Наши опыт и знания для надежного производства. В последние годы производство аккумуляторов становится все более популярным, учитывая, что область их применения расширилась от небольших электронных устройств, таких как смартфоны и планшетные ПК, до гибридных и электрических транспортных средств, накопителей энергии большой емкости, а также роботизированных устройств, таких как дроны. Процесс поизводства аккумуляторов ставит перед заказчиками сложные задачи, поскольку требуется обеспечить высокий уровень безопасности, не забывая о экологических проблемах. Кроме того, гибкость и скорость, которые так нужны потребителям, помогут обеспечить оптимальное время выхода на рынок для такой стремительно растущей отрасли. Узнайте о наших ключевых решениях для производства аккумуляторов здесь>>

Wireless robotics: where less is definitely more. Ever yearned for a wireless communication system for your robotics? Fed up with cables and their associated breakages and disconnections? Want lower installation and maintenance costs? Well, wireless robotics is now a reality. In fact, it’s been here for some time, providing totally reliable, noise-resistant communication at a growing number of manufacturers that have adopted the completely unique Wireless Unit from SMC. To help anyone who is still hesitant about wireless communication technology, Juanjo Jubete, Wireless Unit Product Specialist, at SMC Spain, addresses a number of common concerns in this short Q&A.   By Juanjo Jubete, Wireless Unit Product Specialist, SMC Spain MARCH 2022 Q1. How can potential users overcome their fear of the unknown in terms of wireless reliability? A1. It’s a common misconception that wireless is not as reliable as wired, but how many wireless systems have we got functioning in our homes? Headsets, landline phone handsets, car keys and computer keyboards to list but a few. Wireless communication technology has become so robust that most of us take it for granted, so why not let our industrial systems take advantage too? In the seven years since the launch of our Wireless Unit, we’ve had no notable problems reported. It has even been standardised as reliable communication equipment at leading manufacturers in the automotive industry. Q2. What if my IT department is reluctant to accept the addition of new external wireless networks, thinking that they may conflict with internal network packets? A2. It’s important to note that our wireless equipment only sends information when necessary, not constantly, in very small network packets. Furthermore, the system incorporates FHSS (Frequency Hopping Spread Spectrum) technology, which has been widely proven for many years to work without problems in areas where several devices transmit information in the same bandwidth simultaneously. All of these factors help to ensure robust and reliable communication. Q3. Will wireless communication equipment perform stably and reliably in environments where there is a high level of electromagnetic noise, such as spot welding? A3. The origins of the product’s development are in the automotive sector, whose natural habitat is a sea of electromagnetic noise derived from motors, inverters, heaters, spot-welding equipment, RFIDs and so on. There’s no danger of the equipment being susceptible to failure due to electromagnetic noise. In fact, we know that it’s far more immune to noise than copper communication, almost behaving like fibre optics, but without the associated high costs and delicate care requirements. Q4. What are the optimal industrial applications for wireless communications technology? A4. Although suitable for all industrial sectors, most of the applications to date have been for robots and robot peripherals. The power packs found in systems such as robots and turntables subject the communication cables they carry to extreme twists and turns, eventually causing them to fatigue and break. The result is random system stoppages that often take extensive time to identify and repair, and which will ultimately reappear as they are endemic. With wireless, we can basically eliminate any cables that carry electrical control signals. Part positioning and orientation - Pick & Place - SMC´s EX600 Wireless Unit Q5. Can you set out the most important wireless benefits? A5. Adopting a wireless solution avoids unproductive stoppages derived from loose or broken communication cables or bad contacts. It also avoids failures caused by electromagnetic noise thanks to the better immunity of wireless communication. In addition, cost savings result as there is no longer any need for ultra-flexible cables, special swivel joints, highly protected connectors and so on. SMC´s Wireless Unit – EX600-W Series  

Pneumatic cylinders: drive energy efficiency by switching to 4 bar operating pressure. Climate change, sustainability and energy efficiency have never been so high on the political agenda. The UN’s recent Climate Change Conference (COP26) in Glasgow, UK brought the world’s political leaders, Non-Governmental Organisations (NGOs), businesses and scientists together with the aim of accelerating action towards the goals of the Paris Agreement on Climate Change. The question for those of us at the industrial machinery level, is how can we contribute? Today, I see a new generation of engineers keen on influencing the industrial world in a positive way, creating machines that attain new levels of energy efficiency to help protect the Earth for future generations.   By Séamus Dunne, Actuator Section Technical Manager, SMC European Technical Centre JANUARY 2022 By designing industrial machinery and systems for an operating pressure of 4 bar, rather than 7 bar, end users can cut their energy consumption by up to 29%. With such an enormous environmental benefit on offer, the question is how to turn this idea into reality? SMC’s Industry Projects Manager for Europe, Andy Still, has extensive experience in this area. Check out his article on energy efficiency: ‘Release the pressure’. Here at SMC, thinking about our energy-saving products, we offer both ISO and non-ISO cylinders; each has its own attributes and advantages. ISO cylinders prove beneficial in a variety of different applications which, in addition to their consistency in dimensions (regardless of pneumatic supplier), is why they remain popular for industrial machinery projects around the world. However, if you really want to push energy efficiency to new levels, I’d suggest that non-ISO solutions are the product of choice. Our engineers in Japan are always looking to design more efficient alternatives in order to drive down energy consumption and help OEMs create more sustainable solutions. We believe that more compact and lighter is the way forward