03s 6 06controllers - festo...matics. these information ranges from simple to advanced application...

Energy Saving

Description

555 662

en0508a

[736 421]

Energy_Questions_A5_140808.qxp:Layout 1 14.08.2008 13:33 Uhr Seite 1

Contents and general instructions

IFesto P.BE−FESS−01−EN en 0508a

Author Leonard Lau. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Editors U. Will, S. Lensdorf. . . . . . . . . . . . . . . . . . . . . . . . . . .

Original en. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Layout Festo AG & Co. KG, Abtl. SV−P. . . . . . . . . . . . . . . . . .

Type setting DUCOM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Edition en 0508a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Title MANUAL−EN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Designation P.BE−FESS−01−EN. . . . . . . . . . . . . . . . . . . . . . . .

Order no. 555 662. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [736 421]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E (Festo AG�&�Co., D�73726 Esslingen, Federal Republic of Germany 2008). .

Internet: �http://www.festo.comE−Mail: �[email protected]

The copying, distribution and utilization of this document aswell as the communication of its contents to others without expressed authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design registration.


II Festo P.BE−FESS−01−EN en 0508a


IIIFesto P.BE−FESS−01−EN en 0508a

Contents

Important user instructions VII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction IX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Cylinder 1−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Case 1 � Reduction in compressed air consumption 1−4 . . . . . . . . . . . . . . . . . .

1.1.1 Tip 1 � Use single acting cylinders 1−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.2 Tip 2 � Use clamping modules to hold cylinder in position 1−8 . . . . . . . . . . . .

1.1.3 Tip 3 � Use cylinders with integrated valve and flow controllers 1−10 . . . . . . .

1.1.4 Tip 4 � Use correct dimensioned cylinders 1−12 . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Case 2 � Reduction in compressed air leakage 1−14 . . . . . . . . . . . . . . . . . . . . . . .

1.2.1 Tip 1 � Use special seals in cylinders 1−14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.2 Tip 2 � Use round piston/piston rod cylinders 1−16 . . . . . . . . . . . . . . . . . . . . . .

1.2.3 Tip 3 � Use guides to prevent deflection of piston rods 1−18 . . . . . . . . . . . . . .

1.2.4 Tip 4 � Use flexible couplings to prevent deflection of piston rods 1−20 . . . . .

1.3 Case 3 � Reduction in friction 1−22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.1 Tip 1 � Choose cylinders with less sealing points 1−22 . . . . . . . . . . . . . . . . . . .

1.3.2 Tip 2 � In dusty environment, use lubricated compressed air 1−24 . . . . . . . . .

1.3.3 Tip 3 � If cylinder is operated at more than 1 m/s, use lubricated compressed air 1−26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.4 Tip 4 � In dusty environment, use covers wipers for exposed piston rod 1−28 .

1.4 Case 4 � Reduction in Pressure lost 1−30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.1 Tip 1 � Reduce working pressure 1−30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.2 Tip 2 � Reduce working pressure of non−productive stroke 1−32 . . . . . . . . . . .

2. Valves 2−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


2.1.1 Tip 1 � Select valve terminal according to flow rate for optimum performance 2−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.2 Tip 2 � Select valve size according to flow rate for optimum performance 2−6

2.1.3 Tip 3 � Select valve function carefully 2−8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.4 Tip 4 � Supply lower pressure for external pilot supply 2−10 . . . . . . . . . . . . . .

2.1.5 Tip 5 � Use 5/2 valves with reversible port 2−12 . . . . . . . . . . . . . . . . . . . . . . . .


IV Festo P.BE−FESS−01−EN en 0508a

2.1.6 Tip 6 � Use valve terminals with integrated (sandwich) pressure regulators 2−14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.7 Tip 7 � Shut off compressed air supply when inactive for long periods 2−16 . .


2.2.1 Tip 1 � Use valves with the poppet or cartridge design 2−18 . . . . . . . . . . . . . . .

2.2.2 Tip 2 � Use mainfold instead of individual valves 2−20 . . . . . . . . . . . . . . . . . . .

2.3 Case 3 � Reduction of electrical power 2−22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.1 Tip 1 � Use valves with reduction of holding current 2−22. . . . . . . . . . . . . . . . .

3. Air preparation 3−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


3.1.1 Tip 1 � Monitor compressed air consumption of machine/application 3−4 . .

3.1.2 Tip 2 � Use directly actuated pressure regulator instead of pilot actuated pressure regulator 3−6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.3 Tip 3 � Use automated drain instead of manual drain 3−8 . . . . . . . . . . . . . . . .

3.2 Case 2 � Reduction in pressure lost 3−10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1 Tip 1 � Maintain required system pressure 3−10 . . . . . . . . . . . . . . . . . . . . . . . .

3.2.2 Tip 2 � Ensure filter elements are changed or maintained 3−12 . . . . . . . . . . . .

3.2.3 Tip 3 � Reduce system pressure − use pressure booster for specificapplications 3−14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Vacuum application 4−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


4.1.1 Tip 1 � Use vacuum switch with vacuum applications 4−4 . . . . . . . . . . . . . . . .

4.1.2 Tip 2 � Use the correct pressure supply for vacuum generators 4−8 . . . . . . . .

4.1.3 Tip 3 � Maintain integrated silencers and filters of vacuum generators regularly 4−10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.4 Tip 4 � Use vacuum pump for applications that require constant vacuum 4−12

4.1.5 Tip 5 � Place vacuum generator close to application 4−14 . . . . . . . . . . . . . . . . .

4.1.6 Tip 6 � Choose suitable succion cups 4−20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


VFesto P.BE−FESS−01−EN en 0508a

5. Accessoires 5−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Case 1 � Reduction in compressed air leakage 5−4 . . . . . . . . . . . . . . . . . . . . . .

5.1.1 Tip 1 � Ensure tubings are mounted properly 5−4 . . . . . . . . . . . . . . . . . . . . . .

5.1.2 Tip 2 � Use push/pull fittings with sealing lip 5−6 . . . . . . . . . . . . . . . . . . . . . .

5.1.3 Tip 3 � Select correct tubing design suitable to the purpose used for 5−8 . . .

5.1.4 Tip 4 � Tighten sealing rings for threading connections 5−10 . . . . . . . . . . . . . .


5.2.1 Tip 1 � Reduce the length of the tubing used 5−12 . . . . . . . . . . . . . . . . . . . . . . .

5.2.2 Tip 2 � Use multiple distributors 5−15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.3 Tip 3 � Ensure that exhaust interfaces are suitable 5−18. . . . . . . . . . . . . . . . . .

6. Controllers and concepts 6−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Case 1 � Reduction in compressed air consumption 6−4. . . . . . . . . . . . . . . . . .

6.1.1 Tip 1 � Decentralise pneumatic circuits 6−4. . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.2 Tip 1 � Analyse high frequent operations to find energy waist 6−6. . . . . . . . .

6.2 Case 2 � Reduction in compressed air leakage 6−8. . . . . . . . . . . . . . . . . . . . . .

6.2.1 Tip 1 � Monitor continiously the energy status 6−8. . . . . . . . . . . . . . . . . . . . .

6.3 Case 3 � Reduction in electrical power 6−10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.1 Tip 1 � Select positioning drive according to the specific demands 6−10. . . . .

6.3.2 Tip 2 � Use self−locking lead screw drives 6−12. . . . . . . . . . . . . . . . . . . . . . . . .


VI Festo P.BE−FESS−01−EN en 0508a

Important user instructions

Danger categories

This manual contains instructions on the dangers which mayoccur if the product is not used correctly. These instructionsare marked with a heading (Warning, Caution, etc.), printedon a shaded background and accompanied by a pictogram. Adistinction is made between the following danger categories:

WarningThis means that there is a danger of serious human injuryand damage to property if these instructions are not ob�served.

CautionThis means that there is a danger of human injury anddamage to property if these instructions are not observed.

Please noteThis means that there is a danger of damage to property ifthese instructions are not observed.

