SMC ECOLOGY PNEUMATICS SYSTEM

Transcription

1 CAT.E- B Proposals for Energy Saving SMC ECOLOGY PNEUMATICS SYSTEM Pneumatic Systems SMC supports innovations in energy saving production systems. As countermeasures for global warming are coming into effect, "energy savings" has become a key theme for corporate reforms. At the Kyoto Conference on Climate Change (December 997), a 6% reduction of CO emissions from the 99 emission rate was set as a target to be achieved by. Also, as amendment of the energy saving law in Japan suggests, it is predicted that the trend for energy savings involving corporations will become increasingly demanding. In this climate, SMC will strive for innovations of production systems with energy savings in mind. With cooperation from customers, we will promote energy saving programs for pneumatic systems.

2 Energy Saving Equipment Actuators Non-rotating double power cylinder Guide table PFC/QFC valves Air saving valves Hollow rod cylinders Free mount cylinder for vacuum Water resistant air cylinders Cylinder with heavy duty scraper Cylinder with coil scraper Air-hydro booster Air-hydro converter Directional Control Equipment Series MGZ Series MGF PFC/QFC valves Series ASR/ASQ (Made to Order) Series ZCUK (Made to Order) (Made to Order) (Made to Order) Series CCT Actuator Actuator Actuator Actuator Air blow Air blow Air leakage Air leakage Air leakage Hydraulic clamp Hydraulic clamp Page Actuators Pilot operated port solenoid valve Direct operated port solenoid valve Pilot operated port solenoid valve Zero differential pressure operated port solenoid valve Direct air operated port valve Pilot operated port solenoid valve Pilot operated port solenoid valve Large port solenoid valve port mechanical valve Coolant valve Flow switching port air operated valve Booster valve Series VXD// Series VCA Series VQ/ Series VXZ Series VXA/ Series VP/5/7 Series VG Series VP5/65/85 Series VM VM// Series VNC (Special order product) Series VBA to Air blow, Air tool, Non-operation Air blow, Air tool Air blow, Air tool Cooling water Air purge Air purge, Paint stirring Air purge, Non-operation Air purge, Non-operation Air purge Coolant Paint stirring Hydraulic clamp Page Directional Control Equipment Auxiliary Pneumatic Equipment/Air Preparation Equipment Blow gun Nozzles for blowing/sensing heads S couplers FR double layer tubing FR double layer polyurethane tubing Double layer tubing stripper Polyurethane coil tubing Tube cutter Modular type regulator Pilot operated regulator Regulator with back flow mechanism Filter regulator Filter regulator with back flow mechanism Air filter element part number list Differential pressure gauge Filter with element service indicator Sensors/Measuring Instruments Digital flow switch High precision -color display digital pressure switch High precision digital pressure switch Digital pressure switch High precision digital pressure switch for general fluids -color display digital pressure switch Digital pressure switch with backlight Compact manometer Air leakage tester Air catch sensor Air catch sensor Negative pressure detection valve Vacuum Equipment Vacuum ejector In-line vacuum ejector Multistage ejector Vacuum ejector with check valve Pad with check valve Vacuum ejector for water soluble coolant removal Series VMG Series KN Series KK Series TRB Series TRBU Series TKS Series TCU Series TK Series AR to 6 Series AR5 to 95 Series ARK to 6K Series AW to Series AWK to K GD-- Series PFA/PFW Series ZSE/ISE Series ZSE/ISE Series ZSE/ISE Series ZSE5F/ISE5 Series ISE7/75/75H Series ZSE5B/ISE5B Series PPA (Made to Order) Series ISA Series ISA (Special order product) Series ZH Series ZU Series ZL/ (Special order product) (Special order product) (Special order product) Air blow Air blow, Air tool, Coolant Air blow, Air tool, Air leakage Air leakage Air leakage Air leakage Air blow, Air tool Air leakage Air blow, Air tool Air blow, Air tool Actuator Air blow, Air tool Actuator Air line maintenance Air line maintenance Air line maintenance Air line maintenance, Air blow, Air tool, Air leakage, Cooling water Air line maintenance, Air blow, Air tool, Vacuum Air line maintenance, Air blow, Air tool, Vacuum Air line maintenance Air line maintenance, Liquid removal, Coolant Air line maintenance, Liquid removal, Coolant Air line maintenance, Liquid removal, Coolant Air blow, Air tool Air line maintenance, Air blow, Air leakage Air purge Air purge Liquid removal Liquid removal Liquid removal Vacuum Vacuum Vacuum Liquid removal Page Page Page Auxiliary Pneumatic Equipment Air Preparation Equipment Sensors Measuring Instruments Vacuum Equipment Industrial Filters Industrial Filters Industrial filter Refresh filter Other (CD-ROM) Model Selection Software Ver.. Energy Saving Program Ver. SMC Pneumatics CAD System Ver..6 Series FG Series FN Coolant Air line maintenance, Coolant Actuator Air blow, Air tool, Coolant Actuator Page 8 Page Table of Contents Other (CD-ROM)

