In one application, SMC’s customer was using hundreds of metres of cabling to control cobots on a 40 metre production line, resulting in complex looms. These were time-consuming to build, added weight to the robot armature, created additional costs for maintenance and unplanned downtime due to cable failures through wear and tear.

By adopting SMC wireless systems the customer successfully eliminated the cable looms – cutting costs and improving cobot build time. SMC also converted all other manifolds on the line to wireless, further improving the benefits.

The customer is enjoying significantly lower costs for build time, labour and materials, improved commissioning time as well as reduced maintenance and downtime.

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Once the preserve of high-volume operations at automotive plants, we’re today finding that robots are infiltrating all sectors of the commercial world. Even beyond traditional manufacturing, inspection and packaging operations, we see robots fulfilling tasks that extend from mining and space exploration, through to surgery and laboratory research, and even fruit picking.

According to a McKinsey report, 88% of businesses worldwide plan to introduce robotic automation into their infrastructure. With so many new industries driving sales, Mordor Intelligence reports that the global robotics market could reach $74.1 billion by 2026 (up from 27.73 billion in 2020), registering a CAGR of 17.45%. However, while the future looks bright for those in the robotics arena, we know from experience that there are certain prerequisites which underline success in sectors other than automotive.

Whereas robots in the high-volume automotive arena typically perform a single task, flexibility is the key word for non-automotive robot applications. Here, users assign robots to different tasks that may change regularly. For those of you thinking that programming is an issue in high-mix, low-volume manufacturing environments, think again. Robot OEMs, cobot (collaborative robot) specialists and software companies are today providing solutions that ensure straightforward programming, to the point where even operators with little or no experience can generate motion paths in next to no time.

AI and machine learning

While we are all aware that robots perform repetitive tasks more efficiently than humans, there’s a new trend here: with AI (artificial intelligence) and ML (machine learning), robots are able to think, learn and draw accurate conclusions without the help of their human colleagues. It’s an exciting prospect for industry across the board, particularly when you consider that robots can support the shift to Industry 4.0/digitalisation, largely because they outperform traditional motion systems in complex tasks.

For instance, while many machines on the shop floor feature full automation, handling tasks from the warehouse to final assembly and packaging are often unautomated due to the inherent complexities involved. Today, however, the latest robotic solutions are assisting continuous flow across the factory, potentially leading to the concept of ‘dark’ or lights-out manufacturing, with no or very few people controlling operations.

With robots set to become a core resource at many types of factory, achieving flexibility is paramount for any tasks that involve handling or servicing. Here, around 50% of applications require finger and/or gripper modifications to suit customer requirements.

For both robot users and manufacturers there are several objectives when it comes to product selection, including price-performance ratio, flexibility, ease of adoption and safety. However, end-of-arm gripper technology is a key factor for tasks such as materials handling, packaging, machine tending, assembly, quality control and surface finishing.

SMC offers a full range of gripper solutions, including pneumatic, electrical, magnetic and vacuum, ensuring adaptability to all gripping needs. The company can also supply FRL units, tubing, valves and serial communication, either using wireless or traditional wired technology, thus creating a turnkey solution for new robot installations or retrofit projects.

SMC helps robotics engineers tap into ‘languages’ with which they are likely unfamiliar, such as pneumatics, by helping to translate or interpret the requirements of air-driven motion control and the benefits it can bring. Its expert team can help explain everything from valve island technology and filtration, to air flow and system pressure. Even though SMC offers an extensive series of electric actuators, pneumatics remains its principal language, which is why increasing numbers of robot OEMs and manufacturing plants are requesting our help.

Rapid tool changes

To deliver flexibility, robots frequently need to use multiple different grippers, which is why fast and reliable tool-change technology is paramount. However, many solutions are expensive and carry some risk due to complex air/signal connections. For this reason, SMC developed the MHF2-X7076A, a modular, low-profile air gripper with finger-change function.

This automatic tool-change device for robots means users simply replace the end of the gripper (the finger) without any risk. The wiring and piping are bundled together in the body of the air gripper (robot side) to improve electrical contact during tool changes and reduce air leakage.

As a further market differentiator, SMC offers wireless communication with the gripper to eliminate any risk of communication loss and stoppages. The EX600-W wireless system means less cables and connectors, reduced installation and maintenance, and fewer breakages and disconnections to deliver totally reliable, noise-resistant communication. Robot users are increasingly adopting our fast-response EX600-W wireless system improve their OEE (overall equipment effectiveness), a key metric for any production or process operations.

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OEMs traditionally design their pneumatic machinery and equipment for an operating pressure of 7 bar. “The shift to 4 bar standard operating pressure is already taking place at some large manufacturing companies,” says Roy Schep (pictured), manager for energy efficiency at SMC Netherlands. “While not seeing mainstream adoption just yet, we believe it will become standard practice in the not-too-distant future as regulations tighten and public pressure for more energy-efficient industry grows.”

By making the transition to 4 bar now, Schep argues that OEMs can become industry pioneers, not only helping to capture a larger share of a rapidly emerging market, but significantly boosting their corporate image. “While this task may at first appear daunting, working with the right technology partner can help ensure a painless changeover,” he says.

