Product simplicity, flexibility, adaptability, modularity and connectivity have to be coupled with easy integration of the product into existing factory-wide communication systems.

In addition to the perennial demand from OEM machine builders for more performance from a smaller product envelope, the current 'holy grail' is Lowest Installed Cost. In today's global manufacturing environment competitiveness is paramount. Lowest installed cost helps OEMs to achieve competitiveness by providing reductions in cabling, both on the product and in the control cubicle, and (commensurate) reductions in materials, labour and commissioning costs.

Contributing factors - and essential customer prerequisites - which make a big difference to lowest installed cost are product simplicity, flexibility, adaptability, modularity (or multi-functionality) and connectivity - the facility for easy integration of the product into existing factory-wide communication systems (fieldbus).

Added to these must the traditional demands made upon any equipment supplier for excellent reliability and long life.

ASCO Joucomatic's MEGA valve islands and VCS (Valve Connection System) have been introduced to meet all of these demands.

A new concept in valve design, the MEGA spool valve islands, offer the OEM and user total flexibility in their construction, mounting and the type of control that they perform.

The MEGA's modular construction requires no tools for assembly yet enables almost any configuration of valves to assembled, enabling all OEM control needs to met from a single manifold platform - which itself is compatible with standard fieldbuses such as Profibus-DP, Interbus-S and DeviceNet.

In terms of improved performance from a smaller product envelope, the reduced size, modularity, low weight, high flow rate (900 litre/min) and connection via 6mm or 8mm instant fittings, of the MEGA valve islands make them the ideal product for installations where compactness and high performance are essential requirements.

Importantly, the user saves much time and effort as assembly of the MEGA islands is achieved without tools, the different elements are simply clipped onto connecting rods.

The effectiveness of this procedure can be judged from the fact that it takes less than 20 seconds to mount a spool valve on a MEGA island.

Moreover, once complete, the assembly, because it is IP65 rated, can be mounted directly onto what it is controlling, reducing the size of an installation, or mounted conveniently in a control panel on industry standard DIN rails.

Comprising up to a maximum of sixteen monostable or bistable valves the MEGA valves are equipped with space saving, low wattage (1.5Watts) push/pull coils, which require the minimum of cabling and connection time.

Finally they offer the OEM and machine builder unmatched connection flexibility with an industry leading range of connection options including Classic connector, Multipol single wire, AS network interface and the new intelligent VCS - Valve Connection System, which is compatible with standard communication protocols, such as Profibus-DP, Interbus-S and DeviceNet.

The poet John Donne wrote: 'no man is an island', an assertion that today could easily translate into pneumatic and process systems.

Integration is the keyword, the synergy of electronic, pneumatic and fluid control.

In achieving integration ease and speed of connectivity are two of the primary factors.

These have been realised with ASCO Joucomatic's new unique VCS (Valve Connection System) a new system for connecting up to 127 valves (pneumatic, hydraulic, general purpose, water, gas and, oil), and up to 254 sensors, to a centralised controller over distances of 2.5km.

With its single flat cable and quick connector, the VCS system can be installed in seconds (even on previously installed valves) without tools and without the need for cable stripping and fastening.

Each VCS connector is simply clamped, via a vampire type plug, onto the 2-wire profiled VCS cable, establishing automatic connection.

This reduces cabling costs and installation time to an absolute minimum.

The flexibility of the VCS system means that valves can be added or retrofitted to the VCS control loop at any time.

In addition to posing no physical installation problems, this procedure creates no control problems either, as the loop structure provides for automatic addressing - each valve being automatically recognised by its position in the loop.

Data for each participant in the loop is transmitted over the VCS cable in the form of a differential signal.

A complete data cycle is processed within approximately 3 milliseconds via the protocol and 127 connectors.

The 'brain' of the VCS system is an intelligent interface, which acts as a communication centre for a PLC, a fieldbus and up to 127 VCS connectors.

In accordance with the fieldbus system used, the VCS interface is equipped with a corresponding fieldbus module.

Push-in connection of pneumatic tube fittings provides a secure leak free joint in moments. Disconnection is equally straightforward, allowing simple reconfiguration of pneumatic circuits.

