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Automation: The digital transformation is going green

Automation ensures competitiveness and eases labour shortages. However, the increasing use of robots also increases energy requirements. Schmalz designs new systems for particularly sustainable vacuum automation.

Automation ensures competitiveness and eases labour shortages. However, the increasing use of robots also increases energy requirements and therefore the product carbon footprint. Schmalz is therefore focussing on resource-efficient product life cycles and designing new systems for sustainable vacuum automation.

After two years of decline more industrial robots have returned to service in Europe for the first time in 2021. As the International Federation of Robotics (IFR) reported in June 2022, last year's level of around 78,000 units was even higher than the 2018 high, with demand in the metal and machinery (+50 per cent) and plastics and chemical products (+30 per cent) sectors increasing in particular. The automotive industry, on the other hand, did not record any growth, but remained at its high level of 19,300 installations.

The renewed growth is positive for robot and component manufacturers, but the EU's Green Deal is putting them under pressure. Call for climate neutrality challenges developers of automation solutions, combine the digital and green transitions.

To ensure that the widespread use of digital technologies does not inevitably lead to a steady increase in energy consumption, electronic waste and the ecological footprint, it is important to keep an eye on the product life cycle - from design to recycling.

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"We have to minimise CO2-"We want to differentiate between the emissions generated by the packaging we use to send our product to the customer and the emissions generated during use." 

Dr Maik Fiedler, Head of the Vacuum Automation and Vacuum Handling business units at J. Schmalz GmbH

To keep the package as small as possible, Schmalz uses on short procurement routes - 50 per cent of suppliers come from our own federal state -electricity from renewable sources and a sustainable distribution system. "We avoid energy-intensive materials and production processes right from the development stage. This allows us to save material and the customer consumes less energy during subsequent operation," says Fiedler, citing an approach that has been practised at Schmalz for years. Now the vacuum expert is writing the next chapter and develops systems that are completely independent of compressed air.

Performance with pneumatic solutions

This sounds like a simple solution, but there are hurdles to overcome. One of these is the higher power density of pneumatic vacuum generators. "We develop new system concepts that intelligently combine purely electrical components. This enables us to achieve cycle times that are comparable with high-performance pneumatic vacuum generators, including active blow-off," says Fiedler.

The efficient concept consists of a centrally installed electric vacuum pump on one side, a reservoir in between and valves mounted close to the suction pad on the other side. "Our accumulator is the hoses in which we pre-tension the vacuum in order to call it up as required. This leads to a significant reduction in the evacuation time. By using several valves, we can install various independent suction circuits", explains the vacuum expert.

When presenting the all-electric solution, which is on a par with pneumatic systems, Fiedler the new LQE ventilation valve in mind. It is mounted directly on the gripper and reduces the actual volume to be evacuated by pre-tensioning. This enables rapid ventilation. "Depending on the system, we are talking about times of less than 50 milliseconds. The secret behind this is the large cross-section, which achieves flow rates of over 300 litres per minute," emphasises Fiedler.

The all-electric actuator control of the 3/2-way vacuum valve contributes to the higher energy efficiency of the overall system. Schmalz has also A sensor is integrated - it monitors and controls the vacuum and the process directly on the gripper. "This is how we harmonise sustainability with the digital transformation," says Fiedler.

The centrepiece of the compressed air-free vacuum automation is a powerful vacuum generator: the Compact-Pump GCPi. It weighs around three kilograms and is built so compact that it can also be used on lightweight robots. In combination with a battery - a 24-volt supply is sufficient - it is ready for mobile applications with autonomous transport systems (AGV) and robots (AMR). "The new compact pump is significantly cheaper to operate than a comparable ejector, even after a short duty cycle," emphasises Fiedler.

Lard automation
(Image: Schmalz)

This concept follows the efficiency strategy of Lardwhose products focus on the more effective use of energy. Pneumatic vacuum generators such as the RECB will remain part of the portfolio. They achieve high vacuum values and volume flows in relation to the installation space, are robust and can utilise existing compressed air lines. Schmalz continuously optimises the pneumatic vacuum generators in terms of their energy efficiency.

But there are other aspects that make automation sustainable: On the one hand, it is a question of service life and how easy it is to replace wearing parts or separate and recycle the different materials. On the other hand, digitalisation provides support with condition monitoring and predictive maintenance. This allows users to keep an eye on the process and the vacuum components used, among other things. In addition Digital twins speed up commissioning and realistically simulate the subsequent process. "Digitalisation provides us with many tools to identify and eliminate energy guzzlers," says Fiedler.

Source: Lard

 

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