for those seeking ultra-efficient solutions. Less material means lighter machines and lower shipping costs. Smaller products ultimately lead to smaller machine footprints. More machine lines can be installed into factories increasing productivity. And, although I can’t state that lighter and smaller always translates into less air consumption, fitting such components to moving parts of the machine can translate into less energy consumption. To give you an idea of the difference between ISO and non-ISO, here’s one example: compared with the SMC C96-C ISO cylinder (50 mm bore, 100 mm stroke), the length of our new JMB series demonstrates an 18% length reduction, while width is 9% less and weight is 39% lighter. Notably, it is possible to deliver air consumption savings through the use of intermediate bore sizes. For instance, to move a workpiece with a weight of 37 kg, a cylinder with a bore diameter of 43 mm or more is required (if operating at 5 bar pressure). Previously, a conventional 50 mm diameter bore would have been the closest option since the next smallest size, 40 mm, has insufficient output. However, with the newly released JMB cylinder in 45 mm diameter bore, sufficient output is available while also saving air due to a 0.4 L (ANR) reduction in air consumption compared with the 50 mm variant. SMC´s JMB Series – Offers intermediate bores Customers frequently tell me they want more compact cylinders that still offer optimal performance while also reducing energy requirements. Unfortunately, achieving these optimisations and the high levels of energy consumption savings that the climate crisis demands, is extremely difficult within the constraints of ISO 15552. Although we of course continue supporting customers with an extensive range of ISO cylinders and options, we’re advancing the development of other cylinder ranges - such as our JMB series - to satisfy market demand for more compact and energy-efficient products. We are at a time of critical decision-making for the entire planet. Let’s make the right choices. Additional graphical data Air consumption can be reduced by optimal size selection EXAMPLE In order to move a workpiece with a weight of 37 kg, a bore size of Ø 43 or more is required. Previously, a Ø 50 bore size would have been the closest option since the next smallest size, the Ø 40, has insufficient output. However, with the newly released bore size of Ø 45, sufficient output can be obtained while also saving air due to a 0.4 L (ANR) reduction in air consumption compared with the Ø 50.   ∗ Conditions/Supply pressure: 0.5 MPa, Load factor: 50 % Current bore size output NOTE 1 - Supply pressure: 0.5 MPa, Load factor: 50 % When the intermediary bore size of Ø 45 is used NOTE 1 - Supply pressure: 0.5 MPa, Load factor: 50 % AIR CONSUMPTION - Ø 50: 2.2 L (ANR) − Ø 45: 1.8 L (ANR) = 0.4 L (ANR) 18 % reduction Air cylinder and ISO 15552 Cylinder dimension & weight comparison Compared at ø63-200 mm stroke  For CO2 emissions reductions of our ISO cylinders versus their Non ISO alternatives, please check the Sustainable Management of CO2 catalogue here.

Energy efficiency: amplifying the benefits of working at 4 bar. Although most pneumatic machinery and equipment operates at 7 bar, I know from experience that taking steps to reduce the system’s operating pressure to 4 bar can enhance energy efficiency, cost savings and environmental credentials. After all, every company is usually looking to save something, be it money, air, CO2, or even the planet. Unfortunately, in the majority of cases, big savings do not happen overnight. Only by implementing small improvements step-by-step is it possible to bring about the overall gains desired. Here at SMC we have a simple yet highly effective product that can be one of those steps.   By Marek Strojil, Customised services, SMC Czech Republic JANUARY 2022 Our ZH-X185 air amplifier multiplies air blow/suction by 4 and 3 times respectively. The upshot is that you can save up to 70% in air consumption through the ability to reduce input pressure, without any compromise in results. In fact, the ZH-X185 outperforms alternative products from other suppliers in Europe, typically by around 20%. SMC´s Air Amplifier - Blow your air consumption away An air amplifier has many uses, such as blowing away machining chips and water droplets. In suction applications, the device can collect dust/powder when performing resin part marking, and transfer or relocate loose items such as pellets in material handling tasks. Our ZH-X185 is maintenance-free, easy-to-use and safe. Importantly, an air amplifier can provide the solution to a number of your every-day workshop challenges, such as where an existing device has insufficient blow, where high air consumption is proving costly, or where air flow is too slow. In instances such as these, I’m well aware of the temptation to simply turn up the pressure, but this of course comes at a price. The reality is that a cost-effective alternative exists wherever you require a bigger output: an air amplifier. Although this solution is often not considered, it should be, because it can bring about notable savings. It’s worth me pointing out that the ZH-X185 is also a good solution for use in potentially explosive (ATEX) environments, as the product is entirely air-driven (no electricity required). In fact, the only type of application not suitable for an air amplifier is where extremely clean air is necessary: the device uses surrounding air to amplify. In relation to their impact in reducing energy costs, you’ll be pleased to learn that air amplifiers are not expensive devices, as evidenced by a major brewery in Eastern Europe. The brewery’s bottling line was suffering from an inability to consistently adhere labels due to wet glass. However, by adopting our ZH-X185 it was possibly to blow dry the bottles sufficiently to allow proper label adhesion. Along with a much-improved process, I can report that ROI (return on investment) was achieved in just 7½ months thanks to annual savings in air consumption. The brewery is also enjoying improved safety and simplified maintenance. You’ll probably be aware that an alternative approach is to use a common air nozzle, which can sometimes be the right fit in applications where you require a high peak pressure. With an air amplifier, the output pressure is lower but the volume of air is higher to achieve a similar result. Most importantly of all, an air amplifier needs less pressure to achieve the same air flow, allowing you to reduce air consumption and enjoy the energy savings that come with generating less compressed air. In all cases, the optimal way forward is to seek the advice of one of our specialists here at SMC.

