Automation for tomorrow: digital and green

After two years of decline, more industrial robots went into service in Europe again 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. Demand in the metal and machinery (+50%) and plastics and chemical products (+30%) sectors increased 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: the call for climate neutrality is challenging developers of automation solutions to combine digital and green change.

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. "We have to differentiate between the_{CO2 package} in which we send our product to the customer and the emissions that arise during use," says Dr. Maik Fiedler, Head of Vacuum Automation and Vacuum Handling at J. Schmalz. To keep the package as small as possible, Schmalz relies on short procurement routes - 50 percent of its suppliers come from within Germany - 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 developing systems that are completely independent of compressed air.

Performance on a par 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 are developing 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, an accumulator 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 purely electrical solution, which is on a par with pneumatic systems, Fiedler has 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 liters per minute," emphasizes 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 integrated a sensor - it monitors and controls the vacuum and the process directly on the gripper. "This is how we harmonize sustainability with the digital transformation," says Fiedler.