Pneumatic actuators have a place in industry, but electromechanical alternatives are putting the squeeze on them.
Engines have been using pneumatic actuators to move loads for decades. They are fast, up to 0.5 sec/stroke; powerful, with up to 40,000 lbf behind each stroke; and engineers can easily fine-tune these parameters by adjusting air pressure, valving, and bore size. One of the major advantages of pneumatics over other actuators, namely electromechanical and hydraulic alternatives, is their low cost. Trends and Capabilities Still, trends in a host of industries indicate that the growth in pneumatic actuators is in the low single digits, according to Gary Rosengren, director of engineering at Tolomatic Inc., Hamel, Minn., a company that designs and markets pneumatic and electromechanical actuators. “For electromechanical actuators, growth is five times that,” he says. “So clearly the trend is toward electromechanical actuators. That’s because they offer more benefits, including energy efficiency, safety, better control of the motion profile, and lower cost of ownership over the course of the machine’s lifetime.” “But pneumatics are inexpensive and everyone is looking to save a buck,” notes Rosengren. “And because pneumatics is considered a mature technology, the expectations are for cost to continue to go down. We also see a lot of pressures from offshore sources offering similar pneumatic products for lower prices. They might not have the quality, and that is up for debate, but in most cases, they are not bad. And in many cases, buyers only look at price, not the downstream costs or quality.” Pneumatic linear actuators offer several other benefits. “They are more reliable than their electromechanical counterparts, and offer a wide variety of sizes and faster actuation times,” says said Peter Farkas, president of American Grippers Inc., Trumbull, Conn., a pneumatic-device manufacturer. “Pneumatic actuators can also produce considerably more force than their electric counterparts within the same footprint, the cost is much lower, and they’re simple to control,” Farkas explains. “Compressed shop air is readily available in most plants and pneumatics don’t have the added weight of motors and drive mechanisms, so they can fit into limited spaces. Pneumatic actuators can also be held in any position for unlimited time without overheating like electric actuators do, and they do not have limits on duty cycles (rest period) between actuation.” Safety First Whenever technicians and employees work close to machinery that moves quickly and with lots of force, there’s always a risk of accidents. “And there’s definitely a trend toward making pneumatic cylinders safer for workers,” says Brad Weedon, online marketing manager for SMC Corp. of America, Noblesville, Ind. “Our company offers many products that can be used as safety-related components for pneumatic actuators, as well as actuators with locks, emergency shut-off valves, and other safety-related equipment.” However, most of the progress in safety is driven by OSHA directives, according to Jerry Scherzinger, product marketing manager for pneumatics at Bimba Manufacturing Co., University Park, Ill. “Examples include energy dissipation and lock out/tag out,” he says. “OSHA also has specific requirements for safety shutoff valves that regulate specific valve requirements. It is required that valves must be push/pull style for positive shut off of airflow. Rotary valves are not acceptable. Another requirement is that valve exhaust ports must be larger than their input ports to facilitate the rapid dumping of system air pressure (energy dissipation).” Environmental Pressures Although pneumatics are considered cleaner than hydraulics, electromechanical actuators are considered cleanest of all. And if environmental regulations become stricter, which they will if EPA continues cracking down on industries, and energy prices rise, pneumatic actuators will likely be replaced by electromechanical actuators. “There are factories with hundreds of horsepower in compressors running constantly to support actuators and other machinery,” notes Rosengren. “That gobbles up lots of energy, even when the actuators aren’t being used. Electromechanical devices, on the other hand, only use power when they are moving.” One way factory managers can make pneumatics more “green is to size their compressors to the actual load,” notes Farkas. Making the actuators lighter so that they use less energy is also a valid approach. Energy use isn’t the only environmental concern, says Rosengren “Pneumatics still need lubricants, and they can be contaminants if they escape into the environment, and that includes the atmosphere,” he says “All the air pressure that goes into a pneumatic cylinder must also go out. And that exhaust, which is similar to the exhaust coming out of the tailpipe of your car, has to be treated because it’s contaminated at some level.” IoT Activity While safety and environmental concerns are affecting pneumatic actuators due to stricter regulations, the Internet of Things (IoT) is affecting them by pushing for more sensors and remote controls on industrial equipment and hooking them