Hoerbiger-Origa has added the Pisco T-series range of pneumatic tube fittings and speed controllers to its Express Service for rapid delivery and also made them available via the on-line ordering page of its UK website. Hoerbiger-Origa and Pisco have had a successful partnership going back many years. 'We are Pisco's UK and Eire agent,' says Ray Barnes of Hoerbiger-Origa, 'and have always enjoyed an especially closed relationship with their staff, the company is extremely responsive to local market needs and their high standards of quality and customer service reflect those of Hoerbiger-Origa ' The push-in connection of Pisco fittings provides a secure leak free joint in moments.

Disconnection is equally straightforward, allowing simple reconfiguration of the pneumatic circuits in which they are used, a feature increasingly in demand as industry becomes more flexible and responsive to changes in market requirements.

The T-series fittings come in many formats, including straight, elbow, long elbow, universal elbow, T-junction and duplex splitter.

They are available in a wide variety of tube and thread sizes, including metric and imperial options, and can operate with both positive and vacuum pressure.

Although primarily intended for use in pneumatic or vacuum installations, they can all be used with water and other non-aggressive fluids.

Extreme environment versions are also available for use in marine and other demanding applications.

Pisco T-series fittings are complemented by a range of speed controllers for controlling the extension rate of pneumatic cylinders and other air driven actuators.

Precision made components and accurate assembly means the controllers can be used to tune speed to a very high level of tolerance and ensure a long a trouble free service life.

Combining functionality with performance the smart cylinder features an integrated valve, its own sensors, flow regulators, adjustable cushioning and ASI Bus or Mulitpole fieldbus connections.

Combining functionality with performance the smart cylinder from Norgren delivers a wealth of benefits to the machine design engineer. Ideal for use in most machine building applications, the smart cylinder is fully compliant to ISO 6431 and VDMA 24562 standards within the VDMA envelope. Featuring an integrated valve and offering a wealth of functionality the smart cylinder contains its own sensors, flow regulators, adjustable cushioning, integrated 5/2 or 5/3 valve and ASI Bus or Mulitpole fieldbus connections inside the casing.

The actuator is fully interchangeable with other VDMA actuators across the complete range from 32 - 100mm bore.

Employing the integrated valve technique allows the smart cylinder to benefit from enhanced response times.

Achieving a top speed of 1.5 metres per second the smart cylinder is available in stroke lengths of up to one metre.

Offering fast and simple installation the smart cylinder requires one electrical and one pneumatic connection thus wiring costs are reduced and machine design times are cut.

The Smart Cylinder brings simplification and therefore cost savings.

Instant savings of approximately 25 per cent are achieved by buying the one unit compared to buying all the components separately.

It can also increase up time by dramatically reducing maintenance needs.

Maintenance engineers know immediately which actuator to change and can quickly and easily replace the smart cylinder, due to the simple installation, without the need to carry out complicated troubleshooting routines.

This can save serious money by slashing downtime.

Other user benefits include diagnostics via the fieldbus system, which tell the operator whether the cylinder is functioning normally.

Data is fed back to the operator which shows if the unit has stopped functioning correctly, if there is maintenance required and shows exactly which unit on the machine has failed and therefore needs to be replaced.

Unlike conventional pneumatic spool valves that do not lend themselves to dusty, humid environments and become easily contaminated and damaged, poppet valves operate in such aggressive conditions.

Unlike conventional pneumatic spool valves that do not lend themselves to dusty, humid environments and become easily contaminated and damaged, KV's new poppet valves have been specifically designed to operate in such aggressive conditions. Termed 'The Rhino' series for their durability and performance under the harshest working conditions, the Rhino is available as air or solenoid actuated with 3/2 and 5/2 versions having G1/8in and G1/4in inputs, and for body porting or manifold mounting. The valves are also available with a 2 to 6 station manifold option and are supplied complete with valve mounting screws and seals.

Interchangeability with another leading poppet valve on the market is an additional benefit of the new range.

The Rhino's durability and performance is achieved through its rugged metal construction and the use of a seating poppet principle which provides the valve with few moving parts resulting in the benefits of low stiction and low wear thus prolonging product life.

The Rhino valve operates with a filtration level of just 100 micron compared to a normal spool valve requiring a 40æm filtration level and, in keeping with the majority of other KV products, operates on unlubricated air.

Typical industries that would benefit from KV's Rhino series of valves include cement, fertiliser, flour, woodworking and ceramics, and also any process which has high dust or particles in the air supply or where the moisture level is high.

