A leading pneumatic solutions manufacturer has produced a new software package, as a CD, which allows designers and specifiers to take the guesswork out of Rodless Cylinder selection.

Leading pneumatic solutions manufacturer KV has produced a new software package, available free as a CD, which allows designers and specifiers to take the guesswork out of Rodless Cylinder selection. The CD, which is a powerful but very user friendly design tool, has been developed alongside the company's new range of Ultraline Rodless Cylinders, and includes the most common applications. It allows the design engineer to take 6 easy steps to input details of an application, see the calculated results of the suggested cylinder, and import 2D or 3D drawing files direct into the application design work.

The costs of over-engineering are well known, therefore accurate product selection can save both space and cost, by designing in the most appropriate product for the application, and the CD enables size and selection of Rodless cylinders to be made.

KV offers demonstrations of the selection software on request, and for those design engineers planning to use Rodless cylinders, a free copy is available.

The whole manufacture, assembly and test of a 5.9m rodless cylinder was carried out in less than a day for a customer seeking a short lead time.

The launch of KV's new 'Ultraline' range of pneumatic Rodless cylinders was well and truly tested when a customer was seeking a short lead time, for a 5.9m rodless cylinder! 'This was by far the longest cylinder the company has currently assembled' advises Steve Hart, KV's production manager. 'however the whole manufacture, assembly and test was carried out in less than a day' Unlike normal rodless cylinders, where the open design of the extrusion can cause problematic leakages, KV's unique sealing technology combined with a simplistic assembly process ensures that irrespective of bore or stroke, the cylinders can be assembled quickly and efficiently. Urgently required for use on a transfer packaging line, the cylinder was packed and despatched the following day exceeding all the customers expectations.

KV's new 'Ultraline' series of rodless cylinders are available in bores from 18mm to 63mm diameter and standard stroke lengths up to 6m.

Compact cylinders with built-in air cushions provide the possibility of applying pneumatic power into small spaces where, previously, cylinders could not be mounted.

Compact cylinders provide the possibility of applying pneumatic power into small spaces where, previously, cylinders could not be mounted. SMC, the pioneer of compact cylinder design, have now launched a new compact cylinder, designated series RQ, utilising a unique air cushion mechanism. This unique cushion system, designed by SMC's engineers, is located in the same profile as the cylinder itself, with the adjustment screws on the same face as the connections - this eliminates the need for traditional cushion bosses, thereby retaining the compact size of the unit.

The RQ also offers noise reduction at stroke end of 14dB or more, improved repeatability at the stroke end compared to units with rubber bumpers, and up to three time more allowable kinetic energy than standard versions, at the end of stroke which enables heavier weights to be moved, at higher speeds without producing undesirable impacts at the ends of stroke.

In addition, this series is presently offered in bore sizes from 20mm to 50mm, with or without auto switch, and a number of mounting options (through hole, double end tapped, foot, front flange, rear flange and double clevis).

A CD-Rom contains CAD data, for a wide range of pneumatic components arranged in the form of two electronic catalogues for easy reference.

Free CD Rom has CAD data for pneumatics SMC Pneumatics has announced the availability of a CD-Rom containing CAD data, for a wide range of the company's pneumatic components. The CD contains two types of electronic catalogues:- 1. Pneumatics CAD System - from this the user can build complete part numbers, step by step to generate DXF files.

This system mainly covers actuators.

And, 2.

Electronic Catalogue Search System - providing a file name search function, covering SMC's main product range, including actuators.

DXF files can be copied to the users hard drive from the menu.

The data can be accessed by using M/CADAM, DWG, or DMNDOS.

Graham Coats of energy saving specialists EnergAir gives some tips on to overcome it and boost your company's bottom line.

Graham Coats of energy saving specialists EnergAir gives some tips on to overcome it and boost your company's bottom line. The government's climate change levy has concentrated minds on all forms of energy efficiency, and the means to achieve it. Recently, the emphasis has been on the efficient use of compressed air.

This is timely and reverses the ages old message that compressed air is 'cheap' to produce.

In truth, the leakage from ring main systems, and the inefficient running of compressors off-load, have done much to impair the competitiveness of UK industry over the years Compressed air is generated using electricity, and the fact that its generation is equivalent to about 10% of industry's total electricity usage, rising to 30% in some sectors, highlights why companies have compelling reasons to investigate the potential for energy saving in this area.

Recently, industry specialists have given added momentum to this new discipline by calculating that the operating costs of running multiple compressed air installations without some form of management control can be more than 30% higher than they should be.

And this is just one aspect of a system, although usually the main one.

To get the full picture the compressed air system as a whole needs to be examined, from the air compressor itself, to the dryer and filters which condition the air to the pipe work system that delivers it.

As anyone who has ever been concerned with compressed air systems will know, the most basic problem is leakage.

