Comprehensive Application-Based Analysis of Energy-Saving Measures in Pneumatics

Authors

  • Vladimir Boyko Chair of Fluid-Mechatronic Systems (Fluidtronics) – TUD Dresden University of Technology, Helmholtzstraße 7a, 01069 Dresden, Germany https://orcid.org/0009-0008-7446-1121
  • Fedor Nazarov Chair of Fluid-Mechatronic Systems (Fluidtronics) – TUD Dresden University of Technology, Helmholtzstraße 7a, 01069 Dresden, Germany
  • Wolfgang Gauchel Festo SE & Co. KG, Ruiter Straße 82, 73734 Esslingen, Germany
  • Rüdiger Neumann Festo SE & Co. KG, Ruiter Straße 82, 73734 Esslingen, Germany
  • Matthias Doll Festo SE & Co. KG, Ruiter Straße 82, 73734 Esslingen, Germany
  • Jürgen Weber Chair of Fluid-Mechatronic Systems (Fluidtronics) – TUD Dresden University of Technology, Helmholtzstraße 7a, 01069 Dresden, Germany

DOI:

https://doi.org/10.13052/ijfp1439-9776.2512

Keywords:

Energy efficiency, Pneumatics, compressed air systems, dimensioning, sizing, energy-saving circuit

Abstract

The current economic and ecological situation emphasizes the importance of energy efficiency for the industry. Widely applied pneumatic systems are particularly affected by this issue because of their comparatively high energy consumption. To increase the efficiency of pneumatics, numerous energy-saving components and circuits have been developed over the last decades. However, the applicability of these measures for different load cases, their impact on the drive performance, and real economic benefit often remain unclear for the end-user. In this paper, the applicability of the energy-saving measures for typical load cases was analysed on example of two pneumatic cylinders (32 and 50 mm bore) based on their technical performance, energy consumption, and costs. The evidence brought by this experimentally verified research can help one to make a correct decision about configuration of a new pneumatic drive or retrofitting an existing system regarding the costs, efficiency, and application specifics. All studied energy-saving measures were compared to a well-sized meter-out controlled reference drive. It is shown that considerable energy savings without performance loss of a well-sized cylinder are achievable only by means of sophisticated cylinder control. In contrast, simple non-electronic components are mostly convenient only for the retrofitting of an oversized cylinder.

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Author Biographies

Vladimir Boyko, Chair of Fluid-Mechatronic Systems (Fluidtronics) – TUD Dresden University of Technology, Helmholtzstraße 7a, 01069 Dresden, Germany

Vladimir Boyko holds a M.Eng. degree in Mechanical Engineering from the University of Applied Sciences Jena, Germany. Since 2018 he has been working as a research assistant at the Chair of Fluid-Mechatronic Systems (Fluidtronics), Institute of Mechatronic Engineering, TUD Dresden University of Technology, Germany. His current research fields include pneumatics and energy efficiency.

Fedor Nazarov, Chair of Fluid-Mechatronic Systems (Fluidtronics) – TUD Dresden University of Technology, Helmholtzstraße 7a, 01069 Dresden, Germany

Fedor Nazarov received the bachelor’s and master’s degrees in hydraulic, pneumatic, and vacuum system engineering from the South Ural State University in 2014 and 2016 respectively. Since early 2017 to this day, he is working as a research assistant at the Chair of Fluid-Mechatronic Systems (Fluidtronics), Institute of Mechatronic Engineering, TUD Dresden University of Technology. His research areas include simulation and optimisation of pneumatic systems and their components with regard to energy efficiency and performance.

Wolfgang Gauchel, Festo SE & Co. KG, Ruiter Straße 82, 73734 Esslingen, Germany

Wolfgang Gauchel completed his mechanical engineering studies at RWTH Aachen with a diploma in 2001. After that he worked as a research assistant at the Institute of Fluid Power Drives and Controls (IFAS) at RWTH Aachen, where he finished his PhD in 2006 in the field of servopneumatic gripping technology. After that he started his industrial career in the research department of Festo Se & Co. KG in Esslingen, Germany. Alongside his work, he studied economics at the Fernuni Hagen and received the bachelor’s degree in 2012. Currently he is Head of Research Circular Economy and Efficiency.

Rüdiger Neumann, Festo SE & Co. KG, Ruiter Straße 82, 73734 Esslingen, Germany

Rüdiger Neumann has studied mechanical engineering in Paderborn and Nottingham and got his diploma in 1986. After working as a research associate at the University of Paderborn and Ulm he received his PhD in 1995. Since 1996 he works as an engineer of automation and control in the research department of the Festo SE & Co. KG, where he is now head of the department for Robotics and Control. His key activities are the control of pneumatic and electrical servo drives, as well as control of multi axes systems and robots.

Matthias Doll, Festo SE & Co. KG, Ruiter Straße 82, 73734 Esslingen, Germany

Matthias Doll received his diploma degree in engineering cybernetics from the University of Stuttgart, Stuttgart, Germany, in 2009. After that he has been a research assistant at the Institute for System Dynamics (ISYS) at the University of Stuttgart and received his PhD in 2016. Since 2012, he is a research engineer at Festo SE & Co. KG, Esslingen, Germany. His main research interests include modelling and control of pneumatic drive systems with a focus on energy efficiency.

Jürgen Weber, Chair of Fluid-Mechatronic Systems (Fluidtronics) – TUD Dresden University of Technology, Helmholtzstraße 7a, 01069 Dresden, Germany

Jürgen Weber has been appointed in 2010 as a University Professor and the Chair of Fluid-Mechatronic Systems as well as the Director of the Institute of Fluid Power at the TUD Dresden University of Technology, Germany, and took on the leadership of Institute of Mechatronic Engineering in 2018. He finished his doctorate in 1991 and was an active Senior Engineer at the former Chair of Hydraulics and Pneumatics until 1997. This was followed by a 13-year industrial phase. Besides his occupation as the Head of the Department Hydraulics and Design Manager for Mobile and Tracked Excavators, starting in 2002, he took on responsibility for the hydraulics in construction machinery at CNH Worldwide. From 2006 onwards, he was the Global Head of Architecture for hydraulic drive and control systems, system integration and advance development CNH construction machinery.

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Published

2024-07-04

How to Cite

Boyko, V. ., Nazarov, F. ., Gauchel, W. ., Neumann, R. ., Doll, M. ., & Weber, J. . (2024). Comprehensive Application-Based Analysis of Energy-Saving Measures in Pneumatics. International Journal of Fluid Power, 25(01), 27–58. https://doi.org/10.13052/ijfp1439-9776.2512

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