For the latest information on a variety of pneumatics topics, Pneumatic Tips presents our featured articles. These pneumatics articles were handpicked to provide you with the up-to-date news and information you need. Browse our list of featured articles today and learn more about the exciting world of pneumatic design.

First look at Festo’s pneumatic ExoHand HMI system

Festo has been active on the cutting edge of design the last few years, from the award-winning design of its M9 compressed air preparation units to its elegant SmartBird and elephant-inspired robotic arm. So it’s great to see the latest item to come out of their German design team, the ExoHand. And nice to see pneumatics playing a prominent role in this design, which could be revolutionary in the huge human-machine interface (HMI) market. The release is below.

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Presented for the first time at Hanover Fair, the ExoHand from Festo is a solution for future human-machine cooperation in industrial environments based on soft robotics. It is designed to meet the challenge of an aging population by functioning as an assistance system for assembly tasks in production. As a force feedback system, the ExoHand can extend people’s scope of action in production environments. It can also be used as a platform for the development of new applications in service robotics as well as personal assistance systems.

The ExoHand is an exoskeleton that is individually adapted to the human hand. The fingers can be actively moved and their strength amplified. The hand movements can be registered and transmitted to robotic hands in real time. The exoskeleton is a structure that supports the human hand externally and simulates the physiological degrees of freedom of the hand.

Eight pneumatic actuators move the exoskeleton. Sensors record the forces, angles and distances. Servo pneumatic open- and closed-loop control algorithms allow precise movement of the individual finger joints. The ExoHand thus supports the various possibilities for gripping and touching which a human hand has. The pneumatic components allow highly flexible and ergonomic control of the individual finger joints. High forces can thus be transmitted precisely in a small space and with a low weight without the system becoming rigid and restrictive. This flexibility is crucial in human-machine interaction, as it minimises the risk of injury.

Despite a high level of automation, there are still many assembly tasks in industry that can only be performed by humans. Many of these are repetitive tasks that cause fatigue and can be particularly challenging for older members of the workforce. The ExoHand helps operators to remain working longer without incurring permanent physical damage. It can be used as an assistance system, providing enhanced strength for assembly tasks.

When used for remote manipulation of a robotic hand in an industrial environment, the ExoHand allows complex activities in for example dangerous or hazardous environments to be carried out from some distance away. Because all joints and their actuators exist in the form of an exoskeleton outside of the actual hand, the ExoHand can be worn over a human hand or an artificial hand made from silicone. The ExoHand performs two functions here—acting firstly as an interface between the operator and the control system and secondly as a robotic hand. This allows the control of a complete artificial hand with virtually all of the relevant degrees of freedom.

With a single system it is thus possible to design an innovative scenario that combines robotics with orthotics. Forces can be transmitted to the hand as force feedback from another environment, creating an ability to feel shapes. This technology offers enormous potential not only for remote manipulation, but also for navigation in the virtual world.

Synergies in service robotics and rehabilitation
With the ExoHand, Festo has not only developed an effective solution for industrial automation, but also established itself as a pioneer in the area of service robotics. When the ExoHand is used in combination with a robot in domestic or medical environments, human-like characteristics are absolutely essential. The flexibility of pneumatic systems in particular ensures reliable human-machine interaction.

The solution also offers benefits in rehabilitation. In stroke therapy, for example, this hand orthosis can be used to help treat the first signs of paralysis in patients. The ExoHand can be used together with a brain-computer interface to create a closed feedback loop. It can help stroke patients who are showing the first signs of paralysis to restore the missing connection between brain and hand. An electroencephalography signal (EEG) from the brain indicates the patient’s desire to open or close the hand. The active hand orthosis then performs the movement. The result is a training effect, which over time helps patients to move their hand again without any technical assistance. Festo is working together with the Centre for Integrative Neuroscience at the University Hospital Tübingen on this subject.

Festo Corp.

Automation Studio P6 is released

Automation Studio P6 is a multi-user environment. This allows users to perform collaborative work on a project through data sharing and synchronization between different users. Thanks to the Access Rights Manager, users can set access restrictions in reading, publishing, etc. Thus, they can safely share their projects, be it with customers, suppliers, and of course colleagues.

Configurable project explorer
Project Explorer is fully customizable. It allows users, dependent on their needs, to view the necessary and appropriate information. The new interface provides users with a global project overview and keeps them updated on the status of each one of its documents.

LAN/WAN licenses management
Users can access Automation Studio License Server through a LAN or WAN connection. The server provides license usage logs and statistics.