3 SMC FLOW SWITCH RESET SET UNIT SMC FLOW SWITCH RESET SET UNIT SMC FLOW SWITCH RESET SET UNIT Energy Saving Proposals & Energy Saving Equipment List Proposal Pressure/Flow Control Flow rate and pressure controls Digital flow switch Air leakage tester Compact manometer Nozzles for blowing/sensing heads Differential pressure gauge Filter with element service indicator High precision -color display digital pressure switch High precision digital pressure switch LED display digital pressure switch High precision digital pressure switch for general fluids -color display digital pressure switch Digital pressure switch with backlight Low maintenance filter Air filter element part number list Series PFA/PFW (Made to Order) Series PPA Series KN GD-- Series ZSE/ISE Series ISE Series ISE Series ZSE5F/ISE5 Series ISE7/75/75H Series ISE5B Series FN Page Proposal Idling Reduction of air leakage and air for purging when equipment is not operated. Master solenoid valve M/C Pilot operated port solenoid valve Pilot operated port solenoid valve Large port solenoid valve Series VXD// Series VG Series VP5/65/85 Page Proposal Proposal Air Blow Reduction of air for blowing Air blow Air Tools Reduction of air for air tools Impact wrench (air motor) Air gun Pilot operated port solenoid valve Direct operated port solenoid valve Pilot operated port solenoid valve Blow gun Nozzles for blowing/sensing heads S couplers Polyurethane coil tubing Modular type regulator Regulator with back flow mechanism Pilot operated regulator Filter regulator Filter regulator with back flow mechanism Digital flow switch for air High precision -color display digital pressure switch High precision digital pressure switch Compact manometer Air leakage tester Energy Saving Program Ver. Hollow rod cylinders Free mount cylinder for vacuum Series VXD// Series VCA Series VQ/ Series VMG Series KN Series KK Series TCU Series AR to 6 Series ARK to 6K Series AR5 to 95 Series AW to Series AWK to K Series PFA Series ZSE/ISE Series ISE Series PPA (Made to Order) (Made to Order) Series ZCUK Page Proposal 5 Air Leakage Stop air leakage from piping equipment S couplers FR double layer tubing Double layer tubing stripper Tube cutter Air leakage tester Digital flow switch for air Water resistant air cylinders Air cylinder with heavy duty scraper Air cylinder with coil scraper Series KK Series TRB/TRBU Series TKS Series TK (Made to Order) Series PFA (Made to Order) (Made to Order) Page Air Purging (Air Micro) Proposal 6 Reduction of air for purging Workpiece Direct air operated port valve port mechanical valve Air catch sensor Air catch sensor Series VXA/ Series VM VM// Series ISA Series ISA Page Proposal 7 Paint Stirring Reduction of air consumption for paint stirrer Pilot operated port solenoid valve Flow switching port air operated valve Series VP/5/7 (Special order product) Page 58 7 Stirrer Paint pump Paint tank Front matter

