal load fluctuations, stable ambient conditions, large tolerances, and infrequent product changes.
3. Moderate demands on precision
What matters is not the maximum possible accuracy, but the permissible deviation within the process.
4. When standard pneumatics are the better choice
They are suitable when simple, stable functions are more important than continuous closed-loop control, process data or maximum control quality.
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Download now!Controlled Pneumatics becomes relevant when process parameters not only need to be set but actively controlled during operation. The decisive factor is the application, not the technology.
1. High requirements for precision and repeatability
A regulated solution makes sense when tight tolerances, reproducible results, and stable quality are required despite changing conditions. The determining factor is the required process accuracy.
2. Changing loads and disturbances
Controlled Pneumatics can actively balance out deviations when process conditions change during operation. This applies, for example, to different workpieces, fluctuating material properties, changing loads or external influences such as pressure and friction changes. Despite these variations, closed-loop control ensures that the desired process parameters are kept stable and consistent results are achieved.
3. Variable products and frequent adjustments
During frequent product changes, digitally adjustable parameters can reduce manual settings and errors. This can shorten changeover times and allow processes to adapt more quickly to new requirements. The benefit depends heavily on the frequency of changes and the current effort involved.
4. Continuous control requirements
A controlled solution is relevant when process variables fluctuate, intermediate values are needed, or deviations need to be automatically corrected. The key question: is a fixed controller sufficient, or must the process respond?
5. Process data for greater transparency
Available process data provide transparency and can offer insights into the health status of applications and machines. Control systems support diagnostics, documentation, and quality assurance. They make sense when process values and machine or system states need to be traceable, deviations should be detected early, or real process values are fed into the controller. Real added value only arises when this data is actively analysed and purposefully utilised.
Before making a selection, it must be clear which variable determines the process. Controlled Pneumatics can control pressure, flow rate or motion.
Pressure
Relevant when the pressure directly affects the force or quality. It is essential to define the operating range, permissible deviation, reaction time, and potential disturbances.
Flow rate
Determines speed and supply. It is necessary to clarify the volumetric flow rate, setpoint behaviour, fluctuations, and dynamics.
Motion
What matters is whether only end positions or also intermediate values are relevant. Examples include variable speeds, intermediate positions, different motion profiles or changing loads.
Standard pneumatics are ideal for stable, straightforward applications with clear conditions. Controlled Pneumatics become relevant when processes vary, need precise control, or must adapt dynamically. The decision does not depend on the technology but on how strongly and precisely the process needs to respond to changes.