Seven rodless pneumatic cylinders have been incorporated into a giant plastic thermoforming machine for making the main body panels for static and touring caravans.

Seven rodless pneumatic cylinders have been incorporated into a giant plastic thermoforming machine just built by Format (UK) for making the main body panels for static and touring caravans. The cylinders provide the main axes of linear movement within the machine. Two feed sheet plastic into the forming chamber; two more remove the finished panels; numbers five and six provide the traverse movement for the lower heating element, and the final cylinder traverses the top heater.

'All seven drive cylinders are from Hoerbiger-Origa,' says Brian Waller, who founded Format nearly twenty years ago.

'This was a prestige order for us, and the machine will be expected to work very hard throughout its long life, so there was no thought of skimping on component quality.' In thermo- or vacuum forming, plastic sheets or panels are fed into a chamber and positioned just over a platen.

The chamber is sealed and the heaters positioned and activated to soften the plastic into a malleable state.

The air is then evacuated via vents in the bottom of the chamber, this having the effect of pulling the plastic down over the platen to form the finished product.

The heat is then reduced and the heaters retracted; after a short dwell time to allow the plastic to harden again, the product can be removed before the cycle is repeated to make the next product.

The technique is used in a great range of products, from packaging trays to door panels for double-glazing manufactures, shower trays, baths, suitcases, etc.

Caravan panels, forming the walls, roof and doors are too large to be easily handled manually and are also awkwardly flexible until fully cooled.

In order to achieve the hourly throughput volume required by the caravan makers, it was therefore necessary to automate infeed and outfeed to the chamber.

Format has designed and built many such handling systems, so knew that rodless cylinders were likely to provide the best solution.

'Standard pneumatic cylinders are inelegant because they are not load bearing so you cannot use them as structural elements of the system.

Additionally you have to design-in room for the rods when they are at full extension.

This makes for a much more costly machine that going for a rodless solution,' explains Waller.

Of the other forms of actuator, electric cylinders would not stand the heat, hydraulics are too cumbersome and expensive and linear motors nothing like robust enough.

Waller goes on to say that he has tried other makes of rodless cylinder in the past, but that just confirmed his loyalty to the Hoerbiger-Origa product range.

Many of the Origa cylinders he fitted into his earliest machines are still giving good service today.

Format is dedicated to the manufacture of plastic thermoforming machines, each one being bespoke to customer requirements.

In fact the company success is based on its bespoke design and build abilities: twenty years ago nearly all machines were standard designs imported from Germany or Italy, but the market was showing the early signs of wanting to move to bespoke systems because the techniques was moving from its small size/light weight product origins such as packaging trays into larger and larger panels.

One of the groundbreaking successes was the development of the Topper sailing dinghy, at the time the largest ever vacuum formed products.

'Local presence was vital for a bespoke operation in the 1980s, so we were able to win out over imports and get ourselves well established.

The Internet and email arrived at just the right time for us, as we were beginning to export.

Body-ported valves are designed to be non-breathing, providing better environmental protection in clean areas and places where hygiene is paramount.

Asco Joucomatic's new 552 (G3/8) and 553 (G1/2) series of body- ported valves are designed to be non-breathing, providing better environmental protection in clean areas and places where hygiene is paramount. Designed to provide long-term reliability under harsh operating conditions, the valves also offer high levels of environmental protection against the ingress of dust, liquids and other foreign matter. The 552 and 553 series of valves offer high flow (up to 3,800l/min) to directly operate large single or double acting cylinders, rotary actuators and intensifiers, or to provide pilot signals on much larger equipment such as process valve actuators.

They complement Asco Joucomatic's well proven G1/4 551 range, equipping both users and OEMs with a standardised family of valves that can provide high levels of operating flexibility and reliability in normal, demanding or clean environments.

Central to the operating reliability of the 552 and 553 ranges is an environmentally protected construction that protects the valves from the ingress of liquids, dust or other foreign matter.

In addition, the combination of a non-breathing design and the valves' ability to operate on dry air means that they are ideal for use in sensitive areas such as clean rooms, and for applications in the food processing, chemical and pharmaceutical industries.

Also adding to the operational reliability of the 552 and 553 valves is Asco Joucomatic's patented 'T' seal arrangement.

This guarantees low stiction and breakaway friction even if the valve has not been operated for long periods.