4 Actuators Proposal 8 Air reduction for actuators Lifter Non-rotating double power cylinder Guide table PFC/QFC valves Air saving valves Regulator with back flow mechanism Model Selection Program Ver.. SMC Pneumatics CAD System Ver..6 Series MGZ Series MGF Series ASR/ASQ Series ARK to 6K Page Proposal 9 Vacuum Air reduction for vacuum ejectors Suction transfer High precision -color display digital pressure switch High precision digital pressure switch Vacuum ejector with check valve Pad with check valve Multistage ejector Series ZSE/ISE Series ZSE (Special order product) (Special order product) Series ZL, Page Liquid Removal Proposal Air reduction for liquid removal pumps Machine Oil pan Oil waste P Air type liquid removal pump Vacuum ejector for water soluble coolant removal Vacuum ejector Linear vacuum ejector Negative pressure detection valve High precision digital pressure switch for general fluids Digital pressure switch with backlight (Special order product) Series ZH Series ZU (Special order product) Series ZSE5F/ISE5 Series ZSE5B/ISE5B Page Coolant (Cleaning) Blow Proposal Power reduction for coolant pumps Coolant valve Nozzles for blowing/sensing heads High precision digital pressure switch for general fluids -color display digital pressure switch Digital pressure switch with backlight Energy Saving Program Ver. Industrial filter Low maintenance filter Series VNC Series KN Series ZSE5F/ISE5 Series ISE7/75/75H Series ISE5B Series FG Series FN Page Cooling Water Proposal Power reduction for cooling water pump Welding gun Zero differential pressure operated port solenoid valve Digital flow switch for water Series VXZ Series PFW Page 55 8 Hydraulic Clamp Proposal Power M reduction for Hydraulic cylinder Work piece hydraulic pump Hydraulic control valve Hydraulic pump P Air-hydro booster Air-hydro converter (Made to Order) Series CCT Page 5 Low Power Consumption/Long Service Life Proposal Reduction of power used for solenoid valve energization and service life improvement Low power consumption Long service life 5 port solenoid valve 5 port solenoid valve port solenoid valve Series SY Series VQ Front matter 6 Front matter 6 Series VQ/ Page 5 Front matter

5 Recognizing the current state... First step toward energy savings and improving awareness To promote energy savings in pneumatic systems, it is necessary to recognize and control the existing system's air consumption and to improve the awareness of energy saving (cost awareness) in the work place. Based on usage, electric power consumption for air (compressor) is thought to be % of the entire consumption (Figure ). Furthermore, air consumption based on usage is as shown in Figure. It is necessary to understand and control the air consumption for these usages. Air % Coolant % Actuators % Air leakage Other % 5% Air blow 7% (Figure ) (Figure ) Electric power consumption Air consumption It is said that energy saving measures begin with measurement and end with measurement. Find out where, how much, and for what purpose the energy is being used. Then, find out how much can be reduced as a result of improvements. Effective energy saving improvements can be implemented by recognizing and controlling the current state of energy consumption and the result of the improvements, entirely with numerical values. Reason for improvement Measurement Improvement Measurement Energy savings Recognize the potential of improvement Recognize current consumption Verify the enegy consumption after the improvement Air line maintenance equipment to recognize the current state Educational panels to improve energy saving awareness Digital flow switch Series PFA Air leakage tester (Made to Order) Air blow demonstration panel Air leakage demonstration panel Separately measures air consumption by facility and by line. Measured flow rate: l (max.) Compact manometer Series PPA Measures leakage flow rate. Measured flow rate: 9999 l (max.) Guides the approach to and improvement methods for air blow. Coolant blow demonstration panel Air leakage can be heard and felt. Vacuum ejector demonstration panel Measures the workpiece collision pressure. Calculates air blow rate with flow rate formula. Refer to Proposal "Air Line Maintenance" on Front matter 5 for details. Large fluctuations of energy in the discharge, caused by the relationship between the nozzle and upstream piping system, can actually be confirmed. The point where the difference occurs between a good system and a bad system can actually be measured. Demonstrates how suction is maintained by using an ejector with check valve. Air consumption can be compared with a general vacuum suction system. Front matter