all together through the Internet. “Networking machinery, sensors, and control systems together through the IoT will let manufacturing companies improve production and their supply-chain networks in real time,:” explains Farkas. “For pneumatic actuators, adding sensors connected through the Internet will let companies collect useful data on cylinder speed, travel, temperature, and pressure. This information can then be immediately used to optimize production or alert maintenance of an issue before a component fails completely.” For example, pneumatics manufacturer Bimba has already added more connectivity and monitoring to products such as its IntelliSense in anticipation of a sharp increase in IoT activity. It plans on taking advantage of IoT technology to let its manufacturing customers offer uptime guarantees and enhanced service offerings on the machines they make. “To do this, they must be able to monitor every aspect of their machine’s performance, including that of the pneumatic actuators,” says Bimba’s Scherzinger. “We already have customers looking to remotely monitor the machines they sell to ensure they are being operated within the design specifications and help reduce warranty claims,” says Scherzinger. “In addition, remote monitoring lets our customers improve future products because they no longer have to rely on companies using their machines to report how those machines are being used. They can see it for themselves.” Scherzinger also points out that the growing presence of IoT’s influence in other industries has spurred technological development, making sensors, for example, that are more robust and less expensive to embed in traditional pneumatic hardware. Adding sensors is currently the most significant IoT-related trend for pneumatic actuators, according to SMC’s Weedon. “IoT is becoming more popular in all pneumatics,” notes Weedon. “And for actuators, that typically means adding end-of-stroke sensors. Most of the IoT controls for pneumatics apply to valves and pressure regulators. And the main reason for connecting pneumatic cylinders to the IoT is for predicting failures and scheduling maintenance by tracking cycle speeds and cycle counts. Of course, electric actuators are a more natural fit as IoT devices.” There has also been a move to add diagnostics to pneumatic actuators, which could be seen as a nod toward IoT. “Adding diagnostics is a relatively new endeavor for pneumatics and is a way to fend off advances in electromechanical actuators to some extent. It is also relatively expensive,” says Tolomatic’s Rosengren. “And the unanswered question is whether the diagnostics will lead to a quicker ROI for the additional expense.” New Markets for Pneumatics Pneumatics have long provided a unique set of capabilities, and good engineers should be able to exploit them when an application calls for them. “There will always be applications best served by pneumatics,” notes Rosengren. “There are tasks they can do that electromechanical actuators can’t do, at least not for the same low price. For example, the force and speed one can get with pneumatics are unparalleled in most electromechanical devices. They can go fast and create a lot of power. There will be a need for those attributes for as long as I can imagine.” For example, pneumatics is a big part of the semiconductor industry and actuators are a large part of that, says Weedon. “Automotive seems to be using more pneumatic actuators as clamps during welding, and the food-packing industry is using more pneumatic cylinders in their processes because it is clean,” he says. There are also niche applications in which pneumatics should see growth, according to Michael Gust, the industry liaison at the Center for Compact and Efficient Fluid Power. “We see tremendous opportunities for pneumatic-actuation growth in new market growth, particularly in the areas of human-scale assistive fluid power and medical applications,” he says. “Examples include wearable, exoskeleton-like devices to improve human mobility, productivity, and quality of life. Inherent pneumatic properties such as clean, safe, environmentally friendly, portability and ‘usable’ power, that is torque and speeds, align well with these application requirements.” Another potential growth area pointed out by Gust is use of pneumatic actuators for medical rehabilitation and MRI-compliant surgery and treatment. “Examples include prosthetics such as ankle-foot devices to help with weakened limbs or rehab, and steerable needles for brain surgery,” Gust says. “Pneumatics’ inherent ability to be compliant with MRI chambers, as well as the ready availability of air supplies in hospitals and operating rooms, make this technology very attractive. Source: MachineDesign.com
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Commenting on the sustained low demand levels for manufacturing technology products, AMT president Douglas K. Woods said: “While there is a sense of unease in manufacturing now, as indicated by this reduction in orders combined with drops in the PMI and industrial production, some leveling after a period of strong growth is expected and helps build stable, longer-term growth.”