The 'T' seal design also enables the 552 and 553 valves to operate on dry filtered air or neutral gases, so there is no possibility of product contamination from lubrication.

However, 'dry' operation is not exclusive as the 552 and 553 ranges also operate with equal levels of reliability when lubricated conventionally.

The 552 and 553 valves offer all the benefits of a standardised design with both 3/2 and 5/2 versions available, both complemented by a wide range of automatic actuators, including solenoid or air piloted types with solenoid, air pilot or spring return.

The valves accept any Asco Joucomatic solenoid variant, including IP65 rated epoxy moulded units and those to UL and CSA standards.

There is also the facility for mounting ATEX approved operators onto the valves, to widen their scope of operations into hazardous and intrinsically safe areas.

A plate cylinder, with a one-way lock, is approximately 30% taller than standard devices of the same output, but narrower and the total piston area is unchanged.

A plate cylinder, with a one-way lock, is now available as series MLU from SMC Pneumatics. The MLU is half the width of existing cylinders, but provides similar levels of performance. The slim profile has been achieved by modifying the shape of the conventional circular piston, to form a slim rectangle, with curved ends (elliptical).

The piston configuration is approximately 30% taller than standard devices of the same output, but narrower.

Therefore, the total piston area is unchanged, with the piston rod remaining circular.

Originally developed for machine tool manufacturers, the MLU has many applications ranging from heavy-duty automotive through to light industries, this cylinder has a compact and built-in one-way simple lock mechanism, for drop prevention, and home position holding function.

In fact, it can be locked at any desired position.

A manual override mechanism allows unlocking with a commercial hexagon socket head cap screw, and the unlocked state can be maintained using an unlocking screw.

When the air pressure is exhausted from the unlocking port, the spring force tilts the lock ring using the pivot as a fulcrum.

When there is a load that acts on the cylinder, the tilting angle increases, locking the piston rod.

When air pressure is supplied to the unlocking port, the lock ring becomes perpendicular to the piston rod, thereby creating clearance, which then allows the piston rod to move freely.

Various brackets are available to accommodate a wide range of applications, such as foot, flange, knuckle joint, and clevis, with the unit offering universal mountings, meaning that it is possible to mount directly on all sides, except the port side.

Bore sizes range from 25mm to 50mm.

A full range of actuators with similar locking mechanisms is also available from the extensive SMC range.

Using a leak detector to check an existing compressed system will immediately improve system performance and realise notable savings in energy consumption.

Uising a leak detector to check an existing compressed system will immediately improve system performance and realise notable savings in energy consumption. Many companies today are spending time and money carrying out audits by energy specialists in the effort to save in energy costs. They are all to be commended for addressing this issue in energy saving.

They are employing energy specialists to carry out week long audits of existing equipment, where they insert intelligent data logging systems, which use non-obtrusive monitoring techniques.

System pressure, compressor load and power consumption are all monitored for the full week and readings are taken every five seconds and the collated data presented graphically.

Finally, a computer model printout/report is obtained of the comparative energy savings that a new system or different configuration can achieve.

They are in fact paying for information, most plant maintenance managers, in their own mind, already know.

It is difficult, in some circumstances, when companies with a compressor installation over ten years old cannot decide to remain with the existing system for another year or look to undertake to purchase a newer system.

However, obtaining a Logis-Tech EP ultrasonic leak detector, to detect the leaks in the existing compressed system will thus immediately improve system performance and the almost instantaneous notable savings in energy can straight away outstrip the cost of purchasing new equipment.

It is also common to find relatively new installations that are costing more in energy than need be to meet the actual compressor air needs.

Logis-Tech Associates has recently introduced the latest generation of EP ultrasonic sensing detecting equipment, which serves two main functions; leak detection and mechanical fault finding.

The results of both of these operations achieves substantial savings in; energy costs and maintenance costs - thus reducing the possibility of any uncontrolled production stops.

The advantages of these handheld, portable, easy to use, environmentally friendly, fault locating detectors is that there is no longer any requirement for using sprays to detect leaks in airlines, pipe systems, etc They also quickly repay their initial cost outlay and improve overall system performance and efficiency and are ideally suited in noisy environments.

They are essential equipment for including within preventative / predictive energy saving maintenance programmes.

Energy Efficiency states: 'Compressed air ~ a 5mm diameter hole in an airline costs around GBP 1,400 per annum'.

