The industrial sector is estimated to have been responsible for 14% of greenhouse gas emissions in the UK in 2022, with carbon dioxide being the most prominent gas. However, greenhouse gas emissions from industry were 63% lower than in 1990, but this isn’t stopping the industry from seeking more efficient technologies on the path to Net Zero.
EFFICIENT PUMP CONTROL
By controlling the pump drive, pressure and flow can be optimally adapted to the requirements of servo-hydraulic machines at any time. This is particularly important in injection moulding machines, where cycle times are critical. KEB Automation’s Combivert F6 drive controller and S6 servo drives are designed to provide precise and high-performance pump control, ensuring continuous regulation and faster cycle times, thus boosting the productivity of injection moulding machines.
The control system also protects hydraulic valves and extend the service life of the pump. Various parameters in the drive controllers’ firmware are aimed at significantly increasing the lifetime and availability of the injection moulding machines.
“Among other things, we have considered ‘anti-cogging’ in our solution,” says Michael Schulz, application engineer at KEB. “This enables KEB’s inverters to equalise disturbing cogging torques, which are system-immanent in permanent magnet motors. The result is improved concentricity on the motor axis. In combination with the notch filter from the Wizard, which serves to avoid resonances in the hydraulic circuit, the result is highly precise and very good control of flow and pressure. Furthermore, there is the additional feature that the PQ control can be switched on and off by setting a bit. The user therefore has a regular KEB drive in place. This can lead to cost savings.”
Schulz adds that selecting servo pumps is a wise choice when hydraulic systems face highly dynamic or consistently stable control requirements. These applications span various fields such as plastics processing, hydraulics, bending presses and lifting technology. In these contexts, the stability of the KEB system and the effectiveness of its software solution are particularly evident in the precise control of pressure and flow, according to Schulz.
FUTUTE-PROOF VALVES
Festo recently introduced the Valve Terminal VTUX, which combines features from three previous ranges — CPV, MPA-L/S, and VTUG — into a single, user-friendly system. The unit’s size and weight have been reduced compared to the previous three technologies, resulting in a valve that is said to offer excellent speed, payload and flow characteristics. These terminals are suited for installation on handling systems or robots, where size and weight significantly impact performance.
Skye Prato, business unit manager at Festo South Africa, says: “Our adaptable Valve Terminal VTUX offers a highly expandable solution, enabling Festo customers to stay ahead of the technical changes in machine generations, from digitalisation and cloud connectivity to machine design issues.”
Prato emphasised the valve’s user-friendly design, highlighting its ease of disassembly. With just a few screws and an Allen key, users can easily access the valves, simplifying maintenance and troubleshooting. Its modular design also allows for effortless removal and replacement of components, minimising downtime, and maximising productivity.
One of the most noteworthy upgrades is the redesigned valves, which Festo claims deliver higher flow rates and improved efficiency without increasing the footprint. This enhancement allows for greater flexibility and scalability as well as integration into a wide range of automation processes.
The VTUX valve terminal achieves flow rates of up to 670 l/min with a single 10mm valve and a working connection of up to 8mm. It offers a variety of interlinking plate widths tailored to different flow demands while using the same 10mm valve. Two interlinking plate sizes are available for tubing diameters of 4, 6, and 8mm, which can be combined. Interlinking plates are available in configurations of four valves or a single valve. The single connecting plates and modular tie rods enable the system to be expanded as needed and set up quickly.
The high-speed serial communication within the valve terminals and base plates minimises the need for extensive cabling and tubing while facilitating seamless integration of functionalities and diagnostic capabilities. VTUX supports a wide array of interfaces, accommodating various bus systems and communication standards, including IO-Link, ensuring adaptability and future readiness across diverse electrical networks and machinery setups. Whether deployed centrally with numerous IOs and valve positions or used in decentralised valve terminals, the valve proves to be a versatile solution.
Additionally, when paired with the company’s AP system, it enables harmonious integration of both centralised and decentralised configurations, enhancing overall system efficiency and performance. Another benefit of the VTUX unit, according to Prato, is its modularity; components can be arranged as needed. With AP communication technology, connections are simpler, even over long distances. This technology is crucial for creating safety designs, predictive maintenance, and data exchange with the cloud in the Industrial Internet of Things (IIoT).
CASE STUDY
According to Prato, Supplyrite (a Festo ‘official partner’) transformed a customer’s operations using the VTUX Valve Terminal. The customer needed to control an unwinder for material in a Nappy Line, previously managed by a non-Festo valve bank with eight 3/2 way valves.
The VTUX Valve Terminal’s 2x3/2 way configuration within a single valve not only streamlined the installation process but also enhanced efficiency, improving the automation processes. Its Sub-D Multipin design improved panel organisation, providing a neater, more efficient setup.
Transitioning to this valve terminal offered benefits, including product longevity, which aligned with the customer’s phased change-out strategy for older valve banks. By standardising the terminal’s units, the customer ensured continuity in its automation processes and streamlined its stockholding, resulting in cost savings and operational efficiencies.
“This valve is the perfect solution for businesses that are looking to enhance their operations, flexibility, and efficiency and stay ahead of the competition,” states Prato. “Its ability to simplify maintenance procedures, enhance communication, and enable scalability makes it a game-changer in the industry.”
The imperative for industrial companies to adopt efficient, adaptable, and user-friendly pump and valve technologies is evident. Beyond mere cost savings, these advancements offer a gateway to environmental sustainability, regulatory compliance and operational excellence.
Embracing innovation not only fosters a competitive edge but also mitigates risks and future-proofs operations. By prioritising upgrades, companies align with evolving market dynamics, technological advancements, and customer expectations. This proactive stance not only enhances profitability but also signifies a commitment to responsible industrial practices. Investing in these technologies is not just a choice but a strategic necessity for thriving in today’s dynamic industrial landscape.