It is impossible to say whether an electric or pneumatic solution is more efficient, as the correct approach always depends on individual case studies, says industrial control and automation company Festo business development manager Russell Schwulst, who suggests a sensible mixture of the two technologies, taking into consideration energy efficiency and the application in question.

Schwulst maintains that hybrid solutions are often an efficient alternative to using only electric or pneumatic technologies, as a hybrid solution combines the best features of both technologies.

He adds that, while several pneumatic-driven factories have been required to move to electric automation, this does not mean that pneumatic solutions are becoming obsolete. Rather, innovative, amalgamated solutions enhance productivity, increase production output and are cost effective. Both technologies provide different advantages and, by harnessing the advantages of both pneumatic and electric drives, factories can reap the benefits.

Citing the typical application of a packaging machine, Schwulst describes a conveyor belt, which accepts a product and sets it down on a second conveyor belt with an outer packaging. This requires two motions: an X-axis motion with a maximum stroke of about 1 000 mm, and a Z-axis motion with a stroke of about 100 mm.

“Consider the three options available to the user to power these motions: pneumatic, electric or pneumatic-electric drives. A mixed solution with an electric X-axis and a pneumatic Z-axis offers an optimal combination of efficiency, cost, flexibility and performance, since it allows both types of drive to play to their strengths.” For example, the electric X-axis offers highly dynamic operation and flexibility, while the pneumatic Z-axis is distinguished by its compact size and low weight.

There are several schools of thought on pneumatic versus electric technology for automation requirements and Festo’s strength lies in the fact that the company offers both technologies.

“We can provide expert technology-neutral advice, which provides users with a view of the alternatives, owing to the fact that we have knowledge and experience of both electrical and pneumatic solutions.”

Meanwhile, in recent years, ecological factors have become more and more important to customers. However, the question of costs cannot be ignored. Schwulst feels that it is advisable to keep an eye on both these aspects. It is important to focus on not only the initial buying costs but also overall and environmental costs.

Product developers need to consider several criteria in almost every technological decision. “Ultimately, this decision involves a process in which an optimal solution must be found on the basis of specific parameters, without falling back on generalised statements,” says Schwulst.

Latest Pneumatic Trends
“The premise of pneumatics cannot change. It is like a ball – if you change its shape, it is no longer a ball. While the wheel isn’t being reinvented, certain trends are geared towards shaping the industry in 2015,” says Schwulst.

highlights three more pneumatic trends currently prevalent in the industry, including self-adjusting air cushioning, the demand for end-to-end solutions and automated performance feedback.

Innovative Air Cushioning
In previous years, a technician was required to manually set an actuator’s cushioning using a screwdriver. Depending on how many actuators are installed, this can be a time-consuming and
unproductive process and improperly adjusted cushioning can cause substantial wear and damage to a machine. Pneumatic drives are, therefore, using self-adjusting cushioning – a completely dynamic process that happens in real time. The mechanism is capable of adjusting itself to the various loads and speeds of the application, thereby creating optimal and reliable performance, as well as a longer service life.

Complete Solutions
Nowadays, there is a growing demand for a complete end-to-end solution from a reputable manufacturer. Multisource buys are still possible, but upfront investments can also prove to be worthwhile owing to the problems alleviated by it.

Both the International Organisation for Standardisation’s standards and increasing legal requirements have provided businesses with the insight into the value of a single level of quality and standard across all components. In the past, factories featured an array of manufacturers, which resulted in fluctuating quality levels and a varying life span of the system. The increasing cost of labour and the expense of downtime, however, has showed the importance of the accountability gained from a single supplier.

Rate of Production
Measuring production flow and identifying problematic areas show exactly where opportunities lie for cutting costs, as well as where these opportunities are lost. Pneumatic technology has evolved to a point where pneumatic products are more productive and can provide critical feedback about the status of a machine. Flow and pressure sensors are examples of devices that can indicate a potential or current problem. They even point out where these faults lie.