U.S. manufacturers’ new orders of machine tools fell 10.2% from July to August, settling at $285.92 million for the month. The discouraging result — which is drawn from the U.S. Manufacturing Technology Orders Report, issued each month by AMT – the Association for Manufacturing Technology — represents a 21.2% drop from the new-orders total for August 2014, and brings the year-to-date total for manufacturing technology orders to $2.77 billion, a decline of 10.0% compared to the eight-month order total for 2014. It also is the second consecutive monthly decline in new orders, and the sixth monthly decline for 2015. August’s total represents the lowest monthly value for new orders of the current year, and the lowest since the recent peak in new orders, set during September 2014. More particularly, the August total represents the lowest monthly figure for machine units 2015 – at 1,747 it is just one less than the total for January 2015. The USMTO is based on actual data provided by companies participating in the USMTO program, who produce and distribute metal cutting and metal-forming and –fabricating equipment, including domestically manufactured and imported equipment. The report is based on actual values for new orders, and the results are presented as nationwide totals and as totals for six regions of the U.S. “While there is a sense of unease in manufacturing now, as indicated by this reduction in orders combined with drops in the PMI and industrial production, some leveling after a period of strong growth is expected and helps build stable, longer-term growth,” observed AMT president Douglas K. Woods. “We are a diversified industry, and pockets of manufacturing continue to show resilience, such as automotive stamping and medical devices,” Woods assured. “While there is some cause for caution, we do not anticipate more than ‘market flatness’ into the early part of 2016.” August new-order totals were also down markedly in most of the six regional indexes tracked in the USMTO program. Northeast regional orders fell to $50.96 million, down 22.3% from July to August, and down 16.8% from August 2014. The Southeast region is the only one among six to report an increase for the month, up to $45.35 million, and 18.9% improvement over the previous month. The region’s year-to-date total is essentially even with last year’s total, down 0.7% compared to the January-August 2014 period. In the North Central-East region, new orders for manufacturing technology fell 8.0% from July to $79.27 million in August. That figure also is down 12.8% from the August 2014 report, and the eight-month total for the North Central-East region is $762.74 million, down 10.1% from the comparable period last year. In the North Central-West region, new orders in August totaled $51.11 million, down 11.0% from July and down 24.5% from the August 2014 report. In the South Central region, new orders for metal cutting equipment amounted to only $12.5 million, down 42.9% from July and down 73.7% from August 2014. The region’s total new orders reported for the January-August period now stand at $225.18 million, down 53.6% from the same period of 2014. Lastly, in the West region metal cutting machinery orders during August were $44.06 million, down 1.2% from July and down 12.9% from August 2014. Total manufacturing technology orders in the West region are now $427.0 million through the first eight months of this year, down 6.7% from the comparable result of last year. Source: Americanmachinist.com At a press event to launch the IFR’s World Robotics Industrial Robots statistical review of 2014 (with projections through 2018), the $1,350 report forecasts a 15% CAGR, thereby doubling the annual number of units sold to around 400,000 by 2018. 70% of those sales will be to users in China, Japan, the U.S., South Korea and Germany. China purchased 56% more robots in 2014 than 2013, of which approximately 17,000 were made by Chinese vendors. The IFR is forecasting Asian robot sales units to increase from about 140,000 to 275,000 by 2018, by far the largest and fastest growing marketplace in the world. They are projecting 15% CAGR worldwide, but as the chart shows, much lower growth than that for Asia and China in particular. Specifically, sales for the global robotics industry in 2014 were $10.7 billion, a 13% increase over 2013. There are now about 1.5 million robots at work globally, an increase of 11% over 2013. Adding supporting services such as integration, accessories, peripherals, software and systems engineering at a 3X multiplier, worldwide 2014 sales are estimated to be $32 billion. The report suggests that rapid automation in China and global competition of industrial production are the main drivers for the sustained growth forecasts. Further reasons for the increased demand for robots include:
Source: Robohub
The maker community is turning into a quickly-growing movement, as shown by the ever-expanding Maker Faires popping up worldwide. This last weekend was World Maker Faire in New York, where Tormach, a company known for making small, affordable CNC machine tools announced an even smaller, more personal mill, the PCNC 440.
Following in the footsteps of recent desktop CNC (computer numerical control) machines like Carvey and X-Carve, the PCNC 440 mill is designed to fit on benchtops, and lower the barrier of entry to real CNC. What’s different is that this machine is less like a router – it’s truly a CNC mill – allowing travel of 10 x 6.25 x 10 inches / 25.4 x 15.9 x 25.4 cm (X x Y x Z). Real Machining With an R8 spindle, a spindle speed of up to 10,000 RPM and quick-change tooling, Tormach has taken cues from its industrial brethren, but managed to make its machine more approachable. Like major industrial machines, both CAD (computer aided design) and CAM (computer aided manufacturing) software are needed to create a part on the PCNC 440. Being that these are often expensive and cumbersome to learn, Tormach has partnered with Autodesk to provide a free year-long seat to a commercial version of Fusion 360 (CAD/CAM) with the purchase of this machine. Because the PCNC 440 requires traditional software workflows to start cutting parts – unlike other desktop-style CNCs and 3D printers that allow a drag-and-drop file workflow – to some, this may be where the 440 falls short of other maker-oriented cutting machines.