6 What are energy saving measures? Before improvement After improvement Electric power consumption A B C Electric power consumption A B C Time Time Compressor operation capacity Peak consumption of A Consumption of B + Consumption of C Continuous operation of compressor Compressors Compressors Consumption of A: Consumption from equipment operation ) Cylinder operation ) Air blow ) Suction by ejector, etc. Reduction of consumption by optimizing. Reduce the peak flow rate for more even consumption by considering the cycle time and operating time. Consumption of B: Consumption from line operation ) Purge air to prevent intrusion of coolant, etc. ) Air blow to prevent foreign matter adhesion ) Down blow inside the painting booth Reduction of consumption by optimizing. Reduce consumption in connection with equipment operation. Or, hold consumption to the minimum required. Consumption of C ) Air leakage ) Air curtain, etc. ) Liquid stirring system operation, etc. Reduction of consumption by optimizing. Fix air leakage. Fix the cause of air leakage. Consider other methods for consumption such as air curtains that has purpose. Front matter

7 Proposal Air Line Maintenance Purpose Flow maintenance Before Improvement Since the current flow rate based on the usage is not recognized, the target for improvement and its effect are not expressed in numerical values and remain unclear. After Improvement Effective use of measuring instruments. Flow rate is maintained with numerical values, and the target for improvement and its effect are clarified. q Digital flow switch for air Equipment Equipment w Air leakage tester e Compact manometer Equipment Equipment q Equipment w Air leakage tester Main Points Measure main line and branch line flow rates. Digital flow switch for air Series PFA Page 8 Measure air leakage rate and air blow rate Air leakage tester. (Made to Order) Page Measure air blow rate. Compact manometer Series PPA Page 97 Measures workpiece collision pressure to calculate flow rate by using flow formula. Related Equipment Nozzles for blowing/sensing heads Series KN P. 8 Front matter 5

8 Purpose Pressure maintenance Before Improvement The importance of regular maintenance for the pressure loss caused by clogged elements is not recognized. Therefore, a large burden is placed on the compressor and pump, etc. After Improvement Regular maintenance of clogged elements is implemented by mounting pressure and flow monitoring equipment on each type of filter used on each line. Main line Sub line Main line filter Series AFF Reciprocating air compressor Aftercooler (air cooled) Series HAA Aftercooler (water cooled) Series HAW Air tank Series AT Refrigerated air dryer Series IDF Operating line q Differential pressure gauge q Differential pressure gauge IN Upstream side w Element service indicator e Pressure switch OUT Downsteam side Main Points q Check clogged elements by using a differential pressure gauge. Differential pressure gauge GD-- Page 5 w Confirm clogged condition visually. Element service indicator filter Page 6 e Verify pressure loss. High precision digital pressure switch Series ISE Page 6 Related Equipment High precision -color display digital pressure switch Series ZSE/ISE LED display digital pressure switch Series ISE High precision digital pressure switch with backlight Series ZSE5F/ISE5 -color display digital pressure switch Series ISE7/75/75H Digital pressure switch for general purpose fluid Series ISE5B Digital flow switch for water Series PFW Low maintenance filter Series FN Industrial filter Series FG Air filter element list P Front matter 6

9 Proposal Non-operation Purpose Reduction of air for purging and air leakage when equipment is non-operation. Before Improvement Since the compressor is in continuous operation even when the equipment is non-operation, air is constantly consumed due to air leakage and purging, etc. M/C Air purge Air leakage After Improvement Air supply to the equipment is stopped when it is non-operation. Master solenoid valve M/C Effect of Energy Saving Improvement Main Points Mount a master solenoid valve to each line and component. Pilot operated port solenoid valve Series VXD// Page 8 Air consumption % Before % Reduction After Pilot operated port solenoid valve Series VG Page 6 Pilot operated port solenoid valve Series VP5/65/85 Page 6 Front matter 7

