Energy-saving Drive Technology

Cost reduction through pneumatic-free automation technology

Reduce energy consumption sustainably

The efficient use of energy in drive technology is an important goal for sustainable development in many manufacturing companies. This involves their future development and measures to effectively counter the growing cost pressure.

The key to reducing production costs lies in eliminating power losses in the energy-intensive overall processes of factory automation. This is why more and more companies are opting for automation without compressed air and replacing their pneumatic cylinders with electric ones. In assembly and handling technology, electric actuators are used for linear, rotary or gripping movements.

Energy requirements compared to pneumatic cylinders

As the cycle frequency increases, the energy requirement of a pneumatic cylinder increases exponentially, while the energy consumption of the energy-efficient electric cylinders remains constant. The difference in energy consumption increases with the number of work cycles per minute.

If both cylinders work at 10 cycles per minute, a RoboCylinder only uses 1/3 of the energy of a pneumatic cylinder. If both cylinders work at 30 cycles per minute, this difference becomes even clearer: the RoboCylinder from IAI only requires 1/10 of the energy of a pneumatic cylinder!

The more electric cylinders you use in your company, the higher the savings and thus the return on investment.

Potential energy savings of up to 90 percent

Companies often use pneumatic actuators because of the sometimes lower investment costs. However, the generation and distribution of the necessary compressed air is accompanied by very high losses, which can be improved by intensive optimization measures. However, the technological limits are quickly reached. In these cases, a so-called substitution scenario is suitable: In this scenario, the pneumatic positioning systems are replaced by electromechanical ones.

Various scientific studies have already provided the following proof: Such a substitution is clearly preferable to the optimisation of compressed air systems in terms of the economic and ecological savings in energy consumption. In some cases, a savings potential of up to 90 percent has been demonstrated.

Sustainable Development Goals

The Agenda 2030 of the United Nations came into force on 1 January 2016 for a period of 15 years. At its core are 17 ambitious goals for sustainable development. Two goals are of particular relevance for manufacturing companies:

Goal 9: Build resilient infrastructure, promote broad-based and sustainable industrialisation and support innovation.

Goal 12: Ensure sustainable consumption and production methods.

Cost savings in production

Cut electricity bills to 1/5th

The energy efficiency of an pneumatic cylinder is about 1/5th that of an electric EleCylinder.

The energy efficiency comparison depends on operating conditions.

Reduce annual electric bill and CO2 emissions

The difference in the rate of power consumption for EleCylinder and an pneumatic cylinder depends on the frequency of operation. The higher the frequency of operation, the more effective the energy-saving becomes.

Implementation example: Annual electricity bill/CO2 emissions on a production line using 300 cylinders

Improves productivity and reduces labor costs

Pneumatic cylinders cannot operate at high velocity due to the impact at stroke ends which occurs when excess velocity is applied. The EleCylinder allows individual adjustment of AVD with percentage input for smooth starting/stopping at high velocity. This enables reduced cycle time.