Actuators: pushing ahead

When designing a machine from scratch, it makes sense to start with the components that do the work: the actuators. In general terms, these are the elements that may not perform at their best, or sometimes not at all, using lower pressure.

Two variables are key: force and speed. “In my experience, actuators in the majority of horizontal applications operate at lower supply pressure because they are only acting against friction, not force,” says Schep. “As a result, it’s normal to size actuators for use in horizontal orientations to perform at a certain speed.”

In vertical applications, however, the story can be different as the cylinder pressure has to overcome the load pressure. These applications tend to be more critical and usually demand specific considerations to ensure the actuator meets its intended objective. Reducing the pressure to 4 bar in vertical applications may require the use of a larger bore actuator to ensure the required force. “If using a larger bore size is an issue due to lack of space, our VBA series pressure boosters can provide the required pressure level in that local part of the application without having to increase the main line pressure, making it possible to use the existing actuator size,” says Schep.

As a point of note, if working at 4 bar demands a larger bore size, the saving in air consumption will offset any additional cost.

One challenge that could arise is that of space. What if a cylinder with a larger bore will not physically fit with your designated design space? Here, scrutiny is required to select a supplier that can provide compact and lightweight actuator solutions. “A company such as SMC offers more compact cylinder solutions than its competitors,” says Schep. “These products also feature a lower minimum operating pressure and a number of energy-saving concepts.

“The other option is to use a different technology, such as a double-force cylinder. Again, tapping into the expertise of a reputable pneumatics supplier will prove useful in specifying the optimal solution.”

Valves: take control

It’s not really high or low pressure that controls actuator speed, but the flow of air it receives. If you need higher speed; the valve will control that for you. With the cylinder bore and force defined, it’s possible to select the valve size. “We offer directional and process valves with the lowest power consumption, making them ideal for use at 4 bar,” says Schep.

Blowers and vacuum units

When it comes to blowers and vacuum units, higher pressure does not mean higher performance, but quite the opposite, which is why a product like a high-efficiency nozzle has the potential to deliver notable gains. This solution can maximise air blow efficiency thanks to a more focused blowing impact. Indeed, governed by the Bernoulli Effect, you can improve air blow thrust by 10%.

“We recently saw this in action at a customer producing liquid detergent,” Schep says. “The company’s bottle un-scrambler machine housed 25 air nozzles from an SMC competitor, costing €22,441 in annual air consumption. After application analysis we recommended that the customer adopt our high-efficiency nozzles. These products could provide the same blowing performance (flow and impact force), but with a lower nozzle diameter – thus allowing lower inlet pressure. Reduced air consumption led to savings of €6,183 a year, delivering amortisation in just 1.57 months. Performing the same replacement process on six further lines led to total annual savings of €37,098.”

SMC’s firm commitment to 4 bar is also visible with its vacuum units, which actually function at their best (maximum efficiency) when using low operating pressure. “At 4 bar, we ensure the vacuum pressure necessary to hold the component or product securely. Beyond this pressure, air (and money) is simply wasted and the vacuum unit loses efficiency. By turning up the pressure, you are not getting more force or speed, just more inefficiency.”

Regulate to accumulate

As regulators handle point-of-use pressure they can be good collaborators in the 4 bar journey, largely because they can be used to reduce the pressure even further at points where it’s possible. “This might include air blow or vacuum applications, endowing the machine with even more energy efficiency,” says Schep. “Every little helps.”

Monitoring the pressure

Although a pressure switch plays no direct role in the 4 bar concept, it can prove beneficial in the long run. For instance, when designing a machine for 4 bar, you need to monitor pressure as the margin is low. In the first instance, pressure monitoring acts as a control measure for the machine to receive the 4 bar it needs. Secondly, pressure switches can monitor air consumption and identify any pressure losses. Air leakage is something that no machine can afford, especially at 4 bar.

The 4 bar future

Schep concludes: “OEMs should propose that end users adopt machinery which operates at 4 bar in order to stay competitive. To help expedite a project that involves designing a machine for this operating pressure, SMC’s expert team can deliver the optimal outcome for both OEMs and end users.

“Through early project engagement we can provide the correct sizing for each pneumatic component and ensure it consumes less energy without compromising machine performance. In addition, we can deliver solutions with minimal impact on surrounding or connecting components, thus avoiding any unnecessary time and cost for redesigns. Retrofit projects also benefit from this approach.”

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With energy prices surging across Europe, efficiency has become a high priority for all manufacturing and process plants using vacuum handling systems. Using less energy per lift/transfer will provide a direct contribution to your bottom-line profitability while simultaneously supporting industry’s drive to net-zero carbon emissions.

The latest energy-saving technology and process engineering can make a genuine difference to vacuum handling applications, whether the sector is packaging, metalworking, automotive, healthcare or any other.

It’s possible to generate vacuum centrally by means of a vacuum pump or de-centrally (directly on the machine) using vacuum ejectors. SMC’s extensive range of vacuum ejectors – from super compact inline ejectors up to ultra-high efficiency multi-stage ejectors with high-performance silencers – are suitable for vacuum flows up to 600 Nl/min, thus meeting the needs of almost any industrial application.