10 Proposal Air Blow Purpose Reduction of air consumption for air blow Before Improvement Air blow is performed without any attachment at the air outlet. S S Without nozzles ø Effective area ratio.5 : Pressure loss: Large ø P S Workpiece P P S Effective area (mm ) Upstream side S:.6 Nozzle side S: 5. Effective area ratio S : S =.5 : Nozzle size (mm) ø Number of nozzles Regulator pressure (P). MPa Outlet pressure (P).8 MPa Collision pressure (P). MPa The pressure that the work piece receives is called collision pressure. After Improvement Nozzles are attached S Nozzle ø.5 Effective area ratio.5 : S Pressure loss: Small ø.5 P Workpiece P P Effective area (mm ) Upstream side S:.6 Nozzle side S: 6. Effective area ratio S : S =.5 : Nozzle size (mm) ø.5 Number of nozzles Regulator pressure (P).5 MPa Outlet pressure (P).5 MPa Collision pressure (P). MPa The pressure that the work piece receives is called collision pressure. S S Effect of Energy Saving Improvement Air consumption % 75% Reduction Before After Front matter 8

11 Blowing with Air Gun Before Improvement In the case of air guns, energy saving measures are not considered and the factory line pressure is used directly in most cases. S S Effective area ratio. : Pressure loss: Large Without nozzle ø Effective area (mm ) Effective area ratio Nozzle size (mm) Number of nozzles Supply pressure Regulator pressure Outlet pressure Pressure loss ø Pressure Loss of Air Gun Only Upstream side S: 5 Nozzle side S: 6. S : S =. : ø.7 MPa. MPa.6 MPa. MPa After Improvement A nozzle is attached to the tip of the air gun. A regulator is added and pressure control is improved. Fittings and tubing are changed to those with large effective areas. S S Filter regulator S coupler Coil tube Effective area ratio.7 : Pressure loss: Small Nozzle ø ø Effect of Energy Saving Improvement Pressure loss Min. Reduction Pressure Loss of Air Gun Only Effective area (mm ) Effective area ratio Nozzle size (mm) Number of nozzles Supply pressure Regulator pressure Outlet pressure Pressure loss Upstream side S: Nozzle side S:.8 S : S =.7 : ø.7 MPa. MPa.97 MPa. MPa Before After Front matter 9

12 Main Points Pressure loss improvement q The pressure loss has been improved by the straight air flow direction. Blow gun Series VMG Page 7 w Use small size nozzles to improve the effective area ratio with the upstream side. Nozzles for blowing Series KN Page 8 e Reduce pressure for optional usage. Regulator Filter regulator Series AR Page 8 Series AW Page r Improve effective area by changing fittings. S couplers Series KK Page 8 Large effective area Related Equipment Pilot operated port solenoid valve Series VXD// Pilot operated regulator Series AR5 to 95 Digital flow switch for air Series PFA High precision -color display digital pressure switch Series ZSE/ISE High precision digital pressure switch Series ISE Compact manometer Series PPA Polyurethane coil tubing Series TCU Energy Saving Program Ver. Hollow rod cylinders (Made to Order) Free mount cylinder for vacuum Series ZCUK Air leakage tester (Made to Order) P Front matter

13 Proposal Air Tools Purpose Reduction of air consumption for air tools Before Improvement As in the case of air guns, energy saving measures are not considered and the factory line pressure is used directly. Impact wrench Change in immediate pressure Pressure loss: Large Pressure (MPa) cycle (6 sec) Time Since the torque for impact wrenches, etc., is determined by the immediate pressure, a large pressure loss will cause problems such as torque instability and long cycle time. After Improvement Fittings and tubing are changed to those with large effective areas. A regulator is added and pressure control is improved. Change in immediate pressure Filter regulator S coupler Coil tube Pressure (MPa) Pressure loss: Small Before improvement cycle ( sec) Torque stability Shortened cycle time Effect of Energy Saving Improvement Air consumption % 5% Reduction Main Points Pressure loss improvement Methods and related equipment are the same as Proposal "Air Blow" on Front matter. Before After Front matter