The technical challenge of sustainable packaging. The trend is clear, and there is no going back. Consumer environmental and sustainability concerns, in terms of plastic pollution and the rise of Circular Economy principles consciousness compel the packaging industry towards a more ethical packaging. This means using material easier to recycle like monolayer plastic or paper and reducing the quantity of material used. Moving towards sustainable packaging brings technical challenges to packaging machines. Furthermore, ensuring higher sustainability goes through higher efficiency. How? Keep on reading.   By Jorge Salgado, Food & Packaging Industry Manager, SMC Spain AUGUST 2021 By 2030 all plastic packaging within the EU will need to be recyclable or reusable. It will concern all kinds of packaging, for primary to secondary packaging, where paper-based materials are often utilized: plastic bottle blow moulding, rigid tray hot stamping, sealing with films or all kinds of bags with flexible material. Less material or new material, the problem is the same. Processes must be more accurate, better controlled, and easy to set-up. Multi-layer plastic in the spotlight as the main way to address plastic pollution Conventional multi-layer composite films are complex and expensive to recycle because of the need to separate the different film layers. Polymer-based multilayer packaging materials are commonly used in order to combine the respective performance of different polymers, the advantages that they bring to packaging are numerous. However, because of their poor recyclability, most multilayers are usually incinerated or landfilled, counteracting the efforts towards a circular economy. Additionally, many countries do not have the necessary recycling systems and processes in place to recycle complex laminates. By contrast, monomaterial films are fully recyclable as all layers are made of the same type of plastic. Concerning the manufacturing process, the transition from multilayer to monomaterial involves some changes. Today, operators have to manually adjust their process and to do some tests before launching the full batch. It must be mentioned that operators need a real know-how as there is no modelling tool enabling to set parameters (time, temperature, pressure…) according to the material property. Process modelling might even be impossible as materials will change from one batch to another. After all the objective is to recycle and re-use plastic, but composition changes as we mix different sources, sometimes directly on the factory floor, and because the more a plastic is recycled the more it will break its carbon chain and material properties. These settings are complex and time consuming and they may change from one batch to another according to the material, even for very similar productions! Another specific problem with monomaterials to consider is the required sealing technology, especially in high-speed range. Operators need to adjust parameters like sealing time, temperature or pressure. For a film, heat sealing has to be aligned precisely to prevent damage to the heat-sensitive outer layer while ensuring the sealing integrity of the inner layer.  What about paper-based solutions? Another superior sustainable alternative are the paper-based solutions. The higher eco-friendliness of this alternative lays mainly in the end-of-life perspective. Once in the environment, paper-based packaging can break down within months, but plastics can take decades or even centuries to degrade. Much of this finds its way into the sea. According to the European Environment Agency, 82% of the litter collected on European beaches is plastic, while only 2% is paper or cardboard Furthermore, the paper recycling rate across Europe already at about 80%. In term of process, sealing is of course also a challenge as it involves accurate adhesion technologies. The biggest problem might be however the cardboard particles which may generate failures and loss of performances.  Less plastic altogether The third trend in sustainable packaging involves packaging redesigning to reduce the quantity of material. Here manufacturing tolerances are smaller and precision, repeatability are essential. Summarizing, this switch to sustainable packaging will involve better precision and better control of the processes to anticipate problems. It will also require a speed-up in production changes. Moreover, meeting ethical packaging objectives, could end up generating an extra-cost of 30 or 40%. This is our proposal to counteract this challenge.  Think about OEE! Overall Equipment Effectiveness (OEE) is a very practical way to prepare and mitigate the challenges of the next decade. Manufacturing only good parts (quality), as fast as possible (performance) with no stop time (availability). Sustainable packaging will for sure put OEE on the ropes. It will increase all these production losses, as setting times are longer and product quality is harder to maintain. This issue will affect machine-builders, but also end-users who are often upgrading or revamping their machinery, instead of investing in a new production line. For example, if the sustainable packaging alternative is paper-based, this encloses pollution and related risk of failure, compromising product quality. For instance, it requires the installation of cylinders with lube retainer in order to maintain a grease film on the piston rod surface and to prevent entry of dust or other pollutants. These cylinders improve by 4 the number of operating cycles. We propose the use of vacuum systems with integrated in-line air filters and lock mechanism or transparent bowls. Furthermore, an adequate selection of the vacuum pad material can reduce line stops. A last alternative to ensure quality in paper dust environment is to switch to the cyclonic vacuum technology where a positive pressure is supplied to the ejector side of vacuum end-effector to eject powder. However, there are other non-sustainable-related-packing issues, associated with product quality that if addressed can increase OEE, and assist in alleviating the extra cost and hassle that the eco alternatives bring to the manufacturing process. Addressing overall product quality – some examples Start-up rejects Plastic wrap, foam packing, or labels cling and attract dust and dirt, causing misapplication or contamination to pharmaceutical and food packaging. Industrial ionizers are the primary tools for static elimination, neutralization, and control. They are available in bar, nozzle and fan types to better accommodate a variety of production spaces that have accumulated static electricity problematic to manufacturing processes.  