Simulation improvements
The simulation in P6 takes into consideration several additional phenomena and improves the evaluation of many existing ones, including:

• Cavitation
• Vapor pressure of the oil
• Motor and pump volumetric and total efficiency
• Very high pressure system (>5000 Bar)

Extra-large flat suction cups provide flexibility

Hingham, MA–Piab has introduced a new line of extra-large flat suction cups that has been designed to handle various product sheets safely and securely in manufacturing environments.

The XLF line of suction cups is available in four different diameter sizes 150mm, 200mm, 250mm and 300mm. All sizes are similarly designed with an aluminum plate molded into the durable and long lasting 60° Shore Nitrile-PVC rubber. This strong material that is PWIS/Silicone-free does not leave behind any marks on the handled product so no extra cleaning is required. The cups are ideal for sensitive surfaces as the soft material will not chip or damage the material being handled.

As certain sheets sometimes have sharp edges or corners that can mar or cut a suction cup, leaving a possibility of diminished lifting capacity and a chance of products dropping, the XLF unique double lip design (inner and outer) increases safety in case of tear or overload.

It is possible to use these cups in a customized mounting frame or lifting device. The build-in dimension of the four cups is identical as they are all of the same height. It is also possible to add features such as vacuum sensing and quick product release. The built-in cleats provide maximum suction cup gripping and these cups can handle weights up to 1100-lb, as well as up to 880-lb of shear force during vertical handling.

Piab

Pilot-operated check valves from Clippard

Clippard Instrument Laboratory Inc. has introduced the new JPC Series check valves. The JPC series uses the company’s poppet design and provides a variety of port configurations.

The JPC Series works as a standard check valve, but can be operated with an air pilot signal providing for “free flow” in the normally checked position. This new valve provides the user with a reliable method to check flow in one direction, with the ability to remotely signal a free flow through the valve. With high flow, low pressure and ease of connection, the JPC Series is a suitable check valve for many applications.

Clippard Instrument Lab

Ashcroft introduces compact, multi-application pressure switch

A tough operating environment is no match for Ashcroft’s new A Series pressure switch. All 316 stainless steel construction, a weatherproof IP67 enclosure and an operating temp from -40°C to 100°C (-40°F to 212°F) make this compact switch the ideal choice for a wide variety of industrial and OEM installations. Other features include:

• Compact Size
• 316 Stainless Steel Construction
• Pressure ranges from Vacuum to 7,500 psi
• Field Adjustable Set Point or Factory Set Only
• Precision Snap Acting Micro Switch Element
• SPDT or DPDT Switching
• UL, CSA Listed Models
• CRN Models Available
• CE and ROHS Complaint

Ashcroft

Finding and measuring pneumatic leaks

Leaks can be a significant source of wasted energy in an industrial compressed air system.

If compressed air were hydraulic fluid, leaks would be so visible that we would ensure their reduction. As it is, we accept a low level hiss in our work places as simply a ‘part of the job.’ At a price that is roughly comparable to that of domestic gas, this attitude costs industry dearly.

It is estimated by the U.S. Department of Energy that industrial energy usage is $1.5 billion per year; 20% to 30% of this amount is lost in air leaks. In addition to being a source of wasted energy, leaks can also contribute to other operating losses. Leaks cause pressure loss in systems, which can mean pressure is too low to the application leading to more reject product. Frequently the generation capacity is increased to compensate, rather than simply fixing the leaks.

Where to find leaks
Pipework—Aging pipework is a prime source of leaks. Replace any corroded pipework sections—for safety as well as energy saving.
Fittings, flanges and manifolds—Large leaks are often found at connection points, both in the main distribution system and in off takes. Sometimes when several snap connectors are used together to form manifolds they can be a source of leakage due to worn connectors and poorly jointed pipe work.
Flexible hoses and couplings—Leaks can be caused by damage to hose due to abrasion by surrounding objects, deterioration of the hose material and strain on the joint because the hose is too long or too short.
Old components not maintained; seals start to leak—Check all pneumatic components, e.g. old cylinders and regulators, for worn internal air seals which can cause large leaks.
Condensate drainage valves—Large amounts of air can be lost when drain valves are stuck open or even left open intentionally. These can often be found in remote parts of the system where condensate collects.
Systems left pressured when not in use—Where subsystems have a large amount of leakage, which cannot be avoided, e.g. presses and drop hammers, isolate them from the air supply when not in use. Simple shut-off valves or electrically operated soft start dump valves offer cost effective ways to isolate leaky systems, or areas of a plant when not in use.