14 Proposal 5 Air Leakage Purpose Stop air leakage from piping components Before Improvement to 5% of air consumption is accounted to air leakage. Since the compressor is in continuous operation regardless of whether equipment is in operation or at rest, a fixed amount of air is constantly consumed due to leakage from piping. Compressor operation status Flow rate Air leakage, purging Air consumption status Tubing, fittings Couplers Rubber hoses Other % 5% % 5% Air leakage is equivalent to to 5%. Air leakage Non-operation time Operating time Time Other Air leakage examples Air leakage from One-touch fittings due to bad cutting surface of tubing Air leakage from couplers due to bad sealing Air leakage from tubing due to chips, wear-out and spatter, etc. Leakage Leakage Leakage Front matter

15 Main Points q Select leakage resistant equipment. S couplers Series KK Page 8 w Use double layer tubing to prevent damage to tubing by chips, spatter and wear-out. Double layer tubing Series TRB/TRBU Page Sealed construction for reduced leakage Inner tube Soft nylon polyurethane Exterior layer FR double layer tubing cross section e Correct tube cutting surface by using special tools. Tube cutter Series TK Page 7 Double layer tube stripper Series TKS Page 6 Effect of Energy Saving Improvement Air consumption % % Reduction Related Equipment Air leakage tester (Made to Order) Digital flow switch for air Series PFA Water resistant air cylinders Air cylinder with heavy duty scraper (Made to Order) Air cylinder with coil scraper (Made to Order) P. 8 6 Before After Front matter

16 Proposal 6 Air Purge (Air Micro) Purpose Reduction of air consumption for air micro Before Improvement An air micro is used on machining equipment to confirm precision after machining. Air is constantly released regardless of the presence of a workpiece. Workpiece After Improvement The circuit is changed to supply air only when measuring workpieces. port air operated valve Workpiece port mechanical valve Main Points Stop the air supply depending on the presence of workpieces. port mechanical valve Series VM Page 6 Effect of Energy Saving Improvement Direct air operated port valve Series VXA/ Page 57 Air consumption % 95% Reduction Related Equipment Before After Air catch sensor Air catch sensor Series ISA Series ISA P. 5 Front matter

17 Proposal 7 Paint Stirring Purpose Reduction of air consumption for paint stirrer Before Improvement In a painting booth, it is necessary to have the stirrer in operation at all times to prevent paint from coagulating. Even when the line is not in operation, air is supplied in the same manner as when it is in operation. Stirrer Paint pump Paint tank After Improvement The circuit is changed to operate the stirrer with a minimal air supply when the line is not in operation. Stirrer Paint pump Paint tank Pilot operated port solenoid valve Flow switching port air operated valve Effect of Energy Saving Improvement Air consumption % 5% Reduction Main Points Switch the line flow rate depending on the operating time and non-operating time. Flow switching port air operated valve (Special order product) Series VKFA-X Page 7 Pilot operated port solenoid valve Series VP/5/7 Page 58 Before After Front matter 5

18 Proposal 8 Actuators Purpose Reduction of air consumption by actuators Before Improvement Cylinder output uses the same pressure for lifting or lowering. Use of an exterior guide adds extra weight. After Improvement By using a double power extension cylinder, a reduction in operating pressure or use of a smaller size cylinder is made possible. Use of a large bore tube rod and non-rotating mechanism makes the guide unnecessary. Effect of Energy Saving Improvement Air consumption % 5% Reduction Main Points Change to a non-rotating double power cylinder. Non-rotating double power cylinder Series MGZ Page Before After Front matter 6

19 After Improvement q To reduce the non-working side output for a lifter when the jig weight is heavy and the workpiece is light Pressure is reduced in the direction that is influenced by the jig and workpiece load. When a large load effects both lifting and lowering Regulator with check valve w To reduce the non-workting side output for horizontal transfer or a clamp A PFC valve is used to reduce pressure in the direction that is not affected by a smaller cylinder output, such as the transfer retraction side or unclamping side. PFC valve Only output to one side is necessary. QFC valve Main Points Reduce pressure on the nonworking side. (Change to a one side regulated circuit.) Regulator with check valve Series AR Page Air saving valves Series ASR/ASQ Page PFC/QFC valves Page Related Equipment Guide table Model Selection Program Ver.. SMC Pneumatics CAD System Ver..6 Series MGF P Front mater 7

