Improving the energy efficiency of pneumatic systems is a key goal for most industries, as doing so can reduce operating costs, improve productivity, and increase the lifespan of valuable equipment. Over time, many systems tend to lose their efficiency as a result of normal wear and tear on the equipment. Without proper maintenance, a great amount of energy is wasted as a result.
Besides staying ahead of necessary maintenance, there are many proactive ways for operators and owners to ensure that their pneumatic technology operates at the highest possible level. These include investing in top-quality components and taking advantage of new, more efficient components to utilize the absolute maximum possible amount of available energy.
In the following blog post, we’ll discuss a few things, both proactive and reactive, that you can do to reduce the overall power consumption of your pneumatic systems. This will ultimately allow you to enhance their performance while also achieving sustainable energy savings.
Parts of a Pneumatic System
While there are many different types of pneumatic systems, what they all have in common is their basic method of generating mechanical power: The term “pneumatic” refers to technology that utilizes compressed air (or sometimes another gas) to provide force. The air, or other gas, is kept pressurized in a tank somewhere within the system.
Gasses under high pressure will always move toward areas with lower pressure. This means that when the pneumatic system is activated, it uses the potential energy of the pressurized gas to provide high-powered motion for some type of mechanical component. The goal of the system, then, is to precisely control the flow of the gas, releasing it to apply the required force when necessary. To this end, pneumatic systems also utilize one or more valves to control airflow and actuators to which the force of the air pressure can be applied.
Upgrading Your Components
These basic components mentioned above are major contributors to the overall efficiency of any pneumatic system. This means that upgrading some of the basic components of your pneumatic technology can go a long way toward saving you money on energy costs.
While advances have been made in the design and implementation of many of these components, the most important element of an upgrade is still a simple one: You must ensure all parts of your system are both properly sized and streamlined.
This means eliminating extraneous pathways for the compressed gas to travel in, as this is a major contributor to energy waste. For example, consider the bore size of your pneumatic cylinders. If they are too large for the actuator they are operating, they may use more energy than is actually required. Similarly, reducing the number of connections between components can give the pressurized air a more streamlined path to travel, allowing more energy to be delivered to the mechanical elements more quickly.
To fully optimize the potential your pneumatic equipment has, it’s a good idea to invest in good-quality, tailored components.
Explore the Aberdeen Dynamic website for more information about custom products.
Leaks: A Major Contributor to Waste
Since pneumatic systems depend on highly pressurized gasses to perform their work, any loss in that pressure will hamper the performance of the system. A pneumatic system that cannot achieve optimal pressure may need to work much harder and use much more energy to perform the same work. Leaks, which often occur as a result of degraded seals and other maintenance issues, are a major contributor to pressure loss.
As part of your system’s routine maintenance, you should regularly monitor for any leaks or compromised areas that may develop leaks in the future. It’s possible to test for leaks with simple store-bought devices, such as ultrasonic leak detectors, but a simple application of soapy water to your machinery can also do the job. If you see bubbles forming, this may indicate that air is escaping from that spot.
Regular professional maintenance, including the repair or replacement of damaged seals and other compromised elements, can prevent leaks from occurring and keep your machinery operating as efficiently as possible.
Invest in Smart Controls
The application of advanced technological solutions is also an excellent method for enhancing energy efficiency in pneumatic systems. Among the most useful tools are electronic systems, sometimes referred to as “smart controls,” which combine both hardware and software to improve performance.
The primary benefit of a smart control system is its ability to improve the interface between pneumatic machines and their operators. Utilizing intelligent sensors, these control systems can update operators in real time, ensuring they are continuously aware of the needs of the system. Often, these machines can detect leaks and provide a diagnostic readout to bring attention to problem areas. This allows problems to be addressed before they escalate and interfere with the performance of the machinery.
Smart control systems can also help enhance performance on their own by adjusting the energy usage of the machinery, depending on the specific needs of the machinery’s current application. This will help prevent machinery from working harder than necessary, eliminating energy waste in the process.
Choosing the Best Components for Your Pneumatic System
Ultimately, achieving the highest level of performance while also saving the most money on energy usage is a matter of equipment quality and diligent maintenance. At Aberdeen Dynamics, we specialize in the design and implementation of top-quality pneumatic systems, including energy-efficient smart control technology. The work we do includes not only the mechanical elements of the system but the installation and programming of software as well. This allows you to get your equipment working for you faster and contributes to ongoing sustainable energy savings.