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 of electric cylinders 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.










umso höher fallen die Einsparungen und damit der Return on Investment aus.

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

Reduction of electricity costs

The savings potential in energy consumption depends on the frequency of operation. The higher the operating frequency, the greater the energy savings for electric cylinders compared to pneumatic cylinders.

For example, based on tests conducted by IAI, the energy consumption of an EleCylinder under the following conditions is only 1/6 of the consumption of a pneumatic cylinder.

Operational conditions:

  • EleCylinder: EC-R7
  • Air cylinder: Ø32
  • Stroke: 300 mm
  • Speed: 280 mm/s
  • Acceleration: 0.3G
  • Load: 30kg
  • Operation cycle: 30s per reciprocating motion
  • Operating days per year: 240 days

Improves productivity and reduces labor costs

Air 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.

Long service life

Instead of an impact mechanism, the EleCylinder incorporates a ball screw and ball circulating type built-in linear guide to achieve a long service life.
Based on calculation using the conditions below, the lifespan of the EleCylinder is five times longer than that of air cylinders.