Measuring the leakage
You can measure the base leakage easily using one of several methods. Install a flowmeter and pressure transducer in the compressed air feeding main (after any receivers). Connect the output of the flowmeter and the pressure transducer to a chart recorder and take readings over a representative period of time. Measure the flow from the compressor when the system is not working, e.g. at a weekend.

Use a compressor of known capacity to pump the system up to normal operating pressure during non-production hours. The compressor will unload at the operating pressure. As the system pressure drops due to leakage the compressor will load at its minimum running pressure. You can then estimate the leakage rate from the average loaded and unloaded times over a representative period.

Pump the system up to pressure and measure the time taken for the pressure to decay to the lower limit. If you know the total volume of the piping network and the receivers, you can calculate the leakage rate. Use a small flowmeter in branch lines to identify real problem areas.

Norgren Ltd.

Air is money—cutting pneumatics operating costs

Pneumatic installations frequently do not include any monitoring facilities—a serious error, as 79% of the costs of compressed air are accounted for by the electricity used for generation and preparation. Even if compressors, distribution systems, and pneumatic actuators are correctly dimensioned, leakage often causes losses of up to 600 lpm. What does it matter, it’s only air, users might think. But even a reduction of compressed air losses of 100 lpm saves up to $1,450 per year.

Potential for savings
However, users often fail to exploit this potential for savings due to lack of know-how. Furthermore, in many cases, the technical equipment necessary to localize losses is not available. Frequently, lack of time prevents the implementation of energy-saving measures. Festo Energy Saving Services can help to monitor and optimize compressed air consumption by simple means.

Reducing energy costs
As part of an efficient leak-management system, a specialist will check during operation the compressed air system in question for leaks and will record each leak together with all the associated technical data, such as details of the spare parts required. This documentation will then show all the required maintenance measures and list the long-term savings against the short-term repair costs.

Optimizing compressed air consumption
More and more industrial companies are using precise compressed air consumption data as the main criterion for the choice of new equipment. With a detailed compressed air consumption analysis, they can make savings of up to 50% more than with conventional methods. Even before commissioning, a compressed air consumption analysis can determine the precise compressed air consumption of an installation—both during normal operation and with machines at a standstill. It thus guarantees optimum dimensioning of the compressed air supply system and prevents unnecessary costs, which might be caused by an over-dimensioned compressed air distribution system.

Increasing service life
Any excesses or shortages in the compressed air quality, with regard, for example, to oil, water or dirt particles, will have a negative effect on the service life of the pneumatic components concerned, resulting increased energy and operating costs. The compressed air quality analysis offered by Festo Energy Saving Services measures the residual oil content and pressure dew point, identifies weaknesses and develops suggestions for improvements, for example filter changes at more frequent intervals. Optimized maintenance allows average savings of 35% to be achieved.

Saving compressed air
Ideally, savings measures should begin at the source of the compressed air, the compressors. An energy analysis of compressed air generation provides detailed consumption profiles for electricity and compressed air, together with data on pressure levels, better timing of compressor run times, and flexible operating scenarios. In this way it is possible to ensure optimum use of available compressor capacity. A measurement of compressed air delivery with machines at a standstill provides a mathematical indication of leakage losses and thus the possible savings in the compressed air system as a whole.

Energy monitoring
When an installation is optimized with Energy Saving Services, the aim is to avoid damage and breakdowns in advance. Festo offers various condition monitoring and diagnostic measures for this purpose. Through the continuous monitoring of critical components, it is possible to detect wear, pressure, and flow changes at an early stage and avoid the danger of machine downtime. If a breakdown nonetheless occurs, the diagnostic systems ensure that the cause of the trouble is quickly located.

Energy Monitoring GFDM is a complete system for the continuous monitoring of compressed air consumption and volumetric flow. Alternatively, installation operators can select a customer-specific condition monitoring system. Diagnostic systems are compiled from function modules in accordance with individual customers’ requirements. The available functions include not only consumption monitoring, but also time monitoring of actuators and valves, monitoring of vacuum applications, and detailed monitoring of actuators (e.g. force monitoring and fault detection).

Festo Corp.

 

New electronic vacuum switch has dual LCD display

Hingham, Mass.—Piab has introduced a new three-color display electronic vacuum switch for vacuum system monitoring and for saving energy.