Every type of ejector has its specific parameters, which are dependent on one another. These include: standard supply pressure (the amount of compressed air you need to achieve the highest possible vacuum pressure); maximum suction flow rate (volume of air taken in by the ejector); maximum vacuum pressure (maximum value of the vacuum pressure generated by the ejector); and air consumption (the amount of air consumed by the ejector when operating with the standard supply pressure).

Use the optimal supply pressure: Ask yourself, do you really need the maximum vacuum pressure to handle your workpiece? You need to pose this question because the level of vacuum pressure will relate directly to your air consumption and your costs. By way of example, if you use of 0.5 MPa (5 bar) main line supply pressure to operate our ZL112A ejector (with valves), your air consumption will total around 78 l/min (4680 l/hour) to achieve a maximum vacuum pressure of -84 kPa. However, by choosing to operate the ejector at a reduced 0.35 MPa (the standard supply pressure for this type of ejector), you can cut air consumption to 57 l/min (3420 l/hour) and still achieve the same maximum vacuum pressure (-84 kPa). A significant 27% energy saving.

As a point of note, while many manufacturers have yet to transition from 7 bar standard shop pressure, optimal vacuum operation takes place at an average of 4 bar, so reducing from 7 bar to 4 bar not only benefits your bottom line and the future of the planet, it will have no impact on the effectiveness of your operations.

Returning to the example, if you can safely handle the workpiece with a maximum vacuum pressure of -65 kPa, you can reduce the supply pressure even further, to 0.25 MPa (2.5 bar). This would cut your air consumption to 45 l/min (2700 l/hour), delivering an impressive 43% energy saving.

Use a bigger pad diameter: Some engineers make the mistake of increasing supply pressure to achieve a higher holding force, but this leads to more energy consumption and more cost. In fact, it’s directly proportional, so doubling the vacuum pressure will double your holding force and double your energy costs.

Instead, it may be possible to increase the diameter of your vacuum pads in certain applications. When doubling pad diameter, your holding force quadruples, while your energy costs remain the same as there is no increase in supply pressure. The price difference between a 20 mm and 40 mm diameter vacuum pad is typically less than €5.

Energy-saving function: Some vacuum ejectors feature a vacuum pressure switch with an energy-saving function that can reduce energy consumption by up to 93%. So how do they work? Well, you first define the pressure range within which you can securely hold the workpiece, for example from -65 to -55 kPa. The integration of pressure switch with energy-saving function serves to cut off the air supply upon reaching the desired vacuum level. Vacuum only generates again when the pressure falls below the lower range, in this case -55 kPa.

Take a vacuum handling application involving a conventional ejector that operates at 450 cycles per hour, 10 hours a day, for 250 days a year. Such a system will consume around 9350 m3 of compressed air every year. However, using a vacuum ejector with an energy-saving function will reduce air consumption to just 638 m³ per year, delivering the aforementioned 93% saving. The potential savings are higher in short-cycle applications.

Smart management: To maximise the use of an energy-efficient vacuum handling system, SMC recommends that you adopt ‘smart’ ejector systems. A serial transmitted ejector manifold requires no separate input/output units to operate and avoids complex electrical wiring of the valves and sensors.

Field devices can connect directly to the PLC. Via the PLC, it is possible to set and monitor the pressure values, suction or release verification, the energy-saving function and the valve protection function. This concept leads to better control of your application, more valuable data, simple set-up and on-board product diagnostics, as well as easy monitoring.

Technical support

If you’ve ever dealt with a vacuum-based system you’ll be aware that vacuum can be unpredictable as the interaction and the behaviour between workpiece and pad differs depending on the application. The only real way to be certain of the results is to take advantage of an expert technology supplier such as SMC, which can conduct tests at customer sites or at its laboratories located across Europe. Vacuum is frequently about trial and error regarding pressure, flow, pad size, number of pads and more, particularly if it involves special workpiece materials, so why not let the experts work it out.

With energy costs rising rapidly around the globe, few can afford to ignore the energy-saving possibilities that a correctly specified and configured vacuum handling system can bring. It’s time to get a grip on efficiency.

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With a holding force of up to 120N, the MHM-X6400 keeps hold of the workpieces even when the air is shut off, giving peace of mind when it comes to reliable and safe movement of workpieces. Furthermore, with a residual force of 0.3N or less, cycle times are reduced and productivity output is improved.

Strategic product sales manager Pete Humphries said: “Thanks to the close working relationship we enjoy with our customers, it became apparent there was a need to develop a gripper for workpieces that vacuum pads could not accommodate. The magnetic MHM-X6400 fills that void, and the initial feedback has been really positive thanks to its clever design that offers flexibility, cost savings and reliability.”

Suitable for a range of transfer applications, the holding force of the MHM-X6400 can be adjusted by changing the type of bumper being used. Made from Fluororubber, the bumper prevents damage to the workpieces, delivering cost savings. The bumper also prevents the workpiece from slipping during operations, improving safety. Featuring three mountable surfaces and the option to mount auto switches, the MHM-X6400 offers flexibility and greater process control.

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