In addition, the following pictogram marks passages in thetext which describe activities involving electrostatically sensi�tive components:

Electrostatically sensitive components: Incorrect handlingmay result in damage to the components.


VIIFesto P.BE−FESS−01−EN en 0508a

Marking special information

The following pictograms mark passages in the text contain�ing special information.

Pictograms

Information:recommendations, tips and references to other sources ofinformation.

Accessories:information on necessary or useful accessories for the Festoproduct.

Environment:information on the environmentally−friendly use of Festoproducts (savings).

Text markings

S The bullet denotes activities which can be carried out inany sequence.

1. Figures denote activities which must be carried out in theorder specified.

� Hyphens denote general activities.


VIII Festo P.BE−FESS−01−EN en 0508a

Introduction

As a family enterprise Festo feels responsible also for long−term questions to its products and technologie. Energy savingin Pneumatics is one of the areas Festo is setting a focus withour services and recommendations.

The purpose of this manual is to give prospective customersand users of pneumatic components some tips and tricks onhow to maximise the advantages of using pneumatic compo�nents while maintaining low energy usage.

This manual for Energy Saving evolved out of necessity dueto the high energy loss in the world. In response to many re�quests from customers, Festo has decided to compile thismanual.

The result is a collection of tips and tricks that has a clearstructured reference layout, specifically designed for theusage of both layman and experts to energy saving in pneu�matics. These information ranges from simple to advancedapplication solutions in this field.

Not all tips and tricks may be applicable to your machine orapplication. With this manual, we hope to be able to induceyou think of more ways to save energy with pneumatics.


IXFesto P.BE−FESS−01−EN en 0508a

"The contents have been divided in six different sections,making it easy for users of this manual to find precisely theinformation they need:"

� Cylinders

� Valves

� Air preparation

� Vacuum application

� Accessories

� Controllers and concepts

It is important to note that while this manual is not designedto solve all your questions you may have on the topic of En�ergy Saving. This represents a start of an ongoing process tomake more effective use of pneumatic energy in your existingor future applications.

Please noteWe strongly recommend contacting our Festo representa�tives to have further discussions on how to implementsome of the tips in this manual.Some of the tips recommended will affect the functionalityand performance of your existing applications. While thesechanges will reduce energy consumption, it is important toconsider how these changes will affect your application.


X Festo P.BE−FESS−01−EN en 0508a

What is Energy Saving?

Energy saving means to be able to run your applications inoptimum performance while using the lowest possible energy.In terms of pneumatic, this means to reduce leakages, loss inpressure and loss during the conversion of pneumatic energyto an action.

Energy saving opportunities are present everywhere in pneu�matics, it just takes minimal effort to recognise where energycan be saved. However, it takes concerted efforts to ensurethat these energy savings can be maintained.

Why Energy Saving is important?

Pneumatic compressed air is not free. It takes an enormousamount of electricity for an air compressor running in yourfactory to produce compressed air. The higher the pressureused in your system or application, the more cost goes intoproducing this pressure. Every leakage present in your ap�plication, represents money being released into the atmos�phere with absolutely no return on investment!

With the raising price of worldwide crude oil prices, energycost are expected to increase higher. Reduction of energyconsumption equals to less overall opearting cost of yourfactory saving money.

There are also environmental concerns in regards to the re�lease of CO2 gas. The less energy consumed means less CO2

emission to the atmosphere which is damaging the environ�ment we live in.


XIFesto P.BE−FESS−01−EN en 0508a

How can Energy Saving be applied?

By simple change of design or by using components withbetter characteristic in energy saving aspect. You can saveenergy cost ranging from 10 % to 60 % (Eliminating leakages)when running pneumatic applications.Very often, by incorporating energy saving designs into yourapplications. The capital cost of making these changes aresmall when you compare with the savings throughout the lifeof the machine or application.

How to use this manual?

This manual is divided into five different sections with severalsub−title under each sector. Each sub−title has several tips inwhich energy saving could be achieved under specific condi�tions. Very often we are unable to illustrate the amount ofactual savings in terms of dollar and cents when the tips areused. This is because normally no two application are operat�ing under exactly the same conditions and achieving thesame results.

To use this manual effectively, start from page 1 and movethrough the pages progressively. Alternatively, you could turnto the content page and search for the topics that you areinterested in.

Useful Festo software

1. Pneumatic dimensioning � ProPneu

2. Fluidic muscle � Festo MuscleSIM

3. Tubing selection � Tube selector

4. Vacuum selection

5. Valve terminal

6. Mass moment of inertia � calculation program

Visit Festo at www.festo.com for more information on energy saving.


XII Festo P.BE−FESS−01−EN en 0508a

Energy saving aspect

Reductionof leakage

Reductionofconsump�tion

Reductionoffriction

Reductionof pressureloss

Reductionof electricalpower

Product range

Cylinder + + + O �

Valves + O O O O

Air preparation O � � + �

Vacuum � + � O �

Accessories + � � + �

Controllers O � � + O

+ = possibility highly given, o = possibility maybe given, � = possibility less given

Fig.�0/1: Overview about saving potential in different product ranges

Cylinder

1−1Festo P.BE−FESS−01−EN en 0508a

Chapter 1

1. Cylinder

1−2 Festo P.BE−FESS−01−EN en 0508a

Contents

1. Cylinder 1−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


1.1.1 Tip 1 � Use single acting cylinders 1−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.2 Tip 2 � Use clamping modules to hold cylinder in position 1−8 . . . . . . . . . . . .

1.1.3 Tip 3 � Use cylinders with integrated valve and flow controllers 1−10 . . . . . . .

1.1.4 Tip 4 � Use correct dimensioned cylinders 1−12 . . . . . . . . . . . . . . . . . . . . . . . . .


1.2.1 Tip 1 � Use special seals in cylinders 1−14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.2 Tip 2 � Use round piston/piston rod cylinders 1−16 . . . . . . . . . . . . . . . . . . . . . .

1.2.3 Tip 3 � Use guides to prevent deflection of piston rods 1−18 . . . . . . . . . . . . . .

1.2.4 Tip 4 � Use flexible couplings to prevent deflection of piston rods 1−20 . . . . .

1.3 Case 3 � Reduction in friction 1−22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.1 Tip 1 � Choose cylinders with less sealing points 1−22 . . . . . . . . . . . . . . . . . . .

1.3.2 Tip 2 � In dusty environment, use lubricated compressed air 1−24 . . . . . . . . .

1.3.3 Tip 3 � If cylinder is operated at more than 1 m/s, use lubricated compressed air 1−26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.4 Tip 4 � In dusty environment, use covers wipers for exposed piston rod 1−28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 Case 4 � Reduction in Pressure lost 1−30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.1 Tip 1 � Reduce working pressure 1−30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.2 Tip 2 � Reduce working pressure of non−productive stroke 1−32 . . . . . . . . . . .

1. Cylinder


Energy saving on cylinders

Double acting cylinder Single acting cylinder

1 2

3

1 2

Fig.�1/1: Saving points at cylinders

Saving points at cylinders are as follows:

1 Inlet, outlet

2 Piston seals

3 Piston rod seals

4 Correct size

Rules for best performance are as follows:

1. Cleaning rods

2. Greasing rods

3. Changing seals

4. Correct loads

1. Cylinder


1.1 Case 1 � Reduction in compressed air consumption

1.1.1 Tip 1 � Use single acting cylinders

Advantage Disadvantage

Reduces volume of compressed air uses

Need to use a bigger cylinder diameter than a double acting cylinderneeds (Force)

Reduces the number of inletports

Unable to increase spring return timeports

Low force for retracting

Short piston stroke

Related Festo products to save energy

ADVU DSNU

ESNU/AEVU } See Fig.�1/3

MAS

MAS } See Fig.�1/4

Fig.�1/2: Single acting cylinders

CautionThis may lead to changes in functionally and performanceof your application.

SavingsA 50 % reduction of compressed air volume. 44 % reduc�tion in potential leakage (number of connections).