Production rejects For plastic bottle blowing and sealing, temperature control is one of the key parameters enabling to maintain quality and to ease set-up time. SMC will provide with a full range of solutions to handle this when it is about cooling the plastic or the sealing after production. They can be controlled digitally. Increase performance with digital control The star solution for addressing performance are digital sensors and connected devices. We rely on a wide portfolio to digitalize all components, to ease production change over, reduce set-up time and that allow configurations to be saved. Sensors and switches that help to implement effective predictive maintenance and check the whole system performance in real time. Every detail counts to reduce downtimes and maintain operating parameters and thus precision and quality High quality sealing. Flow or pressure switch enabling real time monitoring to avoid unplanned maintenance and to guarantee actuators performance. Actuators with metal sealing featuring less wear offering maintenance free operations and stable performance.  Tubing can be improved with a CAD tool to minimize cable length and associated losses in pressure and precision. Additionally, colour tubing will ease installation and maintenance while reducing potential errors.  Before the marking, rotary units can be used for a perfect positioning and blow amplifiers to prepare the surface, offering great return on investment.  Standard magnetic switches which can be adapted to any of our actuators.  Speed controller, maintenance or settings can be done in a much faster way: forget about the screw to adjust the flow and use its user-friendly wheel for a clear display of the value.  Valves, SMC also provides valve systems which allows one valve to change without interrupting the operation of the valve island (hot swap).  On the top of this, practical training will enable operators to quickly solve simple problems. Plastic pollution is an issue to be addressed by all members of society. As consumers and as manufacturers we are sustainably conscious. However, this is going to involve many manufacturing challenges in the next 5 to 10 years. These challenges materialize in machine modifications, higher costs and production uncertainties, which as discussed, can be eased by addressing OEE. At SMC we rely on local packaging trained teams ready to support our customers in the transition to sustainable packaging.

Use robotics to take a firm grip on production flexibility. Once the preserve of high-volume operations at automotive plants, we’re today finding that robots are infiltrating all sectors of the commercial world. Even beyond traditional manufacturing, inspection and packaging operations, we see robots fulfilling tasks that extend from mining and space exploration, through to surgery and laboratory research, and even fruit picking. With such a vast repertoire of applications, the robots of today need one principal attribute: flexibility. Much of this flexibility comes courtesy of the end-of-arm tooling (gripper), which means there are many factors to bear in mind when selecting a gripper technology supplier, not least breadth of portfolio, proven customisation capabilities and high levels of customer support.   By Marcus Mazetti, Global Account Manager, SMC Sweden MARCH 2022 We all know that automobile factories have been running on automation for many years. This sector also remains a key driver of robotics sales worldwide. Aside from welding and painting, the automotive industry deploys robots for tasks that include assembly, trimming, cutting, part transfer and machine tending, to list but a few. Taking note of the progress made by automotive plants is a growing selection of other industries, including food, beverage, life science and agriculture, all of which are increasing their robot uptake in order to drive up productivity, efficiency, staff safety, product quality and revenue. In short, there is additional focus on making production lines more flexible and better able to efficiently achieve high-mix, lower-volume production in response to constantly evolving customer demands. Robot in a packaging application with wireless communication to ensure reliable serial communication and flexibility when changing the end-of-arm tool (EOAT) New industries drive demand According to a McKinsey report, 88% of businesses worldwide plan to introduce robotic automation into their infrastructure. With so many new industries driving sales, Mordor Intelligence reports that the global robotics market could reach $74.1 billion by 2026 (up from 27.73 billion in 2020), registering a CAGR of 17.45%. However, while the future looks bright for those in the robotics arena, we know from experience that there are certain prerequisites which underline success in sectors other than automotive. Whereas robots in the high-volume automotive arena typically perform a single task, flexibility is the