The switch has a powerful three-color (red, orange, green) LCD display that makes it easy to read from a distance, preventing the need to be in close proximity to a moving robot or machine cell. The dual display shows both the set value and the actual value allowing for precise monitoring of the vacuum system.

Set up is easy with the easy control buttons as is the installation as mounting brackets are included. Seven different programmable units of vacuum are available and the switch features two selectable PNP outputs, NO or NC.

A “power save” mode provides up to a 30% savings in energy. Along with an adjustable hysteresis and dual outputs, this switch a perfect tool for an electronic controlled energy-savings system for an air operated vacuum generator.

Other features include a key-lock mode to prevent unauthorized or accidental changes. An adjustable response time feature (2.5 – 1500 ms) makes it easier to fine-tune programming of related sequences for the robot or machine. The switch is both CE approved and RoHs compliant.

Piab

 

AutomationDirect expands tubing and fittings offering in pneumatics line

AutomationDirect has added new models of tubing and fittings to its NITRA line of pneumatic components, as well as blow guns and aluminum manifolds.

Available in 100-and 250-ft lengths, NITRA 16mm polyurethane tubing has a shore A 98 hardness rating, provides tight outside diameter tolerance and has superior kink resistance. The ether-based tubing provides excellent hydrolysis, oil and cold resistance. Available in four colors, 16mm polyurethane tubing starts at $114. A variety of 16mm push-to-connect fittings are also available.

NITRA brass adapter fittings and plugs are available in 10 different styles to meet most pneumatic applications such as air, water, oil, oxygen, nitrogen, and argon. Machined from yellow brass bar stock or forging, the fittings withstand pressure up to 800 psi. Designed with NPT threaded connections, male and female connectors are available in 1/8-to 1/2-in. sizes, in either two-pack or five-pack quantities.

Also added are quick-disconnect fittings which allow easy changing of tools or hose connections. Plugs and couplers, in 1/4.in and 3/8-in. sizes, are available in Industrial Interchange manual or automatic and universal automatic styles. Male and female fittings are NPT threaded and withstand pressure up to 250 psi. Swivel fittings made of chrome-plated steel with maximum pressure of 145 psi are also available.

NITRA aluminum manifolds withstand maximum pressure up to 500 psi and are available in two styles. Round manifolds feature one 3/8-in. NPT threaded input and either two or three 1/4-in. NPT outputs. Rectangular manifolds have 1/2-in. NPT inputs on either end and have either three or five 1/4-in. NPT outputs. Manifold prices start at $6.75.

NITRA blowguns (or nozzles) are available in heavy-duty palm type with safety tip, pistol grips (aluminum and plastic models), pocket, and plastic grip with flexible nozzles in various lengths. The blowguns have a maximum input pressure of 120 psi and start at $4.25. Additional NITRA accessories include 1/2-in. thread sealant tape and a 2-in. tubing cutter.

AutomationDirect

Technology-neutral selection of electric and pneumatic drives

Users often make the choice of drive technology—pneumatic or electric—on the basis of experience alone. However, in order to identify the most energy-efficient customer solution in the field of automation, a technology-neutral comparison is required.

With the engineering software PositioningDrives, users require just a few key data in order to arrive at the right solution. Which electro-mechanical linear actuator best meets requirements? All that is needed is the input of position values, the payload and the installation position, and the software will suggest an optimized solution.

A common dimensioning process for mechanical drive and transmission components and motors prevents a duplication of safety factors, which would result in over-dimensioned electric drive systems and a waste of energy. Calculations have shown that with consistent use of Positioning Drives for dimensioning, energy costs can be reduced by up to 70%.

Correct dimensioning
A similar Festo dimensioning software program helps users select the right-sized pneumatic drive. Excessively large cylinders consume air unnecessarily, while cylinders that are too small need to be operated at the maximum permissible pressure. High system pressures waste money. Air consumption can also be reduced through the use of single-acting cylinders wherever possible.

When Festo dimensioning software is used for pneumatic dimensioning, simulations take the place of costly real-life testing of the entire pneumatic control chain. If a parameter is changed, the program automatically adapts all the other parameters. When users configure a pneumatic control chain, the program ensures that all the system components are the optimum size. This makes it possible to reduce pressure losses, pressure levels and tubing size. In the planning of the pneumatic system, short electric cables and compressed air lines help save energy.

A further factor in choosing a drive technology is that electrical systems can be overloaded for a short time only, while pneumatic systems can be overloaded over a longer period. It is therefore usually possible to use smaller sized components.

Festo Corp.