Give your vacuum handling system a boost

We all know that the most important aspects of a vacuum system are the application and system layout. This usually involves the method of vacuum generation and thus whether you use ejectors or pumps to generate the vacuum and move workpieces. But there are many more important system components that, if overlooked, can cause your vacuum unit to not perform optimally.

Smart solutions

There are several smart vacuum solutions, such as smart valve islands that use real-time control via serial communication. This allows you to control your components via integration with a PLC and more easily introduce condition monitoring and predictive maintenance strategies. Other benefits include remote control of the vacuum ejector, vacuum generation on demand (depending on the preset vacuum level to be maintained) and vacuum flow interruption, which increases the speed of your vacuum application.

An appropriate solution

A vacuum handling system also benefits from correctly specified couplings. Initially, you should always check that pneumatic couplings can operate under negative pressure to avoid ruptures and leaks and ensure that the system works perfectly. The couplings chosen should also allow for the necessary flow without major pressure losses. Based on these considerations, you should choose couplings with a sealing contour that lies against the hose surface such that it seals regardless of whether you use negative or positive pressure. So the seal design of the coupling has an influence. Another good tip is short tubing to reduce cost, risk of leakage and cycle time.

The filtration factor

Filtration is another important system aspect to reduce maintenance time and costs, as it helps to maintain the vacuum system. It is also advisable to install filtration units inside the ejector, between the vacuum suction cap and the ejector, to prevent dust and powder particles from entering the system during the adsorption process. Ingress of contaminants can clog or damage your ejectors, jeopardizing the life of the system.

Centralized or decentralized?

Further, engineers should consider the discussion regarding centralized or decentralized systems. A centralized vacuum system consists of one ejector or vacuum pump for multiple suction cups, usually mounted on the robotic arm and connected to the suction cups via hoses. This type of system is a common solution that can be easily integrated and installed.

In decentralized systems, one ejector operates one vacuum suction cup, usually directly at the suction cup. The typical vacuum source is an ejector that generates vacuum by passing compressed air through a venturi nozzle. An attractive option is an integrated vacuum suction cup/ejector solution. For example, a two-stage SMC ejector increases flow rate to 50% and reduces compressed air consumption to 30%. Above all, the design of these compact units allows series connection, while mounting with locking rings simplifies maintenance, as fewer steps are required to replace the suction cup.

Decentralized systems are also easy to integrate and install. They are often preferred in vacuum handling applications where you do not need to use too many vacuum suction cups, as they can increase productivity through faster response times. At the same time, decentralized systems increase safety by using multiple vacuum circuits to move a single workpiece, since one dedicated ejector controls each individual suction cup. If one vacuum circuit fails, the other vacuum systems that remain operational secure the workpiece.

Vacuum-saving valves

This aspect is often overlooked, but can greatly optimize your vacuum systems. In applications where vacuum ejectors drive multiple suction cups, some of which do not hold the workpiece, a vacuum saving valve limits the decreasing vacuum pressure so that the workpiece is held by the remaining suction cups.

Another advantage of using a vacuum-saving valve is that it eliminates the need to change tools when changing a workpiece. This saves time and simplifies the control circuit.

Size matters

When we talk about optimization, we must also talk about dimensions. Small and light components not only provide direct cycle time benefits, but also make it possible to build more compact machines with lower weight and subsequently lower costs. Smaller components fit into narrow spaces. This responds to more and more machine and robot manufacturers who find that customers need more compact solutions. 

In all cases SMC a total solutions provider and we can advise you on all aspects of your vacuum handling system and address them to optimize performance, cost, energy efficiency and reliability. Find out how our vacuum range takes your system to the next level.