key word for non-automotive robot applications. Here, users assign robots to different tasks that may change regularly. For those of you thinking that programming is an issue in high-mix, low-volume manufacturing environments, think again. Robot OEMs, cobot (collaborative robot) specialists and software companies are today providing solutions that ensure straightforward programming, to the point where even operators with little or no experience can generate motion paths in next to no time. AI and ML While we are all aware that robots perform repetitive tasks more efficiently than humans, there’s a new trend here: with AI (artificial intelligence) and ML (machine learning), robots are able to think, learn and draw accurate conclusions without the help of their human colleagues. It’s an exciting prospect for industry across the board, particularly when you consider that robots can support the shift to Industry 4.0/digitalisation, largely because they outperform traditional motion systems in complex tasks. For instance, while many machines on the shop floor feature full automation, handling tasks from the warehouse to final assembly and packaging are often unautomated due to the inherent complexities involved. Today, however, the latest robotic solutions are assisting continuous flow across the factory, potentially leading to the concept of ‘dark’ or lights-out manufacturing, with no or very few people controlling operations. Bespoke solutions With robots set to become a core resource at many types of factory, achieving flexibility is paramount for any tasks that involve handling or servicing. Here, around 50% of applications require finger and/or gripper modifications to suit customer requirements. For both robot users and manufacturers there are several objectives when it comes to product selection, including price-performance ratio, flexibility, ease of adoption and safety. However, end-of-arm gripper technology is a key factor for tasks such as materials handling, packaging, machine tending, assembly, quality control and surface finishing. Here at SMC we offer a full range of gripper solutions, including pneumatic, electrical, magnetic and vacuum, ensuring adaptability to all gripping needs. We can also supply FRL units, tubing, valves and serial communication, either using wireless or traditional wired technology, thus creating a turnkey solution for new robot installations or retrofit projects. We help robotics engineers tap into ‘languages’ with which they are likely unfamiliar, such as pneumatics, by helping to translate or interpret the requirements of air-driven motion control and the benefits it can bring. Our expert team can help explain everything from valve island technology and filtration, to air flow and system pressure. Even though SMC offers an extensive series of electric actuators, pneumatics remains our principal language, which is why increasing numbers of robot OEMs and manufacturing plants are requesting our help. Rapid tool changes To deliver flexibility, robots frequently need to use multiple different grippers, which is why fast and reliable tool-change technology is paramount. However, many solutions are expensive and carry some risk due to complex air/signal connections. For this reason, our team of design engineers here at SMC developed the MHF2-X7076A, a modular, low-profile air gripper with finger-change function. This automatic tool-change device for robots means users simply replace the end of the gripper (the finger) without any risk. The wiring and piping are bundled together in the body of the air gripper (robot side) to improve electrical contact during tool changes and reduce air leakage. SMC´s Air Gripper with Finger Changer Function – MHF2-X7076A Series As a further market differentiator, we offer wireless communication with the gripper to eliminate any risk of communication loss and stoppages. Our EX600-W wireless system means less cables and connectors, reduced installation and maintenance, and fewer breakages and disconnections to deliver totally reliable, noise-resistant communication. Robot users are increasingly adopting our fast-response EX600-W wireless system improve their OEE (overall equipment effectiveness), a key metric for any production or process operations.  SMC´s Wireless Unit – EX600-W Series Moving forward, our R&D team is working constantly on system modularity, driving up the speed of gripper changes and reducing the risk of stoppages. Your productivity and uptime are our top priorities. Around 50% of all robot grippers we currently produce are custom builds, highlighting our credibility as a capable and proven technology partner.

Решения SMC для промышленных роботов. Ваша правая рука. Люди и роботы работают в тесном взаимодействии: промышленные роботы управляют все большим и большим количеством производств, люди применяют свои навыки для стратегического мышления, изобретений и детальной проработки. Использование роботов в промышленном производстве имеет множество преимуществ. А тесное сотрудничество с нашими клиентами вдохновляет компанию SMC к нахождению и созданию таких решений, о возможности которых раньше не могли и подумать. Обладая соответствующим опытом, SMC может стать “вашей правой рукой” в области помышленных роботов. Наша международная команда специалистов всегда готова поддержать вас в решении повседневных задач, а наш технический центр разработает любое индивидуальное решение, которое может вам потребоваться. Ниже вы найдёте наши основные решения для роботов: коллаборативные, инновационные, компактные, лёгкие и надёжные. Простые и универсальные. Ознакомьтесь также с решениями SMC, которые могут оказать существенную поддержку в области сварки, окраски и перемещения. Кроме того, в вашем распоряжении - многообразие концевых захватов для коллаборативных роботов (коботов).