1. Cylinder


2

1 3

4

5

2

1 3

Air filling of chamber

Air fiiling of tube

L 50 %

22

22

1

9

11

11

1

5

Fig.�1/3: Consumption of air will drop by about 50% simplyby changing double acting cylinder (Example 1) tosingle acting cylinder (Example 2). Cost is reduceddue to cheaper 3/2 way valve and one less flowcontrol valve.

Example 1

Volume of air

Double acting cylinder 0.1719 ltr@ 25 mm, stroke 25 mmTubing @ 6 mm, Length 100 mmPiston rod @ ... mm

Potential leakage

Total number of connection ports 9

1. Cylinder


Example 2

Volume of air

Single acting cylinder 0.087 ltr@ 25 mm, stroke 25 mmTubing @ 6 mm,Length 100 mmPiston rod @ ... mm

Potential leakage


1

2

3

4

5

6

Articulated arm system Using Fluidic Muscles to generate lifting force

1 Pneumatic cylinder to drive lever arm

2 Coupling gear unit

3 Upper arm drive

4 360° turnable

5 Cable, chain, belt or strap

6 Fluidic Muscie

Fig.�1/4: Example of a single acting design replacing a double acting cylinder design. In this application, the new MAS fluidic muscle cylinder is used.

1. Cylinder


1. Cylinder


1.1.2 Tip 2 � Use clamping modules to hold cylinder in position

Clamping modules do not use compressed air to hold pistonin place.


Allows to interrupt the con�stant supply of compressedair

Extended cylinder length

Safety feature in case of airs pply fail re

Additional air portsupply failure

Lifetime of clamping module dependent on load/force

Piston rod may move, when re−pressurized


DNC−...−KP

DNCKE

DNCKE/KP } See Fig.�1/6

DNC−...−EL

Fig.�1/5: Clamping module combinations

CautionThis may lead to changes in functionality and performanceof your application.

1. Cylinder


2

1 3

4

5Example 1

Example 2

Fig.�1/6: Simplified circuit with constant supply of air(Example 1) and with clamping unit to allow inter�ruption of air supply (Example 2)

Example 1

Potential leakage volume

Cylinder, @ 32 mm 1.2 ltr/hrValve 2 ltr/hr

Potential leakage points


Example 2

Volume of air

Total activated clamping module 0.00193 ltr/hr

Potential leakage


1. Cylinder


1.1.3 Tip 3 � Use cylinders with integrated valve and flow controllers

Less external connection points reduces occurrence of leak�age.


Less tubing and connectorsused means less leakage andvolume

Unable to increase speed of cylinder if needed

Quick response of cylinder


DNCV

DNCV } See Fig.�1/8

Fig.�1/7: Integrated valve−cylinder combination


SavingsDouble length of tubing doubles compressed air consump�tion for re−pressuring after exhaust = double cost.

1. Cylinder


$ $

Example 1

Example 2

1 m

2 m

Fig.�1/8: Energy is lost at every actuation with the volume ofair in unnecessary long tubing

Calculated average cost for 1 m3 succed air (Eur) 0.020Pressure in system absolute (bar) 7.00

Example 1

Tubing diameter (mm) 8.00Tubing length (mm) 1000.00Volume in tubing (m3) 0.0000503Value of encapsulated compressed air (Cent) 0.001

Example 2

Tubing diameter (mm) 8.00Tubing length (mm) 2000.00Volume in tubing (m³) 0.0001Value of encapsulated compressed air (�−cent) 0.002

1. Cylinder


1.1.4 Tip 4 � Use correct dimensioned cylinders

Oversized cylinders slower the reaction time by filling largevolumes unnecessarily with air. Undersized cylinders slower the reaction time by resistance inair flow.


Best possible performance Detailed knowledge of all relations needed (force, speed, accuracy)


Fig.�1/9: Dimensioning software ProPneu

1. Cylinder


Fig.�1/10: Calculating the volume of compressed air used in cylinders with Festo’s ProPneu software(www.festo.com) / Engineering / Selection and Dimensioning / Pro Pneu

Check carefully the requirements concerning

S needed forces

S needed stroke

S needed speed, dynamic

S needed accuracy

S possibilities of reducing forces by using counter masses

S possibilities of reducing strokes by using levers

S possibilities of reducing pressure by using a bigger dia−meter.

Fig.�1/11: Counter massto reduce forces

1. Cylinder


1.2 Case 2 � Reduction in compressed air leakage

1.2.1 Tip 1 � Use special seals in cylinders

Life of seals will be extended if used in correct environments.


Different material of internalseals designed for specified applications

Lifetime of these special seals varies, normally lower than PU sealsunder normal conditions


DNC....−S6 } See Fig.�1/13

Fig.�1/12: Special variants of cylinders

1. Cylinder


Symbol Type code indicator Description

S6 Heat−resistantseals for tempera�tures up to 150 °C

Temperature−resistant

Fig.�1/13: Symbols for special variants of cylinders

1. Cylinder


1.2.2 Tip 2 � Use round piston/piston rod cylinders

Non−round piston rods are difficult to seal properly, resultingin higher leakages.


Better sealing surface Cylinder rod can be rotated


ADVU

DSNU

DRQD } See Fig.�1/15 and Fig.�1/16

DRQD

Fig.�1/14: Cylinders with round sealing lines


1. Cylinder


Fig.�1/15: Vane type rotary actuator(Higher leakage ratesbecause of non−round sealing line)

Fig.�1/16: Rack & Pinion type rotary actuator(Sealing designsimilar to linear cylinders)

1. Cylinder


1.2.3 Tip 3 � Use guides to prevent deflection of piston rods

Deflection of cylinder or piston rod damages seals in 1 direc�tion, causing leakage.


Protects the seals on cylinderfrom lateral force

Additional space needed for the guides

Protects seals from damageduring moving of piston rod


DFM

} See Fig.�1/18 } See Fig.�1/18

ADVULFENG

Fig.�1/17: Guided actuators

CautionThis may lead to dimension changes.

1. Cylinder


Fig.�1/18: Cylinders with guides will prevent deflection andstress on the cylinder seals

1. Cylinder


1.2.4 Tip 4 � Use flexible couplings to prevent deflection of piston rods

Misalignment affects the seals on the cylinders causing leak�ages.


Protect piston rod againstmisalignment

Additional length extension

Protects misalignment from360 deg


FK−.. / SGS / KSG} See Fig.�1/20

Fig.�1/19: Flexible coupling


1. Cylinder


Fig.�1/20: Different flexible coupling options from Festo

1. Cylinder


1.3 Case 3 � Reduction in friction

1.3.1 Tip 1 � Choose cylinders with optimized sealing lines

This reduces occurance of leakages.


Less seals means less risk ofwear and leakages

Rodless cylinders (slot design) have large sealing surface, but saveinstallation space. New types have further developped sealingmethods.


DGC... } See Fig.�1/22 DGO... } See Fig.�1/23

Fig.�1/21: Rodless cylinders with different sealing design

1. Cylinder


Fig.�1/22: Festo DGC rodless cylinder has a special sealingdesign that reduces leakages

Fig.�1/23: Festo DGO rodless cylinder (Sealing design similarto linear cylinder)

1. Cylinder


1.3.2 Tip 2 � In dusty environment, use lubricated compressed air

Lubricated air slows down the wearing in dusty environment.In normal cases non−lubricated air supply is recommended.


Prevents the dust entering thecylinder, hardening the grease

Maintenance of oil in lubricator is needed

Less heat generated withinthe cylinder

Contamination of environment if leakage exist and if exhaust is notfiltered


LOE

Fig.�1/24: Lubricator


1. Cylinder


1. Cylinder


1.3.3 Tip 3 � If cylinder is operated at more than 1 m/s, use lubricated compressed air

Lubricated air protects the seals to heat up and wear quickly.In normal cases non−lubricated air supply is recommended.


