Electric and pneumatic systems often need to operate together smoothly in a machine, but complexity increases when functions, I/O, communication and data management are designed separately. Each additional interface or variant adds effort in engineering, installation and commissioning.

Hybrid automation addresses this by integrating both technologies where they fit best and designing their connections as part of a single architecture. A key point here is that rigid machine concepts are difficult to adapt to new PLC standards, I/O layouts or pneumatic requirements. A modular approach gives engineers more flexibility, so the complete system doesn’t have to be redesigned for every variant.

The following five approaches show you what to focus on first.

Communication links the controller with pneumatic functions but required fieldbus standards often differ between projects. This can be problematic when multiple PLC environments are operated using different hardware. Multi-protocol capability can reduce this complexity, as it allows the communication interface to be adapted without having to change the overall machine architecture.

The key question is not only which protocol is needed today, but how much the system must change when change is needed.

The application determines whether a centralised, decentralised or mixed architecture is most suitable. Remote I/O allows functions to be placed closer to machine modules while keeping other parts centralised. This improves structural flexibility.

Different modules may also require different pneumatic performance levels. If a bigger valve is required to provide a higher or lower flow rate, this can be easily achieved using a modular concept without having to redesign the full system. Controlled flexibility means standardising where possible and varying only where necessary.

Integrated solutions combine the robustness and speed of pneumatic systems with the control and flexibility of electric systems. This leads to improved machine performance and increased system efficiency. Components based on an open architecture promote this synergy, both in centralised and decentralised concepts. The modular structure creates the basis for efficiently meeting both simple and complex requirements. The following solutions will help you to make the best possible use of the strengths of both technologies for your automation solutions.

Integration reduces the number of separate components in a machine. Pneumatic functions, safety functions and sensors can be placed closer to the process. This reduces interfaces, cables and tubing.

The result is a simpler system structure without changing the machine’s core functionality. The value of a simpler system is having no unnecessary complexity while the required functions are still available.

Engineering starts with system planning and continues all the way to configuration and commissioning. Digital tools support this process by structuring components like valve terminals and remote I/O at system level and carrying the design data over into subsequent steps.

This reduces rework and maintains information consistent across project phases. The benefit is better control of complexity throughout the entire engineering process.

Sensor data from pneumatic systems can be included into the machine architecture. Information such as pressure or operating status becomes available closer to the process.

This improves visibility of system behaviour and helps detect deviations earlier. The aim is not to collect more data, but to use relevant process information more effectively.

Once you understand the requirements of your machine architecture, you can start to explore how they translate into a specific automation platform.

The valve terminal VTUX is one example of a platform approach that brings communication, pneumatic performance, safety, I/O and selected integrated functions together in a connected system concept. Remember, though, that the right setup still depends on your application, architecture and required configuration.

Product highlight

With the new VTUX valve terminal family, Festo is focussing on sophisticated modularity that offers a high degree of flexibility and efficiency in combination with a wide range of technical options. Anyone looking for a technology that adaptively supports future developments will find exactly the right solution in VTUX in conjunction with AP communication technology