Indeed, it has been calculated that leakage rates exceeding 50% of site consumption are common across many industries.

For the user looking to save energy, eliminating these levels of leakage is a logical first step, especially as the costs involved are virtually negligible.

But how to go about it?

The first fact that must be borne in mind is that while every effort should be made to keep a compressed air system leak-tight, all systems will have some leakage.

There are however, several ways - basic 'do's and don'ts' that can be followed to reduce the opportunities for leaks: Taking the don'ts first: don't generate at a higher pressure than is necessary - the higher the pressure, the more air that will escape through a given-size hole - and don't keep your whole system pressurised during non-productive hours just because a few items of machinery require a constant supply of compressed air.

In terms of the do's: firstly, isolate parts of the system that require air at different times.

Isolation valves can be operated manually or automatically using simple control devices like time switches or interlocks, or they can be controlled using your building energy management system, if you have one.

Secondly, take advantage of the fact that under the Pressure Systems and Transportable Gas Containers Regulations, you must inspect your compressed air system regularly.

These inspections are an ideal opportunity to find and repair leaks.

Having answered the first question of how to go about leakage elimination, the second is where to look for the leaks.

In most systems the quick answer to this would be: 'just about anywhere! Logically though, the best place to start is at the compressor and then work outwards through pipework and fittings to pneumatic equipment, tools and instrumentation.

The main artery for delivering compressed air is ring main pipe work systems.

In many factories the pipe work is old and a prime source of leaks.

A check of the system for pipe work sections that are leaking or corroded, followed by their replacement, will not only improve the system but will also improve safety.

In addition to the pipework itself, large leaks are often found at connection points where screw fittings or flanges are employed.

These leaks are frequently caused by pipe strain due to inadequate supports, inadequate joints or twisting.

Another potential problem area is where connections to a usage point are made using snap connectors with flexible hoses.

Sometimes several are used together, forming a manifold arrangement.

Such manifolds can leak due to worn connectors and poorly jointed pipework.

In addition, where flexible hoses are used to make connections between the piping network and usage points, leaks can be caused by a number of factors including: damage to the hose, due to abrasion by surrounding objects: strain on the joint because the hose is too long or short, and by deterioration of the hose material, or just by choosing the wrong material, especially where the working environment is aggressive, oily or hot.

Before leaving the subject of connection manifolds, it's also important to remember that all leaks do not occur through large connections.

Many occur through wear on the tubing on small push-in connectors.

Individually, these are of little note but when they are numerous the total leakage can be substantial.

If a compressed air system uses automatic drain traps, these should be 'zero loss' types, and should be checked to determine whether they are functioning correctly.

Some drain traps are not reliable and, in practice, they are often bypassed so that the condensate can be released from the system.

This is undesirable as large amounts of compressed air can be lost.

A way to overcome this is to use electronically operated zero loss condensate traps.

These are very reliable, and by fitting them the requirement for bypassing can be removed.

Filters are an indispensable part of any pneumatic system.

They can, however, be the source of quite large leaks.

Potential problem areas are drainage points on the filter bowls, including poorly sealing automatic drains, badly fitted bowls and bowls that have been contaminated by synthetic compressor lubricant.

Downstream from the filter is not normally the area where the factory engineer would expect to make major savings by reducing leakage.

This is true in the main, but useful contributions to the overall plant savings target can still be obtained by checking such things as connections to regulators, lubricators, valve blocks and sensors, and the internal air seals on pneumatic cylinders, which can cause large leaks Last but not least are air tools.

These can consume large quantities of compressed air in operation.

In many instances their consumption is exacerbated due to leaks that occur at the hose connection and/or the speed control valve.

Worse still, occasionally air tools are left running, even when not in use! Compressed air represents 10% of industrial electrical consumption, but much is wasted.

EnergAir Solutions is a new but highly experienced energy efficiency consultancy, formed to help companies achieve energy saving on compressor installations.

The consultancy concentrates on the compressed air user, putting in place control and monitoring products that will make a noticeable difference in a matter of days.

This is important because compressed air represents 10% of all industrial electrical consumption and in many cases companies use their compressors inefficiently and have inadequate distribution systems.

New regulator design improves relief sensitivity from 14.5 lb/in2 to less than 5 lb/in2 while increasing its resistance to ozone, and also incorporates an optional built in pressure gauge.

SMC Corporation of America, the world's largest manufacturer of pneumatic automation products has announced the release of the next generation modular FRL series. This new series of modular FRL products feature increased flow rates, larger bowl capacities, improved water removal and more precise pressure control. All of this in a more compact, easier to install package.

Port sizes range from 10/32 UNF (M5x0.8) through 1in in NPT, metric (Rc) and G threads.

Standard operating pressures are 0 to 145 lb/in2 gauge with proof pressures of 215 lb/in2 gauge.