Less heat generated withinthe cylinder

Contamination of environment if leakage exists and if exhaust is notfiltered


} See Fig.�1/26

LOE FRM

Fig.�1/25: Lubricator


1. Cylinder


Supply without lubricated compressed air

Supply with lubricated compressed air

15010050200psibar01426

161412108

0

Fig.�1/26: Seperated supply channels (lubricated/non lubri�cated)

Oil specifications for lubrication of Festo products:Festo special oil OFSW−32 DIN 51524−HLP32, Basic viscosity: 32cSt. at 40 °CAmount: 25 mg/m3

(DIN ISO 8573−1, Class 5)

1. Cylinder


1.3.4 Tip 4 � In dusty environment, use cover wipers for exposed piston rod

Piston is protected and reduces occurrence of dust broughtinto the cylinder.


Protect against accumulationof dust on the piston rod} less wear of the cylinder

Sometimes additional stroke length needed (for dust covers) friction is slightly higher than without dust cover

} less wear of the cylinder rod seal} less leakage

If full stroke of cylinder not used, life of cylinder is reduced becauseof missing cleaning effect on the rest stroke


DNC..−R8 } See Fig.�1/28

Fig.�1/27: Cylinders with wiper seals


1. Cylinder


Symbol Type code indicator

Description

R8Dust protectionusing wiper seals

The cylinder equipped witha hard−chrome plated pis�ton rod and a rigid scraper,which protects against dry,dusty media.

Fig.�1/28: Symbols for cylinders with wiper seals

1. Cylinder


1.4 Case 4 � Reduction in Pressure losss

1.4.1 Tip 1 � Reduce working pressure

Reduction of supply pressure saves energy in the wholedown−stream branch.


Lower pressure means sav�ings in costs

Performance factor of the application may be compromised


LR

LR−..−D } See Fig.�1/30

Fig.�1/29: Pressure regulators


1. Cylinder


Pressure (bar) Ratio of pressuredifference

Savings (%)against 6 bar

3456

4 (abs.)5 (abs.)6 (abs.)7 (abs.)

4/7 = 0,575/7 = 0,716/7 = 0,857/7 = 1,00

43 %29 %15 %0 %

Fig.�1/30: Every reduction in system pressure leads to directsavings

If pressure is reduced, speed of cylinders is not necessarilyslower if the nozzles are opened on the other hand.

1. Cylinder


1.4.2 Tip 2 � Reduce working pressure of non−productive stroke

Reduction of pressure to save energy.


Lower pressure means sav�in s in costs

Speed of return may be compromisedings in costs

Exhaust through the regulator reduces its life because of ...


LRMA... } See Fig.�1/32

P1

P2

Fig.�1/31: Inline pressure regulators


1. Cylinder


2

1 3

4

5 6 barL1 = 0L2

3 barL1 L2 = 0

24

1 35

single cylinder

combined cylinders

Fig.�1/32: Addition of an inline regulator reduces pressure for non−working stroke

1. Cylinder


Tamb = 20 °C without regulator with regulator

Tube length L1 + L2 1 m 1 m

Outer Tube Diameter @A 8 mm 8 mm

Inner Tube Diameter @I 5,9 mm 5,9 mm

Tube volume 2,73 x 10−5 m3 2,73 x 10−5 m3

Inside volume flow control valve (GRLA) 1,8 x 10−6 m3 �

Inside volume regulator (LRMAQ−1/8−QS8) � 2,5 x 10−6 m3

Cycles per minute 2 2

Cycles per year*) 1 048 320 1 048 320

Volume per year (compressed) 30,5 m3 31,23 m3

Volume per year (atmospheric) 209,8 m3 122,7 m3

Costs per m3 0,02 �/m3 0,02 �/m3

Costs per year 4,19 � 2,45 �

[%] 100 58

*) running all the time

Fig.�1/33: Comparison in detail without invest costs

Valves


Chapter 2

2. Valves


Contents

2. Valves 2−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


2.1.1 Tip 1 � Select valve terminal according to flow rate for optimum performance 2−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.2 Tip 2 � Select valve size according to flow rate for optimum performance 2−6

2.1.3 Tip 3 � Select valve function carefully 2−8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.4 Tip 4 � Supply lower pressure for external pilot supply 2−10 . . . . . . . . . . . . . .

2.1.5 Tip 5 � Use 5/2 valves with reversible port 2−12 . . . . . . . . . . . . . . . . . . . . . . . .

2.1.6 Tip 6 � Use valve terminals with integrated (sandwich) pressure regulators 2−14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.7 Tip 7 � Shut off compressed air supply when inactive for long periods 2−16 . .


2.2.1 Tip 1 � Use valves with the poppet or cartridge design 2−18 . . . . . . . . . . . . . . .

2.2.2 Tip 2 � Use mainfold instead of individual valves 2−20 . . . . . . . . . . . . . . . . . . .

2.3 Case 3 � Reduction of electrical power 2−22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.1 Tip 1 − Use valves with reduction of holding current 2−22. . . . . . . . . . . . . . . . . . .

2. Valves


Energy saving on valves

Zone 1 Zone 2

1

z{1}

Fig.�2/1: Saving points at valve terminals (here: with pres�sure zones)

Saving points at valves are as follows:

1 Right dimensioning


1. Short distances between valve and actuator

2. Pressure zones for branches with lower pressure level

2. Valves



2.1.1 Tip 1 � Select valve terminal according to flow rate for optimum performance

By range of modules to select valve terminal according toyour requirements.


Select valve terminal ideal forspecific application

�

Avoid oversizing/undersizingof valves

�


Festo valve terminal software } See Fig.�2/3

Fig.�2/2: Valve terminal configurator www.festo.com/products/dimensioning software orwww.festo.com/engineering/selection/selection&dimensioning/software

2. Valves


Fig.�2/3: Festo valve terminal selection tool allows selection�from all valve terminal types from Festowww.festo.com/products/dimensioning softwareor www.festo.com/engineering/selection/selec�tion&dimensioning/software

2. Valves


2.1.2 Tip 2 � Select valve size according to flow rate for optimum performance

Avoid oversizing or undersizing of the valve.


Reduce volume of com�pressed air used

�


} See Fig.�2/5

MPA Typ 44 (VTSA)

ProPneu for valves

Fig.�2/4: Valve selection tool www.festo.com/products/dimensioning software/down�load for windows


2. Valves


Size of valve Flow rate (litre/min)

M5 180

M7 350

1/8" 800

1/4" 1,500

3/8" 2,900

1/2" 3,700

3/4" 7,500

1" 11,500

Fig.�2/5: Relation of size and flow rates of valves

size 1size 2size 3

Fig.�2/6: Possible mix on one platform of precise fittingvalve sizes

2. Valves


2.1.3 Tip 3 � Select valve function carefully

5/2 Double solenoid valve


After switching pulse current can be shut off

Two solenoids

5/3 valve with closed position


After the cylinder reached theend position pressure supplycan be shut off

2. Valves


Fig.�2/7: Interruption of air supply if valve has switched

2. Valves


2.1.4 Tip 4 � Supply lower pressure for external pilot supply or cylinderback stroke

A different pressure can be used for external pilot supply onvalves.


Pilot supply can be lower thenworking pressure (e.g. in highpressure applications)

Additional connections required, which means potential leakage

External pilot valves allowslower working pressure

Additional connections are required for external pilot


} See Fig.�2/9 } See Fig.�2/10

Fig.�2/8: Valves with seperate pilot supply

2. Valves


Fig.�2/9: Internal pilot valve uses supply pressure to assistin switching of the spool in the valve

Fig.�2/10: External pilot valve have additional ports (82, 84,12, 14) for pilot supply pressure to switch thespool in the valve

2. Valves


2.1.5 Tip 5 � Use 5/2 valves with reversible port

In this configuration, exhaust air does not pass through thepressure regulators, extending their life.


Reduction of supply pressurefor non−working stroke

�


} See Fig.�2/12

} CPV (port 3 and 5 combined)

} MPA

} VTSA

} CPASC

} Tiger 2000

} ISO

Fig.�2/11:


2. Valves


6 bar 3 bar

3 bar6 bar

Fig.�2/12: If valves are driven reversibly different pressurecan be supplied to port 3 and 5 for forward andreturn stroke. Port 1 will be used as exhaust port inthis configuration.

