Perfect combination of electrics and pneumatics

More efficient automation thanks to the combination of electric and pneumatic systems

When designing machines, you face the daily challenge of having to minimise costs and speed up processes. At the same time, you need to adapt quickly and flexibly to technological transformations and changing market conditions. This article shows you how you can use modular concepts to sustainably reduce costs in all phases of the machine life cycle and how you can optimise the savings potential of modular systems for your automation solutions.

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.


5 approaches for integrating electric and pneumatic systems

1. Using valve terminals with fieldbus interfaces

Valve terminals that are compatible with various fieldbus systems offer an efficient solution for communication between the electronic controller and the pneumatic version. These systems minimise installation complexity and increase the reliability of the overall system by allowing a direct connection between the control units and actuators.

2. Open system architecture with a modular approach

Systems that support both centralised and decentralised I/Os and integrated valve terminals enable a significant increase in flexibility without additional complexity. By selecting a network protocol, different operating requirements can be accommodated for a precise and tailored result. This modular approach reduces storage costs and ensures product availability. It also offers a comprehensive integration of electric and pneumatic systems and optimises network resources.

3. Integrated automation platforms

Integrated automation platforms that combine controller units with modular I/O and fieldbus interfaces are especially suitable for managing hybrid systems in industrial automation. They facilitate the efficient control and monitoring of both electric and pneumatic components and create a sturdy foundation for complex automation requirements.

4. Using software tools and digital twins

Software tools that support the design, simulation and diagnostics of automation systems play a decisive role in modern automation technology. Engineering tools, for example for creating circuit diagrams or configuring complex products, simplify and speed up development. By using digital twins, engineers can virtually simulate and test systems before they are implemented physically. This contributes to the optimisation of system integration and helps identify and minimise errors at an early stage.

5. Implementing IoT solutions for networked automation

IoT-enabled technologies that enable networked maintenance and monitoring of automation systems improve predictive maintenance and fault detection. By recording and analysing status data in real time, maintenance requirements can be identified at an early stage and downtime minimised, thus increasing the overall efficiency of the system.


Automate more efficiently with the best of electrics and pneumatics

From valve terminals with fieldbus interfaces to open system architecture and IoT solutions, each of these approaches helps to minimise system complexity and maximise performance. Take advantage of these advanced technologies to perfectly combine electric and pneumatic systems for greater efficiency and flexibility in your machine concepts.

Ralf Höhn, Valve Terminals Product Management


About the author

Ralf Höhn
Valve Terminals Product Management
Festo SE & Co. KG

October 2024

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