Modular media control saves time and cost in robotic welding. We all know that high-volume automotive applications such as welding have numerous demands, not least high productivity and reliability. Any failures or inconsistencies with the robotic solutions deployed in these processes can lead to costly production stoppages and expensive maintenance or repairs. For this reason, a growing number of robot OEMs are choosing to work with our team of expert engineers here at SMC, which can offer a highly effective and convenient modular solution for handing welding-specific media such as air, gases and water.   By Zdenek Velfl, Business Consultant, SMC Czech Republic MARCH 2022 Arc, laser and spot welding are all commonplace in the automotive sector, where media requirements for the robot can include compressed air, water and welding gases such as N2 or CO2. We are able to adapt each of our panel-based modular solutions to suit different configurations, controlling the pressure and flow of media in line with specific application demands. For instance, many welding tasks need pressure between 2 and 6 bar, and flow rate between 200 and 500 l/min. SMC´s Customised media control panel replica We help robotics engineers tap into the ‘language’ of pneumatics, helping to translate or interpret the requirements of air-driven motion control and the benefits it can bring. By way of example, what type of solenoid valve is required to meet the demands of specific robotic welding tasks? Perhaps the robot arm needs to move at different speeds during the welding process, so how is it best to reduce or increase the flow of media accordingly? Pneumatics is our language and we can help find the answers to these important questions and many more. By way of example, we’ve recently developed a pneumatic panel for a major robot OEM that is ideal for laser welding cells. The panel features separate compressed air and gas circuits to deliver precise welding control. We can ensure that the filtration and adjustment of compressed air and welding gas pressure provides repeatable quality of the finished product, which is of paramount importance in the high-scrutiny automotive industry. The panel houses a safety start-up valve for low-speed air supply that gradually raises initial pressure in the air system. This valve also facilitates quick exhaust by cutting off the air supply. Our modular media-handling solutions are also ideal for painting operations in the automotive industry, where quality is again essential. Typical media might include silicone-free products, which are popular in automotive applications as silicone has a detrimental effect on paint adhesion. Alongside precise control, adopting a modular media handling solution provides energy efficiency, with media delivery only taking place when needed via a proportional regulator. Safety is a further advantage as the integral valves ensure the whole system stops working if anyone steps inside the protective barrier. Electro-Pneumatic Regulator – ITV Series Residual Pressure Relief Valve ISO 13849-1 – VP544-X536 Series To make life easy for robot OEMs, we make sure that every panel comprises all the components necessary to provide a complete solution, including FRL units with residual pressure release valve and soft start-up function, as well as cooling water pipes (if needed), fittings, hoses and accessories. The robust design of the panels ensures their suitability for use in all welding and painting applications, where extremely demanding environmental operating conditions are prevalent.

A rebirth in the name of innovation. SMC, the world leader in pneumatic automation, and DMC Automation of Turin, which has created a robotic island equipped with SMC components, including an innovative wireless control transmission system, is a solid and stimulating technological partnership oriented towards the search for cutting-edge solutions. By Simona Recanatini   In Grugliasco, in the province of Turin, exactly in the same places where the automotive district that made the Piedmontese city famous throughout the world took shape a few decades ago, is based a company strongly projected on innovation. A challenging company that loves to try new ways and find new technological solutions to stand out and emerge in a highly competitive and complicated world like that of industrial automation today. DMC Automation, a small-to-medium-sized company that nevertheless boasts solid roots and a natural openness towards innovation, has recently moved to a new and modern location, which also marks the beginning of a new course. Let's take a step back: the history of the company began in 1972 with DNC, founded by Domenico De Caroli. In 1992 it began producing machines for the assembly of the metal structure that is in fact the 'skeleton' of car seats: it was a turning point as it marked the entry into a fundamental sector that is still one of the company's core businesses today. All the biggest car seat manufacturers, in fact, use machines supplied by the Turin-based company to make the internal structure of the seat. "We are specialized in the realization of machines for the assembly of this 'skeleton' starting from elements that are composed together and assembled to realize the supporting structure of the seat, an important piece because it allows to satisfy the main safety criteria" explains Carlo Amicilia, sales director of DMC Automation. In 2018, the owner of DNC decides to retire and is succeeded by two young entrepreneurs, Mauro Esposito and Daniele Signoretta, who take over the company and relaunch it, based on a more structured and modern organization. With the change of ownership also comes the transfer to the new headquarters in Grugliasco, a moment that for DMC takes on the symbolic role of the beginning of a new era. As a result of the new, more organised approach, ISO certification also arrives: being able to rely on procedures that follow precise standards is an important business card for DMC to show its customers. Simplify production Accelerating and simplifying the production process of different sectors using intelligent technologies is the philosophy with which DMC Automation approaches the market. "We want to work in the field of robotics and automation and we have an in-house design and manufacturing office for the machines and lines we produce. Everything we design is always pre-assembled and tested in-house and then delivered to the end customer," explains Amicilia. "Our production program is quite articulated: machines and assembly lines for the realization of metal structures of car seats but also robotized assembly and welding lines. Then there are machines and lines for assembly (with processes and technologies that allow to put the pieces together and make a finished product, which are coordinated thanks to SMC components), vision systems, material handling, testing equipment and above all machines and lines made to measure for the individual needs of our customers" explains the manager. An important partnership In order to meet the needs of its customers in a precise and timely manner, DMC relies on