Reversibility of valves means that the exhaust ports can beused as supply ports and vice versa.This is possible if the seals are designed in a symmetric wayso that no sealing lip will be lifted if pressure lies at the otherside.

2. Valves


2.1.6 Tip 6 � Use valve terminals with integrated (sandwich) pressure regu−lators

An integrated (sandwich) pressure regulator reduces theworking pressure for each single valve and the number ofconnection points of the regulator (exhaust air do not passthrough regulator).


Integrated design reduces connections. Space for installation is increased

Individually adjusted pressure according to application needs �


MPAVTSA... } See Fig.�2/3 Valve terminal software

Fig.�2/13: Valve modules with integrated pressure regulators


SavingsUp to 50 % of energy can be saved if different pressure isused.

2. Valves


Cost for 1 m3 air at 7 bar abso�lute pressure (Eur)

0.020 Cycle per Minute 12.00

Pressure in system absolute(bar)

7.00 1 Machine working time per day (hours) 14.00

Tubing inner diameter (mm) 8.00 Number of working days per year 240.00

Tubing length (mm) 3000.00 Cycles per year 2419200.00

Volume in tubing (m3) 0.00015 Pressure of working stroke (bar) 5.00 2

Pressure of return stroke (bar) 3.00 3

Cylinder diameter (mm) 100.00 Energy saving for working stroke (Eur) 10.03

Stroke length (mm) 70.00 Energy saving for return stroke (Eur) 20.05

Cylinder volume (m3) 0.0005 Energy saving total per year (Eur) 30.08

Fig.�2/14: Example calculation with reduced pressure lines (approx.: stroke vol. = return vol.)

5 bar1

7 bar

3 bar2

Fig.�2/15: Exhaust air does not pass through regulators, life istherefore extended because the seals are lessstressed.

2. Valves


2.1.7 Tip 7 � Shut off compressed air supply when inactive for long periods

Advantage Disatvantage

No leakage and no consump�tion in the branch

Piston rods of cylinders move freely and maybe suddenlytion in the branch

Re−filling and re−pressurization required

If 3/2 valve is used, system air is purged

Related Festo Energy saving products

} See Fig.�2/17

MSX−...−EE QH−... SOE−... F−...

Fig.�2/16: Shut−off and softstarting valve


SavingsPotential leakages via pressurized cylinder and fittingsduring non−movement would be totally removed by this.

2. Valves


Fig.�2/17: This master on/off valve could be either manually�actuated or actuated by a solenoid

Examples for shut−off/interruption possibilities:

S vacuum generation with vacuum ejectors

S blowing air

S mechanical stirers (e.g. stiring paint, glue, ...)

S any process with participation of staff by means of pres�ence circuits (e.g. quality proof by air gap resistance isshut off by means of light barriers if no staff is working).

2. Valves



2.2.1 Tip 1 � Use valves with the poppet or cartridge design

Rubber sealed design principle has no leakage rate in com�parison to lapped spool design.


Less leakage rates comparedto lapp spool principle

Contains wearing parts


} See Fig.�2/20 } See Fig.�2/19

CartridgeCPASCCPV04 (ISO)MPATyp03 MIDI/MAXITyp 44 (ISO)

PoppetTiger Classic

Fig.�2/18: Valves with poppet or cartridge design


2. Valves


Fig.�2/19: Poppet principle

Fig.�2/20: Cartridge principle

2. Valves


2.2.2 Tip 2 � Use mainfold instead of individual valves

Manifold reduces number of connectors used.


Less connections means lessplace for leakages

Distance from cylinders may affect performace of application

Space saving design Volume of air in tubing to cylinder is increased

Common compressed air sup�ply to manifold

�

Different pressure zone withinmanifold possible

�


CPV... } See Fig.�2/22 CPV−SC... } See Fig.�2/22

Fig.�2/21: Configurable manifolds to adapt to specific needs.


2. Valves


Zone 1 Zone 2

Fig.�2/22: Valve terminals assembled at Festo are completelytested concerning leackage aspects.

2. Valves


2.3 Case 3 � Reduction of electrical power

2.3.1 Tip 1 − Use valves with reduction of holding current


After switching off solenoidpower supply is reduced electrically without loss offunction

�


CPVMPACPASC

Fig.�2/23: Since the 1990ties used circuit sheme

SavingsElectrical savings up to 70 %.

Air preparation


Chapter 3

3. Air preparation


Contents

3. Air preparation 3−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


3.1.1 Tip 1 � Monitor compressed air consumption of machine/application 3−4. .

3.1.2 Tip 2 � Use directly actuated pressure regulator instead of pilot actuated pressure regulator 3−6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.3 Tip 3 � Use automated drain instead of manual drain 3−8. . . . . . . . . . . . . . . .

3.2 Case 2 � Reduction in pressure lost 3−10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1 Tip 1 � Maintain required system pressure 3−10. . . . . . . . . . . . . . . . . . . . . . . .

3.2.2 Tip 2 � Ensure filter elements are changed or maintained 3−12. . . . . . . . . . . .

3.2.3 Tip 3 � Reduce system pressure − use pressure booster for specificapplications 3−16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Air preparation


Energy saving on Air supply

1

2

3

4

5

6 1

Fig.�3/1: Saving points at air supply products

Saving points at regulators, filter units, oilers, tubes, fittingsare as follows:

1 Pressure level adjusted

2 Seal of bowl

3 Oil regulation as low as possible in order to avoid washing out the life time lubrication

4 Drain tightening

5 Switch off valves if machine not needed (2/2−valve to encapsulate the pressure downstream)

6 Pressure switches


1. Switch off as often as possible

2. Lowest pressure level as possible

3. Splitted pressure levels

3. Air preparation



3.1.1 Tip 1 � Monitor compressed air consumption of machine/application

Any changes to normal air consumption can be detected at avery early stage.


Comparison of consumptiongives indication of the performance

Cost of investment

Charting gives indicationwhen the peaks of usage are

�


MS..SFE / SFE3 / SFE1 } See Fig.�3/3

SFE1−...

SFE3−... SFET−...F

MS..−SFE−... GFDM−...

Fig.�3/2: Monitoring devices

3. Air preparation


Fig.�3/3: In−line detection of flow indicates abnormal consumption

Fast response (response time depends on internal volume ofthe piping and pressure etc.)Free from readjustment and wrong detection caused by pres�sure change.Can detect clogging of nozzle and/or filter.Can detect incomplete suction like a sensor.

3. Air preparation


3.1.2 Tip 2 � Use directly actuated pressure regulator instead of precision pressure regulator

Reduce in use of compressed air with directly actuated pres�sure regulator because of self consumption of indirect actu�ated regulators.


Non−pilot actuated regulatordo not use compressed air tomaintain accuracy

Accuracy is not as good as with precision pressure regulator


LR−... LRP−...

Fig.�3/4: Directly actuated pressure regulators

3. Air preparation


Fig.�3/5: Additional air volume with pilot actuated regula�tors

Precision regulator needs internal operation air consumption.If accuracy of pressure regulation is not needed a standardregulator is recommended.

3. Air preparation


3.1.3 Tip 3 � Use automated drain instead of manual drain

If mositure is released periodically occurance of moisture intoproducts is reduced. Moisture affects seals and greaseconditions.


Collected moisture is releasedregularly

�

Duration time when releasingcollected moisture is con�trolled

�


PWEA WA−...

Fig.�3/6: Automated drain devices

3. Air preparation


Strengths of PWEA

High functionality, since the system reliably operates even inthe case of problematic condensate.

� Large cross section: Even coarse contaminants andcoagulate are easily removed.

� No pressure loss when emptying thanks to prompt seal�ing of the system.

� Flexible areas of application, since the system automati�cally adapts to changing operating conditions (e.g. chang�ing viscosity of condensate and pressure fluctuations).

� Prevention of downtimes thanks to alarm function! Thealarm mode is triggered after 60 s , if the condensatedrain is faulty. The solenoid valve then opens the valvediaphragm at specific intervals.