Space savings and simplified installation are achieved through a new modular spacer design.

The new spacer takes up roughly a third less space.

Self-contained screws and gaskets allow for simple foolproof installation and maintenance.

The new filter design features 30% larger bowl capacities without changing the envelope size.

A new baffle design increases water removal to over 90%.

Automatic float drains are also now available on all sizes.

The new regulator design improves relief sensitivity from 14.5 lb/in2 to less than 5 lb/in2 while increasing its resistance to ozone.

The design also incorporates a built in pressure gauge as a standard option.

The new lubricator design features a combination sight glass and graduated drip rate adjustment knob.

This allows for simpler and more consistent setting of lubrication rates.

Additionally, the bowl capacities have been increased by roughly 40% without changing envelope dimensions and the 1/8in and larger sizes can be filled under pressure for simplified maintenance.

SMC Corporation manufactures high quality actuators and cylinders, airline and air preparation equipment, high-purity products, vacuum components, instrumentation, and a host of fittings and accessories applicable to the pneumatic automation industry.

SMC has a total of 14 production facilities, 3 of which are in North America -Indiana, California, and Ontario, Canada.

SMC's global presence enables it to provide quality customer service in any part of the world.

Series ARJ310 Miniature Air Regulator, from SMC, gives improved flow rates over similar units. In addition, the ARJ is compact (W18.3cm, H82.5cm, D46cm) and lightweight (65 grams approx).

Series ARJ310 Miniature Air Regulator, from SMC, gives improved flow rates over similar units. In addition, the ARJ is compact (W18.3cm, H82.5cm, D46cm) and lightweight (65 grams approx), and accommodates two types of thread, (inside female M5 x 0.8 outside male thread 1/8in). One touch fittings are available on the ARJ310F version - these features offer easy connection and smaller mounting pitch, which is ideal for panel assembly.

Standard specifications include proof pressure of 1.2MPa, maximum operating pressure of 0.8MPa, and ambient and operating temperature range of 5 to 60degC (with no freezing).

SMC Pneumatics compact high precision, double acting, guide cylinder, now incorporates a shock absorber, for absorbing impact at the end of the extended stroke.

Compact guide cylinder incorporates shock absorber SMC Pneumatics compact high precision, double acting, guide cylinder, now incorporates a shock absorber, for absorbing impact at the end of the extended stroke. Series MGP-XC69 incorporates an extension adjustment mechanism which gives, for example, an adjustment of 25mm on the stroke of the 32 to 63mm diameter bore units. (The MGP Compact Guide cylinder range covers 12 to 100mm bore and strokes from 10 to 400mm).

Options include a choice of bearings (slide or ball) within the guide mechanism, and a range of autoswitch (reed or solid state), both giving optimum application performance The MGP with shock absorber is ideal for any application where precision is important, i.e pick and place.

SMC Pneumatics have launched two new series of High Precision Digital Pressure Switches, for use with air, inert gas, and non-flammable gas, designated the ZSE/ISE 30 and 40.

SMC Pneumatics have launched two new series of High Precision Digital Pressure Switches, for use with air, inert gas, and non-flammable gas, designated the ZSE/ISE 30 and 40. The ZSE for vacuum/low pressure, and the ISE for positive pressure. These models give a high-speed response of 2.5ms, or less.

The ZSE/ISE40, in addition, offers a stable switch output, possible even with sudden changes in the primary pressure, i.e when operating large bore cylinders.

This function is known as 'anti-chattering'.

Devices such as large bore cylinders and high-flow vacuum ejectors consume a large volume of air when they operate, and this may cause a momentary drop in the primary pressure.

'Anti-chattering' prevents such momentary pressure drops from being detected as abnormal pressures, by allowing the response time selection to be changed.

The ZSE30/ISE30 has a two colour (green and red) digital display giving a choice of four settings (depending upon application requirements), and therefore allowing abnormal operating conditions to be detected at a glance.

The display is easy to set as the raised, soft touch, rubber button controls are clearly set apart, ensuring ease and simplicity of operation.

The units are lightweight (43g without lead wire), and space saving, when panel mounted only 6mm stands proud, and where more than one switch is required any number of units can be stacked vertically or horizontally.

Bracket mounting is also an option.

Time can also be saved, in installation, as the ZSE/ISE30 series has a plug-type connector to take the burden out of wiring work and, for the future, maintenance.

Being dust-tight and splash proof the unit is also IP65 compatible.

Both series offer pressure ranges of 100.0 to 100.0kPa (compound) 0.0 to 101.3kPa (vacuum), and 0.000 to 1.000Mpa (positive), and three types of piping, allowing for various methods of installation.

A complete EnergAir compressed air management system installed at a GlaxoSmithKline manufacturing site is ensuring optimum system efficiency and providing detailed running data.