Heavy duty pneumatic solenoid valves are compact and rugged, incorporate innovative spool technology and have been developed for use in extreme temperatures, as low as -40 deg C.
Parker, the world's largest manufacturer of motion and control technology, has launched a range of revolutionary heavy duty pneumatic solenoid valves, designed for use in extreme conditions. Called Viking Xtreme, the new valves are compact and rugged, incorporate innovative spool technology and have been developed for use in applications where pneumatics systems have to operate at extreme temperatures, as low as -40 deg C, and at pressures of up to 16 bar. Unlike traditional solenoid valves, which typically use O-ring or lip seals between the valve spool and body, the new Viking Xtreme valves feature a single piece aluminium spool, over-moulded with a specially formulated rubber compound.

This eliminates the problems of seals deforming or extruding especially under conditions of high pressure or flow, reduces the number of component parts and provides an extended operating life.

As a result, the new Viking Xtreme valves can be used in higher pressure, high flow applications and offer excellent response times, with extremely low levels of spool break-away force or sticktion, allowing fast change-over even at low operating pressures.

The high pressure capabilities of the new valves, together with their robust construction, enable them to be used in applications that include logging and construction equipment, quarrying and in sawmills or paper and pulp mills.

In addition, Viking Xtreme valves meet the requirements of the various salt spray and vibration tests required by the transport sector and can therefore be used on commercial vehicles, buses and railway carriages.

The New Viking Xtreme is available in four versions, with 1/8, 1/4, 3/8 and 1/2in ports, are fitted 22mm wide solenoids as standard and can be supplied with a choice of coil voltage options, making them suitable for use in European and North American markets.

SMC Pneumatics has announced the launch of a new series of high resistant tubing, made from FEP (polyfluoroethylene propropylene), for harsh chemical environments and high temperatures.

SMC Pneumatics has announced the launch of a new series of high resistant tubing, made from FEP (polyfluoroethylene propropylene), for harsh chemical environments and high temperatures. Designated series TH, this tubing can operate with air or inert gas temperatures ranging between 20 to 200C, and with water temperatures between 0 and 100C. Available in a choice of four colours, and with eight size variations from 4 to 12mm, the tubing can be used with various types of SMC fittings, such as high purity Fluoropolymer (series LQ), one touch (KQ2/KJ), miniature (M, MS) and insert (KF).

This series can be used in many applications, ranging from medical, semiconductor, automotive, food and general pneumatics.

Compact pneumatic motor, available with a variety of geared drives and custom flange configurations, delivers almost 1kW at 3000rev/min from a 6bar supply.
Motair has developed the new M42 Pneumatic Motor. The compact unit delivers almost 1kW at 3000rev/min from a 6bar supply. The motor which is also available in Stainless Steel, making it suitable for mixing applications in the pharmaceutical and food industries etc.

As well as the standard D71 output flange, the M42 is also available with special and custom output configurations to suit any application.

Gearboxes options include helical or worm style up to 300:1 ratios, with a fail-safe brake and both lever and pilot operated valves within the range.

Other Motors in the range are also available in S/S 316, as well as the standard cast iron, please contact us for more information.

Motair can now offer a full range of air motors and drives from fractional to over 50kW.

Requests from the electronics and semi-conductor industries for a compact pressure controller with a small lightweight pressure sensor have been answered.
SMC Requests from the market for a compact pressure controller with a small lightweight pressure sensor have been answered, with the latest series PSE 300/540 from leading pneumatics supplier, SMC. For use in the electronics and semi-conductor industries, Series PSE300 Controller and Series PSE540 Sensor, have been designed for ease of use, in high-speed applications requiring space saving solutions. The pressure controller (PSE300) with its 2 colour LED display and auto-preset function, has a switch output response time of 1ms.

With two digital and one analogue outputs, it can be used in various control environments and will not malfunction in the case of pressure fluctuation, due to its unique anti-chattering feature.

Series PSE300 can be mounted either longitudinal, or lateral and offers real space savings compared to other existing models.

Weighing in at 3.2g and offering up to 40% size reduction over existing products, the PSE 540 (pressure sensor) with flexible cable, can be mounted on almost every moving part and importantly, due to its compact size, close to the action.

This pressure sensor is available in a range of port size options, can include vacuum pads and also be mounted manifold style if required.

It can also be used in conjunction with existing control equipment using the standard 1-5V DC output signal in various control environments.