� External fault signal, a red LED flashes and a digital signalapplies., indicating the status.

3. Air preparation


3.2 Case 2 � Reduction in pressure lost

3.2.1 Tip 1 � Maintain required system pressure

Any changes to the required system pressure affects perform�ance. Registration of changes points to losses or manipula�tion.


Process operation is optimum �

Ensure application is workingproperly

�


FRCS... E11 MA...E−RGZVS−...

Fig.�3/7: Pressure keeping products

3. Air preparation


Lockable service units contribute to a remaining pressurelevel.

A planned cascading of filtration ensures the less pressurelosses.

40 m 5 m finefiltered air

Fig.�3/8: Filter cascade

Fig.�3/9: Check for energy saving features

Configuration tools help to think energy saving (e.g. shut−offvalve yes/no, regulator lockable yes/no, different pressurezones yes/no, inserted distributers yes/no, filter cascadeyes/no, ...).Volume can help to equalize the pressure niveau if consump�tion is very dynamic.

3. Air preparation


3.2.2 Tip 2 � Ensure filter elements are changed or maintained

Clogged filter units reduce efficiency of service units.


No pressure loss besause ofno clogged filter elements

�

Gives an indication of thequality of compressed air supply

�


MS...−LFM−...−DA } See MSLFMA } See Fig.�3/11

Fig.�3/10: Products with instruction of pressure fall

3. Air preparation


Fig.�3/11: LFMA − Fine filter with visual indicator. Condition ofthe filter element is indicated via the differentialpressure

Recommendation:If the pressure drop inside a filter is more than 0, 3 bar,change the filter elements in the service unit.

Example:

with old filter element with new filter element

Pressure drop in the filter 0,4 bar 0,2 bar

Pressure difference in supply 0,2 bar 0 bar

Consumption difference because ofpressure difference

2 % 0 %

Average consumption of the machine 612 l/min320 786 m//year

600 l/min 314 496 m3/year

Costs per m3 succed air 0,02 �/ m3 0,02 �/ m3

Costs per year 6 416 � 6 290 �

Difference in the year 126 � 0 �

Costs of new filter element 0 � 11,80 �

Amortisation time � ca. 1 month

Fig.�3/12: Comparison of maintained and not maintained filter

3. Air preparation


Check pre−Filter (40 m / 5 m) if dirty or broken. They areflown through from outside to inside and their condition canbe seen.

Fig.�3/13: Different examples of weared filter cartridges

3. Air preparation


3. Air preparation


3.2.3 Tip 3 � Reduce system pressure − use pressure booster for specificapplications


Not all applications need tobe supplied with 8 bar pressure

Pressure booster uses compressed air to boost pressure. Up to50% volume lost

Increase pressure only forspecific application, savingenergy cost for rest of applications

Noise pollution


DPA... } See Fig.�3/15

Fig.�3/14: Pressure booster

CautionThis may lead to changes in functionality and performanceof your application investments.

SavingsUp to 15% savings after factoring the cost of investments.

3. Air preparation


Variant ISupply 10 bar

Variant IISupply 6 bar + 5 % of volume at 10 barvia pressure booster

Purchase

CompressorCooler/refrigerating dryer

80.000 � 80.000 �

Operation

Costs m3

Delivery volume/min.Operating hours/aDelivery volume (p.a.)

0.0385.01.200360.000

360.000

�/m3

m3/min.h/am3/a

m3/a

0.0265.01.200360.000

plus 5 % for pressurebooster supply air: 18.000

378.000

�/m3

m3/min.h/am3/a

m3/am3/a

Delivery costs of compressor intotal

13.572 � 9.828 �

Total costs p.a.

Write−down 10% p.a.New investment p.a. (pr.boosters)Operating costs

8.000

13.572

�/a

�/a

8.0001.000

9.828

�/a�

�/a

Total costs p.a. 21.572 �/a 18.828 �/a

Saving p.a. � �/a 2.744 �/a

a= annum (year)

Fig.�3/15: Costs balance with DPA (example)

Behind the booster a dryer or a filter may be needed, if thepressure jump in the given ambient temperature causes con�densing of the air. A tank may be needed if bigger volume ofhigher pressurised air is needed.

3. Air preparation


Supply/

Exhaust valve

Pneumaticactuator

Pressure regulator for low−pressure setting

Fig.�3/16: Tank as buffer for bigger volumes

Vacuum application


Chapter 4

4. Vacuum application


Contents

4. Vacuum application 4−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


4.1.1 Tip 1 � Use vacuum switch with vacuum applications 4−4 . . . . . . . . . . . . . . . .

4.1.2 Tip 2 � Use the correct pressure supply for vacuum generators 4−8 . . . . . . . .

4.1.3 Tip 3 � Maintain integrated silencers and filters of vacuum generators regularly 4−10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.4 Tip 4 � Use vacuum pump for applications that require constant vacuum 4−12

4.1.5 Tip 5 � Place vacuum generator close to application 4−14 . . . . . . . . . . . . . . . . .

4.1.6 Tip 6 � Choose suitable succion cups 4−20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



Energy saving on Vacuum

1

2

3

Fig.�4/1: Saving points at vacuum lines

Saving points at vacuum lines are as follows:

1 Pressure line

2 Vacuum line

3 Suction cup


1. Short pressure line distances

2. Short vacuum line distances

3. Adequate suction−cups for perfect sealing




4.1.1 Tip 1 � Use vacuum switch with vacuum applications

Using a vacuum switch allows switching off the vacuum gen�erator when required pressure is reached.


Allows the switching off ofvacuum when desired pres�sure is reached

�

Detected pressure changecould be used as a signal thatwork piece is present

�


VPEV...

VN−...P } See Fig.�4/4

VADMI } See Fig.�4/3

SDE5

SDE1

OVEM−...

Fig.�4/2: Vacuum switches or integrated switches



Fig.�4/3: Savings in vacuum generation

� Vacuum is automatically switched off when required vac�uum is reached 2 (VADMI−P−LS, OVEM−... )

� and automatically switched on again 3 to achieve re�quired vacuum

� without need for any external wiring and PLC program�ming

� integrated non−return valve prevents purging of the vac�uum (VADMI−P−LS, OVEM−...)

� detector registers the increase of suction an switches offin case of mal function (VADMI−...−P/N−LS, OVEM−...).



Operation cycle to handle a workpiece

Evacuation time Transport

Drop off Back to zero position

Total cycle time

Fig.�4/4: Switch−off functionality during return time

Example

Energy cost comparison between VN−05 and VADMI−45. In asimilar problem during 250 days/year and 16 h/day:

� Energy costs without switch−off function (VN−...): 37 �/a

� Energy costs with switch−off function (VADMI−...−LS): 12 �/a.



Optical part detection sensors in combination with an air stopvalve help to save compressed air if no workpiece is there tobe succed.

Fig.�4/5: Sensors to clarify need of vacuum



4.1.2 Tip 2 � Use the correct pressure supply for vacuum generators

Supply pressure affects the vacuum pressure directly.


Vacuum is not generated ac�cording to the higher pres�sure. Check the operatingpressure to achive optimumvacuum.

�


} See Fig.�4/7

VN−...

Fig.�4/6: Vacuum generators



Vacuum depending on supply pressure Faster evacuation time with L type generator at 0,4 bar vacuum

Supply pressure [bar] Supply pressure 6 bar

(L)

(H)

(L)

(H)

Fig.�4/7: Example of Festo VADM vacuum generators vacuum generators VN−...−H andVN−...−L

The relation between vacuum ’output’ and pressure ’input’follows a graph. Different productlines have a specific char�acteristic.Large flow characteristic (L) is energy saving because

� of a linear ratio of pressure and generated vacuum

� of a faster evacuation time and as a result the possibilityto switch off the vacuum generation earlier.

See poster 050093 Three selection criteria"



4.1.3 Tip 3 � Maintain integrated silencers and filters of vacuum generators regularly

Peformance of the vacuum genrator can be improved withbetter maintenance.


