1. Why is it important to optimise the pressure or flow rate?
Ulrich Sixt: For automation to be efficient, both variables need to be precisely controlled. In pneumatic systems, pressure and flow rate are inextricably linked. A cylinder does not only move because there is pressure,air must also flow to enable movement. That means purely static pressure control is not sufficient.
A well-coordinated closed-loop control system has several advantages. Energy efficiency plays a big role, as an excessive compressed air supply leads to unnecessary consumption and rising costs. Proportional-pressure regulators can help to precisely control the air flow and supply only the required amount. Last but not least, when using precise closed-loop control, sudden pressure fluctuations are avoided and the service life of the components is increased, as fluctuations accelerate the wear of valves and actuators.
2. What are the developments in pressure or flow control, and how do they differ from conventional systems?
Ulrich Sixt: Proportional technology, sensors and intelligent algorithms in modern automated systems significantly optimise precision and efficiency. One of these developments are regulators that are pneumatically or electrically controlled. These adjust the flow rate and pressure to a setpoint value or to an external signal, which is interesting if the process requires different pressures. Proportional pressure regulators keep the system pressure constant in real time, regardless of fluctuations.
In many applications, pressure and flow rate are still controlled manually or with simple regulators. These are tried and tested, but often insufficient for greater precision and efficiency. Manual valves, for example, require regular readjustments as they do not adjust automatically to pressure fluctuations.
3. What advantages do modern proportional pneumatic valves offer for automation?
Ulrich Sixt: The pressure, flow rate and movement can be very accurately controlled thanks to the intelligent combination of highly dynamic final control elements, sensors and control algorithms. Everything is automated, efficient and adaptable to a wide range of process requirements. It is precisely this principle that Festo has successfully implemented with Controlled Pneumatics.
Modern proportional pneumatic valves operate in a dynamic, closed control loop, facilitating continuous adaptation to changing conditions. Sensors continuously measure the current pressure and transmit the values to the electronic control systems. This compares the measured actual value with the specified setpoint value and immediately identifies deviations. The valve reacts in real time and automatically increases or reduces the pressure to precisely maintain the required value (flow control). Flow regulators play a crucial role in this control loop. They ensure that the volumetric flow rate is precisely dispensed to optimise energy consumption and at the same time guarantee constant performance. This intelligent closed-loop control system makes for stable process conditions, reduces energy losses and increases the efficiency of the entire system.
4. What are the advantages of intelligent pressure or flow control?
Ulrich Sixt: Intelligent pressure and flow control increases efficiency, process stability and plant and system availability. Precise closed-loop control without fluctuations optimises energy consumption and improves product quality. Constant pressure protects pneumatic components from excessive stress and wear. This increases process reliability. The automated adjustment also means that different materials and processes can be flexibly controlled. This reduces operating costs without compromising performance.
5. How does intelligent pressure or flow control improve process reliability and quality assurance?
Ulrich Sixt: In practice, I see time and again how pressure or flow fluctuations lead to faulty products. Stable processes are crucial in order to avoid rejects and rework, especially in sensitive sectors such as the automotive industry, medical technology, and food and packaging.
A common problem is that different production stations need different pressures; this can result in a cylinder not positioning components accurately or a seal not being pressed with the correct force. Proportional pneumatic valves with closed-loop control can make a big difference here. They keep the pressure at the required level, regardless of load changes, fluctuating input pressure or leakage. In practice, this means that inconsistent processes can result in high reject rates, but these can be significantly reduced with intelligent closed-loop control.
My conclusion: If you want to improve process reliability and quality, there is no way around precise, automated pressure or flow rate. That not only reduces errors, but also ensures consistent product quality, lowers downtime and creates greater overall system efficiency.
6. What potential do you see in terms of energy efficiency?
Ulrich Sixt: Compressed air is one of the most expensive forms of energy in industry, as the compressors used to produce it consume a lot of electricity. However, many systems operate at a higher pressure than necessary, which leads to unnecessary energy consumption. Even reducing the system pressure by 1 bar can significantly reduce energy consumption.