the support of leading partners. In this path of change that has just begun, the historical collaboration with SMC, world leader in the pneumatic automation sector, is even more important. Thanks to its expertise and constant technological innovation, the Turin-based company is able to respond to customers' requests but also to expand its field of action and approach new market niches. "SMC is a must for us, a fundamental partner and we consider their components a real standard, which facilitates us in the design and allows us to have a continuity of service, spare parts, product updates and much more" underlines Amicilia. "On the one hand, there is the certainty of the quality of their components, but we are also very satisfied with the close collaboration with their team of technicians and salespeople, with whom a real technological partnership has developed over time in both pre and post sales, which has led us to the use of new and cutting-edge products in terms of technological innovation. And this is also an important plus for our customers..." he adds. An innovative robotic island Among the machines produced in the DMC plant in Grugliasco stands out a robotized island equipped with SMC components, characterized by a control transmission system realized through wi-fi, a decidedly avant-garde innovation for the sector. Intended for a Turkish customer, it is a jewel in terms of innovation. "It is an automatic machine for the assembly and testing of a car's rear backrest locking system. It features manual loading stations with presence controls via cameras while all the assembly stations are automatic. There is also a robot for the 'transfer' from a first table to the testing table. Parts are marked and values stored on a PC for traceability. On this machine we decided to use the wireless solenoid valve system that allows us to have the I/Os on board the table without the use of the classic air-electric joint, which is subject to wear and tear, is not easy to maintain and requires a dedicated electrical cabinet that involves additional costs," explains Carmelo Todaro, Technical Office Manager. The heart of the machine consists of a series of electrical connections that are in contact via wi-fi with the central detector, which is able to manage them without contact. From phase to phase the table rotates and consequently all the groups rotate while the central pin remains fixed: every single element is therefore managed in wi-fi through SMC's innovative EX600W. Effective solutions "Many of our machines, including this robotic island, are made with rotary tables with different positions that transfer groups, subgroups or components from one workstation to another. One of the problems is the need to maintain control during movement: when moving, the table should carry electrical wires and controls. The jump on wi-fi that SMC proposed to us was really enlightening and epoch-making and allowed us to solve this problem effectively," Carmelo Todaro points out. The technological collaboration with SMC is full of new and innovative solutions. "The SMC flow switch, which monitors air consumption during machine operation, is useful for troubleshooting and monitoring the air consumption in the plant and thus evaluating energy savings. In another application, we used the SMC CKZT series air closures, which allowed us to clamp the entire diameter of the tube so that we could work evenly. Another important product that we use here in DMC are the SMC electric axes, especially the Ley series, which allows us flexibility in positioning and setting up the machine both to us during the pointing phase and to the customer in the various phases of process and part modification" concludes Todaro. Integration 4.0 A final note: all DMC machines are already designed to meet the requirements of Industry 4.0, an important plus for companies that are already oriented to a production management with sophisticated systems. "For us it is fundamental to rethink and develop new production, organizational and management processes. This is why our machines are designed to be integrated into our customers' centralized management systems. On this, a bitter reflection: p er absurd we are finding more application, from the point of view of the 4.0 philosophy, in the foreign market: our machines have all the interface modules but it is the international customers who use for example the ethernet cable to connect and manage the machines remotely, the Italians decidedly less. We currently have three lines in Morocco, Romania and Turkey, all three of which have software and IT dialogue modules to demonstrate how much these markets have grown from a technological point of view..." stresses the DMC sales manager. Published in Technè (Open Factory) October 2019, Italia, written by Simona Recanatini

What you should know about air preparation. Even though almost all factories have air preparation systems to protect their pneumatic equipment, the subject is still not so well known, and it hides some interesting aspects and optimization. One of the key questions is how prepared should my compressed air be? There is not one simple answer to this question, because compressed air quality depends on a myriad of variables, such as the air quality coming in (from the compressor), the air quality requirements in the end-of-line applications, the process or industry requirements or even the position of the filtration units. With all these uncertainties, SMC, an Expert in air treatment, will be able to support you.   By Mark Brinsley, Sales Engineering Group; Air and Fluid Equipment, SMC UK OCTOBER 2021 A prior triad to consider Compressed air quality is just one of the 3 issues to consider: Dust and other airborne particles – The compressed air leaving the compressor room, which has already passed through a filter, still contains particles. If the air quality is too poor, it can ruin even the best actuators in just a few months, not to mention what it could do to sensitive end equipment such as flow sensors. The compressed air, if not treated, will contain varying levels of particles which will affect your production processes: the consequence will be generation of particle deposits leading to mechanical friction, e.g. between the cylinder wall and the piston seal. Water droplets or large potential for condensation – This ends up generating corrosion of parts and rust particles that can cause mechanical damage or block small flow cross sections. Moisture can also cause seals to swell resulting in additional friction in actuators. Other issues that might occur are: spray painting by change in color, adherence and finish quality industrial ink-jet printers in adherence and finish quality blow molding plastic bottles’ viscosity and material consistency gluing/taping adhesiveness of cardboard boxes pharmaceuticals compound mixing and integrity food processing contamination because of micro-organism growth air purge or air cooling where moisture will cause problems Oil mist carryover or odour from a compressor: consequences are particle clumping leading to blocked cross sections. Additionally, oil