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.
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.
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.
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.
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.
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.
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.
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.