Ensure optimum performanceof application

�


VAF... In line filter } See Fig.�4/10

Fig.�4/8: Filter spare parts, silencers



Fig.�4/9: Silencer elements to be changed

Fig.�4/10: In line filter (VAF−...) to protect vacuum generatorfrom being clogged

Fig.�4/11: Noise reduction with new filter types UO−... main�tenance free because it’s open at the end



4.1.4 Tip 4 � Use vacuum pump for applications that require constant vacuum


Minimum possible air con�sumption

�

� �

�


Fig.�4/12: Economy function www.festo.com/products/dimensioning software/downloadfor windows




For more detailed calculation, refer to Festo’s System guide−Vacuum Selection Tool.



4.1.5 Tip 5 � Place vacuum generator close to application

Nearer to application means faster evacuation time and there�fore less air consumption.


Faster evacuation time Weight of the vacuum generator will be on the moving axis of theapplication


VN... } See Fig.�4/14 VN−cartridge } See Fig.�4/18

Fig.�4/13: Light vacuum generators for decentral placement



P

1

2

1 @ andlength of the tube influences the pressure dropΔp and therefore the vacuum level

2 @ and length of the tube influences the evacuation time Δt

Fig.�4/14: Tubing lengths and diameters

Tubing lengths and diameters have a decisive influence onvacuum level and evacuation time. Paying attention to thesefactors has a positive effect on energy consumption.



Example 1

� Service unit: MS4, 1/4 inch connectionQNN = 2000 l/min. flow rate

� Load device: Vacuum generator VADMI−200, QN = 240 l/min., 6 bar, @ 2 mm (Laval nozzle)

Tubing Supply pressure

Vacuum level

Short connection 6.0 bar 89 %

PUN−8 ND (5.7 mm) 2.5 m long 5.8 bar 87 %

PUN−6 ND (4.0 mm) 2.5 m long 4.6 bar 80 %

Fig.�4/15: Resisting factors in vacuum generation

ND = Nominal diameter, inner diameter as given in paran�theses.

In this configuration, the air consumption of the suction cupis only approx. 1/10 of what the service unit can deliver. The addition of further load devices increases the drop invacuum!



Example 2

1st group of bars in Fig.�4/17: According to the dimensioningformula (Fig.�4/16), PUN 4 will be adequate for the vacuumgenerator VN−07−H (Laval nozzle diameter 0.7 mm). Due tothe increase in volume of 1.4 % (from 1000 cm3 to 1014 cm3)caused by the 2.5 m long PUN 4 tubing, the evacuation timerises by 77 % (from 6.2 s to 11 s). The time advantage ofshort tubing is even greater at low vacuum levels, see 1st and2nd bar groups in Fig.�4/17.The influence of the nominal tubing diameter is even greaterin the case of vacuum generators with a low−volume suctioncup.

12

Fig.�4/16: Calculation of the table diameters with given nozzle size

Formula for the nominal size (mm)

Supply port 1 ≥ 2 x @ venturi nozzleVacuum port 2 ≥ 3 x @ venturi nozzle (high vacuum)Vacuum port 2 ≥ 4 x @ venturi nozzle (large flow)



1234 Evacuation time with p1 = 6 bar

Vacuum generators

time

1 Suction cup volume only 1000 cm3

2 Suction cup volume only 1000 cm3 plus PUN−4; 2.5 mlong (tubing volume 14 cm3)



Fig.�4/17: Evacuation time as a function of tubing length withP1 = 6 bar



Fig.�4/18: Mounting of VN−cardridges in a bore hole of yourmachine rack



4.1.6 Tip 6 � Choose suitable succion cups

Best thightness allows to reduce the input pressure.


Less consumption Surface changes of sucked material during production may be diffi�cult


Fig.�4/19: Different succion cups for every purpose



Example

Step 1 Calculating the weight of the workpiece

Step 2 Selecting the succion gripper

Step 3 Calculating the holding and on breakaway forces

Step 4 Selecting the connection diameter in relation to succion diameter

Step 5 Taking into account the ambient conditions

Fig.�4/20: Different shapes depending on surface finish

See poster 053719 Vacuum Handling"See Poster 053799 Trend, modular vacuum suction

grippers"

Accessories


Chapter 5

5. Accessories


Contents

5. Accessories 5−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


5.1.1 Tip 1 � Ensure tubings are mounted properly 5−4 . . . . . . . . . . . . . . . . . . . . . .

5.1.2 Tip 2 � Use push/pull fittings with sealing lip 5−6 . . . . . . . . . . . . . . . . . . . . . .

5.1.3 Tip 3 � Select correct tubing design suitable to the purpose used for 5−8 . . .

5.1.4 Tip 4 � Tighten sealing rings for threading connections 5−10 . . . . . . . . . . . . . .


5.2.1 Tip 1 � Reduce the length of the tubing used 5−12 . . . . . . . . . . . . . . . . . . . . . . .

5.2.2 Tip 2 � Use multiple distributors 5−15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.3 Tip 3 � Ensure that exhaust interfaces are suitable 5−18. . . . . . . . . . . . . . . . . .

5. Accessories


Energy saving on Accessories

1

2

3

Fig.�5/1: Saving points on accessories

Saving points at tubing, connectors, sealing rings are as follows:

1 Tubing (dimensioning, length, bendings)

2 Cutted surface (rectangled, not stressed)

3 Sealing rings and threads (face, tape, material)


KISS − keep it striktly

1. Short (tubings)

2. Smooth (diameter variations)

3. Straight (adapters)

4. Same (size of fittings)Maintain the connections

5. Accessories



5.1.1 Tip 1 � Ensure tubings are mounted properly

Eliminate burrs on tubing, deformation of the tubing and en�sure the orthogonal cut of the tube end.


Less leakages from incorrectsealing of connectors

�


ZRS } Pipe and tube cutter ZDS QSO

Fig.�5/2: Assembly tools for best results

5. Accessories


cutted with scissors cutted with knife

Fig.�5/3: Burrs on tubing � the tubing then damages the sealsystem

Fig.�5/4: Cut end of tubing not orthogonal � the tubing isnot guided correctly in the fitting

Fig.�5/5: Tools for easy mounting/demounting without de�formation of other connections

5. Accessories


5.1.2 Tip 2 � Use push/pull fittings with sealing lip

Sealing surface instead of sealing line.


Reduces leakages by com�pensation of grooves in thetube

�

Bigger sealing contact �

Under pressure the inner lip ispressed tightly to the tube

�


QS... Festo push/pull fittings

QS−... QS−F−...QS−B−...

Fig.�5/6: Push/pull fittings

5. Accessories


sealing lip

Fig.�5/7: Washer disc based fitting with sealing lip (QS−...,QS−B−...

o−ring

Fig.�5/8: Washer disc based fitting with o−ring (QS−F−...)

A fitting with a sealing lip offers in comparison to O−ringsealed fitting a better sealing characteristic.

5. Accessories


5.1.3 Tip 3 � Select correct tubing design suitable to the purpose used for

Tubing life will be extended, leading to less leakage over time.


Ensure longer life and durabil�ity of the tubing used

�


Festo tube selection software } See Fig.�5/10 and Fig.�5/11

Fig.�5/9: Tools to define suitable tubing types

5. Accessories


Damage Application

Chemical damage Detergents, disinfection agents, cooling agents

Stress cracks Solvents, lubricants, hydrocarbon

Microbial damage Outdoor areas, stacks, channels, areas withhigh pollution, wet and warm environment(cable channel)

Physical damage Outdoor areas, applications with artificial UV−radiation e. g. disinfection in food industry

Fig.�5/10: Symptoms of stressed tubings

Tube type Tubing Chemicaldamage

Stress cracks Microbialdamage

Physicaldamage

PUN−... Polyesterurethan � 0 � +

PUN−H−... Polyetherurethan + 0 ++ +

PAN−... Polyamide 0 0 0 0

PLN, PEN Polyethylene ++ + ++ +

PFAN−... Perfluoralkoxy−polymer

+++ ++ ++ ++

Fig.�5/11: Rough selection criteria for tubings (� = not resistant against, 0 = critical, (++)+ =

(very) resistant against)

Fig.�5/12: Chemical, biological, physical dammage of tubings

5. Accessories


5.1.4 Tip 4 � Tighten sealing rings for threading connections

Protects better against leakage.