A complete EnergAir compressed air management system installed at the GlaxoSmithKline (GSK) manufacturing site in Ware, Hertfordshire, is ensuring optimum system efficiency while providing detailed running data and precise efficiency reports. In addition, the EnergAir 'Alert Service' also reports any problems or anomalies in the system to a service provider. The message is transmitted and acknowledged in a matter of seconds, giving the user total peace of mind by avoiding dips in system efficiency and preventing failures.

The GSK site includes research units and a manufacturing facility producing over one billion tablets or capsules and in excess of 30 million inhalers each year.

Supplying compressed air to the site are three 132kW and one 90kW oil free compressors, all of which are now controlled by an EnergAir Enercon SX controller.

The controller unit matches compressed air supply to demand from the system, balancing all four compressors to give the most efficient generation combination.

The complete EnergAir package supplied to GSK Ware consists of an SX 5 System Controller, an I/O box, communications box with modem, system monitoring devices, EnerSoft software and Alert services.

GSK were provided with an on-site PC to run the software, but the system can also be accessed via a laptop from any phone line, giving total flexibility.

Although the EnergAir system is intended to show energy savings, the driving force behind its installation at GSK was the precise system monitoring and data logging capabilities on offer.

Dave Wall, Engineering Manager at GSK Ware puts the system in context, 'In our industry, we are under continual pressure to reduce costs.

As a result, monitoring and targeting is becoming an increasingly important part of our business.

The production of compressed air accounts for a large proportion of our expenditure on electricity at this site and without accurate data is has been impossible to measure the efficiency of the system and quantify the effect of any improvements we have made.

'The EnergAir system addresses this situation by accurately monitoring the volume of air we are using and that which we are generating, it then controls the compressors and calculates exactly how efficiently that compressed air has been produced.

We have our own systems for leak detection and prevention across the site, but were not previously able to monitor the effectiveness of this activity without an accurate comparison of generated and used air'.

'An additional benefit has been dealing with sales calls offering energy audits and air supply reviews that inevitably end with the conclusion that our site is inefficient and we need to buy a new compressor.

Now we have the answers to all these questions and can avoid any unnecessary spend on new equipment with confidence.

Trending performance also works both ways; we are able to quantify the improvements in running efficiency we expect to see from using the EnergAir compressor control system and ensure that our expectation is achieved'.

'We now have exactly what we envisaged from the system when we first embarked on the project, which is very satisfying.

The Ware site produces compressed air at a cost of 0.39 pence per m3 compared to the industry average of 0.5 ppm3 for this type and size of installation.

EnergAir have done a lot to get the system to where we wanted it today, that commitment and technical support is much appreciated.

We can now to show the system to other GSK manufacturing sites with confidence and ensure organization benefits as a whole'.

To ensure efficiency targets are met and production downtime avoided at GSK Ware, the site is also connected to the EnergAir 'Alert Service'.

The system dials-out automatically if there is any change from tightly set parameters, hence a problem can be identified and solved before it affects production or working efficiency.

Any trips that occur are reported to the service support supplier, Motivair in this case, via a modem in an on-site communications box.

The message is routed through a server at EnergAir, which has a sequence of destinations for the message, depending on the nature of the message and it's importance.

Some are sent as e-mails to be logged, other more serious messages such as a compressor failing are sent to mobile phones as text massages as well as faxing any relevant parties.

The system will automatically keep sending sequenced messages until one is acknowledged.

The whole process only takes between 60 and 90 seconds to complete, ensuring a prompt response.

On receipt of the trip message, the service provider can interrogate the system remotely and make a recommendation to GSK on the best course of action to take.

There are monitors on: energy usage, system efficiency, compressor status, compressor bearing condition, compressor water coolant temperature, dew point analysis, room temperature, air filter status and air discharge pressure to the system.

According to Marc Saunders EnergAir Technical Director, 'the Alert package is an essential tool for production critical environments, because of the speed of response and the detail available without an on-site visit being required.

The user now has total peace of mind with 24hr unbroken monitoring and support'.

Commenting on the project as a whole, Marc Saunders states: 'EnergAir equipment and services are normally installed to optimise control and make energy savings in the generation of compressed air.

The data monitoring aspect is something that we do in order to identify and effectively calculate the potential savings in a system.

We then use these results to demonstrate the improvements that are made to the customer.

The GSK Ware application shows how this information can also be a valuable asset to an already efficient and well-run compressor house'.

GSK was one of a number of key sites and users of compressed air that were targeted when the EnergAir Company was originally formed.

In this case, their success proves that the EnergAir system can bring significant benefits to a site with a large, up-to-date and already efficiently run compressor house.

The benefits for sites that have several different types of air compressor and large disparate air supply systems can be dramatic, particularly in terms of overall energy savings and prevention of down time where savings running into tens of thousands over a twelve-month period are common.