can cause some elastomers such as those in the seals to swell up. In summary, inadequate air preparation causes higher maintenance costs, operating malfunctions, reduces service life and creates higher energy costs due to leakages. The kind of issues all of us want to avoid. Optimized filtration system – The players involved to remove impurities in your compressed air Depending on the impurities you need to remove, you will need to install different elements. When we talk about air preparation, we tend to think it just refers to filters, but having an optimized filtration system goes beyond that. Air preparation is not just about filters. It should be considered as a whole system: Filters to remove the dust and particles are included in the Air Combination unit made of an air filter, a mist separator, a micro mist separator and an odour removal filter. SMC offers a complete range with a uniform design: air preparation equipment to meet the highest levels of air quality through multistage filtration from basic particle removal (AF series), mist separators (AFM / AFD), activated carbon filters (AMK) to bacterial removal (SFDA). Regulation of the supply pressure is carried out by regulators or filter / regulators. They provide a controlled set pressure with precision regulators being able to hold a set pressure with a reduced impact from flow rates and supply pressure influence. Without local regulation, the supply air pressure from the compressor could be considered wasteful in terms of energy efficiency, as well as potentially dangerous by allowing higher forces from actuators. There may also be plenty of situations where the higher pressure is too much for the local pneumatic equipment. To improve moisture removal a membrane filter can be added to the FRL unit. It might be considered in circumstances where factory piping is exposed to ambient temperatures lower than the dew point achievable by refrigerated drying. Additionally, other components which help to control the operation: Electronic proportional regulators (allowing signalled controlled set pressures useful for stand by pressure reduction) Air flow switches with integrated temperature sensing (to establish “normal” consumption rates and to trigger the sensor if those conditions change for example, in the event of a leak developing. Monitored air dump valves (for safety circuits) Integrated pressure detection (checking if pressures are too high or low) or Slow pressure build up control (to prevent problems of sudden actuator start up) Once your compressed air supply is adequately conditioned - and it should be monitored - your equipment will be safeguarded. Condition monitoring can also make it easy to plan routine maintenance to ensure efficient operation. Pressure switch and flow sensors will help to identify when maintenance should be carried out on a filter, such as emptying dust collectors. Refrigerated air dryers to remove moisture. They should be protected by a main line filter. A refrigerated dryer will further cool the compressed air by removing heat at its inlet side and lowering its temperature dew point down to 3ºC, then expelling the condensation through an automatic condensation drain. The dryer will then reheat the dried compressed air back to ambient temperature by recycling the previously removed heat using a heat exchange process. This reheating of the compressed air to an ambient temperature will eliminate “sweating” on cold pipes when working in humid factory conditions. Additionally, water separators are an important option. They use mechanical separation techniques to remove condensed water in bulk from factory air either by directing inlet air into a spiral and using centrifugal force to separate the water out from the compressed air, or by passing the inlet air through a special resin filter with large meshes to trap water particles that will then drop down to a collection bowl, allowing the compressed air to pass through. SMC’s new AFF series of water separator that combine water removal AND filtration of particles IN A SINGLE FILTER, is capable of removing water droplets up to a 99% water removal rate, using a special resin filter to trap water droplets. However, a water separator is designed to remove water, but it doesn’t lower the dew point which is usually done by a refrigerated air dryer. If it is not enough, you may use a membrane filter to reduce the dew point at the point of use. Do not over specify Assessing the acceptable level of dust, moistness and other potential contaminants will be defined according to the application and the numerous issues that may occur. For sensitive equipment, the ISO standard 8375-1 will help to define the suitable numeric grading for particles and oil content. In simple terms, the lower the number for each category, the cleaner the compressed air. Air preparation equipment has improved over the last few decades, minimizing the flow loss in the circuit thanks to optimization of the internal valve construction. However, Compressed air quantity (Flow) needs to be considered to ensure you can meet the flow requirements of your equipment. This means that the components in the compressed air circuit must be suitably sized based on your flow requirements. Too small and it would be inefficient and you would see a larger drop in pressure, too big and it would be a waste of money. Clearly, compressed air pressure should be considered when selecting your model, ensuring all components operate for your required pressure in the system. Optimised operating pressure increases efficiency; efficiency is increased by running equipment at lower pressures, thus reducing the amount of compressed air lost in leaks. If you lower the operating pressure of your equipment then you could also reduce demand from the compressor and save power consumption. It is vital to consider pressure and flow when properly sizing filtration components in your search for an efficient air quality solution. It is very important NOT TO OVER SPECIFY the cleanliness of compressed air. Unnecessarily over filtering can increase potential pressure drops, can make a compressed air system less efficient and can lead to exorbitant energy bills. A vital final step – cartridge cleansing> Why do you normally empty your vacuum cleaner every now and then? Because it loses power. The same happens with your filtration units. When the cartridge is full performance is reduced, generating pressure drops; significant pressure drops result in poor machine functioning which in many cases leads to turning up the regulator. So, cleaning the cartridge, in the same way we clean our vacuum cleaner every now and then is simpler than turning up the pressure, which can be costly and inefficient.  To conclude, it is a fact that the air let out by the compressor contains impurities. If the air is not treated according to the necessities of your process, those impurities will end up contaminating the final output. Different applications require different level of filtration and overall air treatment. Count on SMC Experts to find the best air treatment for your compressed air system.