"CNC Machining still does not have a one button print function like many of the desktop 3D printers," Tormach’s product marketing manager Andy Grevstad explains. "The PCNC 440 is easily the most approachable CNC mill for beginners, but you’ll still need to invest some time to learn machining techniques and CAD/CAM programming skills. While it lacks the instant gratification of a 3D printer, it is a much more capable and rewarding technology in many aspects."
Also, like its bigger brothers in the industrial world, this machine can cut everything from wood and plastics to real metals like aluminum, steel and even titanium, with precision – although a bit slower. In comparison, one of the smallest industrial machines, the Haas MiniMill, uses a 7.5 HP spindle, compared to the PCNC 440’s ¾ HP spindle, but a MiniMill starts at US$34,995, while the 440 starts at just $4,950. "[The PCNC 440] is more for small prototype work, inventors, educators, and specialty manufacturing," Grevstad says. "There is a need for CNC milling technology outside of traditional manufacturing environments and I think that the PCNC 440 fills that role."
Still for the MakerWhat the machine lacks because of complexity, it gains in approachability. Tormach has developed PathPilot, the company’s machine control system which is rooted in the open-source Linux CNC project. This software reads any industry-standard G-code and also has some conversational programming for those that like to edit and tweak things on the fly.
While Tormach makes two other larger CNC mills (the PCNC 1100 and PCNC 770) and a CNC lathe, the PCNC 440 keeps the tinkering audience in mind. It weighs just 450 lb (204 kg), has a compact footprint of 42 x 36 inches / 106.7 x 91.4 cm (W x D), and runs on 115 VAC, single-phase power. There's more on the way for the PCNC 440, too – Tormach plans to release a power drawbar, an automatic tool changer, and a 4th axis sometime in early 2016, making this thing a tiny, all-encompassing manufacturing center. Currently, the PCNC 440 is available for pre-order only, due to ship in November. Grevstad is sure we will continue to see new advances in many facets of affordable digital tools for things like at-home manufacturing. "It’s an exciting time for makers and those that want to make things," he says.
Source: Gizmag
The Indian textile machinery industry is expected to touch Rs 45,000 crore mark by 2022 from the present Rs 22,000 crore, buoyed by growing demand of textile and apparel market in the country.
"The textile machinery industry witnessed a growth of 8-10 per cent to Rs 22,000 crore in 2014 from Rs 20,000 crore in 2013. The size of the industry is poised to double to Rs 45,000 crore by 2022 in light of new projects and emphasis on setting up textile parks," India International Textile Machinery Exhibitions Chairman Sanjiv Lathia told PTI here. Modi government's 'Make in India' programme is also expected to help the textile sector by way of increase in demand for modern machineries. India's textile and apparel industry is expected to grow from the current USD 107 billion to USD 223 billion by 2021. And India is expected to be a leading textile producing country in the world by 2020, Lathia said. He said the country has the potential to become manufacturing hub in the textile machinery with abundance of skilled labour, low cost and natural resources available. But for this, sufficient focus is to be given on research and development in order to ensure modern and innovative technologies are developed in the country. However, the domestic textile engineering industry is unable to fulfil the industry demand and a large volume of textile machinery is sourced from European countries, which is relatively costly. For textile machinery manufacturers from Switzerland, Germany, Belgium, Italy and Spain, India remains the most important market with the export worth millions of dollars, he added. To tap the global opportunity, India is hopeful of increasing its exports which is now estimated at 15-20 per cent of hi-tech textile machineries production, he said. The major manufacturers of the textile machinery are Germany, Italy, Switzerland, France and China. One of the major trends in the global textile machinery market is the growing number of technological innovations. To tap the growth opportunity, ITME Society, a body of textile industry, is organising the 10th edition of India International Textile Machinery Exhibition from December 3-8, 2016, at Mumbai. India ITME 2016 - the largest textile machinery and accessory exhibition in the country - will be spread over 1,50,000 sq mts and is expected to witness participation from 93 countries. Source: Economic Times |
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