Better sealing means lowerleakages

�

Minimum relaxing effect overlifetime due to solid supportring

�


OK... } See Fig.�5/14

Fig.�5/13: Non−relating sealings for threads (cylindric form)

5. Accessories


Owing to its two products PA and PUR, it is suitablefor use in all pneumatic applications.

With the new OK sealing ring Festo has succeeded indeveloping a sealing ring which is soft−sealing onboth sides when manually tightened. In combination with the fixed stop this new sealingsystem is compatible with ISO 16030.

Fig.�5/14:

Sealing with tape, apart from being slowly installed, can leavedebris on the inside of the elements and can cause obstruc�tions in valves, specially in small holes/ports.

Sealing with liquid is also slowly installed and makes futuredismantling much more difficult.

5. Accessories


5.2 Case 2 � Reduction in pressure loss

5.2.1 Tip 1 � Reduce the resistance of the tubing used

Correct dimensioning of length and diameter reduces the lossof energy over distance.


Actuation time is reduced �

Volume of air in tubing is re�duced

�


} See Fig.�5/16

Fig.�5/15: ProPneu Software for calculation and simultation


5. Accessories


Straight QS−connectors

Tube length [mm]

Fig.�5/16: Flow rate will be reduced over longer length of tubings

Tubings which are filled and exhausted all the time should bedimensioned smaller than supply tubings under continuouspressure.Flow controllers may be avoided by selecting smaller tubesize.

5. Accessories


1

23

1 Supply tubing under constant pressure

2 Tubing for forward stroke (working stroke)

3 Tubing for return stroke

Fig.�5/17: Optimized tubing concept for specific needs

5. Accessories


Fig.�5/18: Minimal restrictions by using straight tubings.

5. Accessories


5.2.2 Tip 2 � Use multiple distributors with adequate counter parts


Pressure loss is lower than itis with single T−distributors

Longer tubings may be necessary


Fig.�5/19: Multiple distributors to replace several T−distributors

5. Accessories


Designation Connectingi

Equivalent length [m]piece Inner diameter [mm]

9 12 14 18 23 40 50 90 100

Ball valve 0.2 0.2 0.2 0.3 0.3 0.5 0.6 1.0 1.3

Elbow 0.6 0.7 1.0 1.3 1.5 2.5 3.5 4.5 6.5

T−connection 0.7 0.85 1.0 1.5 2.0 3.0 4.0 7.0 10

Reducer from 2d to d

0.3 0.4 0.45 0.5 0.6 0.9 1.0 2.0 2.5

Designation Connecting Equivalent length [m] / Nominal diameter [DN]

piece DN25

DN40

DN50

DN80

DN100

DN125

DN150

Poppet valve 8 10 15 25 30 50 60

Slide valve 1.2 2 3 4.5 6 8 10

Ball valve 0.3 0.5 0.7 1 1.5 2 2.5

Elbow sharp 1.5 2.5 3.5 5 7 10 15

Elbow smooth 0.3 0.5 0.6 1 1.5 2 2.5

Bow 0.15 0.25 0.3 0.5 0.8 1 1.5

T−connection 2 3 4 7 10 15 20

Reducer from2d to d

0.5 0.7 1 2 2.5 3.5 4

Fig.�5/20: Equivalent length of connection pieces (indicates flow resistance/pressure loss)

5. Accessories


Interfaces and couplings always consists out of a male and afemale part. Tubes and fittings mostly seal better if they comefrom the same supplier.

Important is the inside passage of couplings to be free ofturbulences.

Fig.�5/21: Air flow (turbulences) in couplings

5. Accessories


5. Accessories


5.2.3 Tip 3 � Ensure that exhaust interfaces are suitable


Minimum use of compressedair

�


Fig.�5/22: Exhausting interfaces

Exhausting interfaces have to be maintained that they will notbe blocked.

5. Accessories


Air savings are possible with adequate solutions:

Blowing air parameters

Description Saving potentials

Blowing time Time, the air blow isactive

Reduction of time

Blowing pulse Interruption rate of asteady blow

Enlarge interruption in�tervals

Blowing pressure Pressure level in thetubing

Use of a regulator

Blowing force Diameter of nozzle inthe mouthpiece

Saving nozzles

Blowing jet number Distribution situationat the mouthpiece

Air fan is often betterthan single jet

Blowing jet length Distance of mouth�piece to the workpiece

Short distances forlower forces

Blowing jet direction Fix or variable orienta�tion of the mouthpiece

Combination withsemi−rotary drive forbest positioning of jet

Fig.�5/23: Realize savings on blowing air

5. Accessories


Fig.�5/24: Circuit for strong air pulse with less air consump�tion

Controllers and concepts


Chapter 6

6. Controllers and concepts


Contents

6. Accessories 6−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


6.1.1 Tip 1 � Decentralise pneumatic circuits 6−4. . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.2 Tip 1 � Analyse high frequent operations to find energy waist 6−6. . . . . . . . .

6.2 Case 2 � Reduction in compressed air leakage 6−8. . . . . . . . . . . . . . . . . . . . . .

6.2.1 Tip 1 � Monitor continuously the energy status 6−8. . . . . . . . . . . . . . . . . . . .

6.3 Case 3 � Reduction in electrical power 6−10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.1 Tip 1 � Select positioning drive according to the specific demands 6−10. . . . .

6.3.2 Tip 2 � Use self−locking lead screw drives 6−12. . . . . . . . . . . . . . . . . . . . . . . . .



Energy saving with controllers and concepts

1 23

Fig.�6/1: Saving points with controllers and concepts

Saving points at controllers and concepts are:

1 High speed motions

2 Stillstand positions

3 Controller distances


1. Stillstand without energy consumptions

2. Clear defined high speed movements

3. Short pneumatic lines, long information lines (electric,wireless)




6.1.1 Tip 1 � Decentralise pneumatic circuits


Minimal tubing volume �


Systems/Decentralized concepts

Fig.�6/2: Decentral cabinet located near the controlled actuators



6.1.2 Tip 1 � Analyse high frequent operations to find energy waist


Operations too quick forhuman eyes become obviousby slow motion films

Additional space needed butonly temporarily needed


SBO..−M−... FCT−...

(plug in for SBO..−M network)

Fig.�6/3: Optical devices to visualize high speed operations




Changes in the status are communicated immediately andtherefore longlasting unfavourable conditions are avoided.

6.2.1 Tip 1 � Monitor continuously the energy status


Quickest possible reactiontimes

additional weight, additional space to calculate


Sensor Controller Software Visualisation

1 SFE−...MS6 SFE

CPX−FEC−... FST4−... FED−.../VIPWIN

2MS6−SFE−...

FMT−...

3 WEBMonitor

Sensor Controller Software Visualisation

4 SFE−...MS6 SFE

CECX−... CoDeSys pbF FED−.../VIPWIN

5MS6−SFE−...

FED−CEC−... VIPWIN

Fig.�6/4: Todays and upcoming concepts to monitor machine conditions



6.3 Case 3 � Reduction in electrical power

6.3.1 Tip 1 � Select positioning drive according to the specific demands


Adequate solution Time intensive trading process


Fig.�6/5: Positioning Drives Software to find the specific solutionwww.festo.com/products/dimensioning software/Download for windows orwww.festo.com/engeneering/selection&dimensioning/software



6.3.2 Tip 2 � Use self−locking drives

Self−locking lead screw drives save energy because they canhold a position without spending extra energy.

Short cables avoid losses of transmitting between motor andcontroller.


No additional break necessary Control unit necessary to shut off current during stillstand of axis


DNCE−... DMES−...

Fig.�6/6: Electrical axes with self locking lead screws

03s 6 06controllers - festo...matics. these information ranges from simple to advanced application...

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