By intelligently controlling the pressure or flow, only as much compressed air is supplied as is actually needed. While conventional systems are often operated at maximum system pressure, modern proportional pneumatic valves with sensor feedback dynamically adjust the pressure to the actual demand. This minimises leakage losses, which can account for up to 20 % of compressed air consumption in many companies. In addition, with demand-based control the operation of compressors can be optimised and their running times reduced. This is directly reflected in lower energy costs. In large systems, this leads to savings in the five-digit euro range per year. Companies that rely on intelligent pressure and flow regulators not only reduce their energy consumption, but also increase sustainability and operating efficiency at the same time.
7. What role does digitalisation play in pressure or flow control?
Ulrich Sixt: A key advantage of digital systems is the transparent availability of data. Pressure or flow values can be called up and optimised at any time via IO-Link® or other fieldbus interfaces. This allows companiesto detect pressure losses or leakages at an early stage, before they cause failures. In practice, we see that companies with networked systems can significantly reduce their unplanned downtime.
Process can also be adjusted more flexibly. In modern production lines, pressure or flow values can be automatically adjusted depending on the material or product without the need for manual intervention by an on-site technician.
To put it briefly: Digitalised pressure or flow regulatorsensure greater process reliability, lower maintenance costs and flexible, future-proof production. Those who rely on networked systems benefit from more efficiency, transparency and control throughout the entire production process.
8. In what direction are the developments in pressure or flow control heading?
Ulrich Sixt: Essentially, I see three requirements for the further development of pressure and flow control: greater precision, greater energy efficiency and greater digitalisation. By integrating sensors directly into regulators, measurement and closed-loop control technology can be combined in one component. This saves space, simplifies installations and improves reaction times.
Sensitive industries such as semiconductor production or medical technology rely on advanced valve technologies. Piezo or plunger coil technologies, for example, provide faster, more precise and more efficient closed-loop control. The third development is adaptive pressure and flow control with AI. In the future, AI-supported algorithms could automatically optimise processes and adapt them to changing production requirements.
9. What is your recommendation for companies who want to optimise their pressure or flow control?
Ulrich Sixt: If you want to improve efficiency and process stability and save energy in production, you should certainly consider intelligent control concepts. With Controlled Pneumatics, Festo offers a solution that combines proportional technology, sensors and digital closed-loop control to regulate pressure and flow rate precisely, energy-efficiently and flexibly.
In contrast to conventional systems with fixed settings, Controlled Pneumatics dynamically adjusts the values in real time. This increases production quality, reduces air consumption and extends the service life of components. For anyone who wants to delve deeper into the topic, our eBook offers insights into how intelligent pressure and flow control reduces costs, stabilises processesand optimally positions companiesfor future requirements.
10. What role does predictive maintenance play in pressure or flow control, and what advantages does it offer?
Ulrich Sixt: Predictive maintenance plays a crucial role in stable and efficient pressure and flow control. Continuous sensor measurements of pressure, flow and temperature allow even the smallest deviations to be identified at an early stage. This allows wear or imminent malfunctions to be identified and rectified at an early stage, before failures occur. Instead of rigid maintenance intervals, you only intervene when it is necessary. This reduces unplanned downtime and maintenance costs while extending the service life of the components.
Of course, integrating these types of systems into existing facilities poses a challenge, especially when it comes to data processing and analysis. But with modern digital solutions, predictive maintenance is increasingly becoming standard. This contributes enormously to greater efficiency, sustainability and process reliability in automation.
A big thank-you to Ulrich Sixt for his fascinating insights into the world of pressure and flow control. His expertise shows how smart technologies not only stabilise processes, but also save energy and improve production quality. Companies that rely on digital proportional pneumatic valves and networked closed-loop control technology benefit from greater efficiency, predictive maintenance and maximum flexibility. The future of pneumatics is smarter than ever before.