20 Proposal 9 Vacuum Ejectors Purpose Reduction of air consumption for vacuum ejectors Before Improvement Normally, in the case of vacuum ejector suction, air needs to be constantly supplied to maintain the suction of a workpiece. Standard ejector Vacuum generation Assumed to be sec. After Improvement Use of an ejector with vacuum holding specification enables stopping air supply to maintain the suction at a workpiece. Air consumption is reduced by shortening the vacuum generation ti me. Ejector with check valve Ejector unit circuit Vacuum generation Vacuum holding Workpiece 8 kpa.5 sec.5 sec Note) Since vacuum pressure may drop due to leakage, etc., use a pressure switch to maintain the vacuum pressure necessary for the suction of a work piece. Effect of Energy Saving Improvement Air consumption % 5 to 75% Reduction Main Points Change to an ejector with built-in check valve. Vacuum ejector with check valve (Special order product) Page Related Equipment High precision -color display digital pressure switch High precision digital pressure switch Pad with check valve Series ZSE/ISE Series ZSE/ISE INO-769 (Special order product) P Before After Front matter 8

21 Before Improvement For suction of a workpiece with leakage, a large suction flow is necessary, which in turn necessitates the use of a larger nozzle size and increased air consumption. Single stage ejector ZH8 SUP. EXH. Vacuum pressure (kpa) Nozzle size ø.8 Air consumption 5 l/min Leakage VAC. 55 Suction flow (l/min) After Improvement Use of an ejector with -stage diffuser construction enables a reduction of the air consumption even with the same suction flow and vacuum pressure. Multistage ejector ZL Vacuum pressure (kpa) Nozzle size ø. Air consumption 6 l/min Leakage 55 Suction flow (l/min) Effect of Energy Saving Improvement Air consumption % 58% Reduction Main Points Change to an ejector with -stage diffuser construction. Multistage ejector Series ZL/ Page 9 Before After Front matter 9

22 Proposal Liquid Removal Purpose Reduction of air for a liquid removal pump Before Improvement Removal of oil waste accumulated in the oil pan under a machine or conveyor. The pump is in operation regardless of the amount of liquid and this causes a great energy loss. P Air operated liquid removal pump Machine Oil pan Damage to the diaphragm due to operating without accumulated liquid Clogged check valve due to foreign matter (chips, etc.) Oil waste After Improvement Suction method is changed to an ejector operated type and an automatic stop circuit is installed to stop operation when there is no liquid. Removal of water soluble coolant Ejector Removal of oil based coolant Machine Water soluble coolants are directly suctioned for removal by the ejector. Ejector Tank Effect of Energy Saving Improvement Machine Since oil based coolants are easily vaporized, they are temporarily stored in a tank. Air consumption % 7 to 95% Reduction Before After Front matter

23 Main Points Start or stop the pump depending on the presence of liquid (waste). q Suction by an ejector prevents clogging (without check valve mechanism) Vacuum ejector for water soluble coolant removal (Special order product) Page 6 Vacuum ejector (for oil based coolant removal) ZH Page 6 w An automatic shut off circuit prevents operation when there is no liquid. Circuit example Discharge side Negative pressure detection valve Removal side Negative pressure detection valve (Special order product) Page Related Equipment In-line vacuum ejector High precision digital pressure switch for general fluids Digital pressure switch with backlight Series ZU Series ZSE5F/ISE5 Series ZSE5B/ISE5B P Front matter

24 Proposal Coolant (Cleaning) Pump Purpose Reduction of electric power consumption for coolant pump Before Improvement Coolant is blown without any attachment at the coolant outlet. Without nozzle For cutting For jig (Blade cooling) (Reference surface cleaning) Small diameter piping S Effective area ratio. : Large diameter nozzle S Pressure loss: Large Washing bed (Washing chips) Workpiece ø Pump capacity Pressure P Pump head (electric power) Discharge rate Pressure Pump outlet Pressure loss: Large Nozzle outlet After Improvement Pressure loss is reduced by attaching nozzles. With nozzle Large diameter piping S Effective area ratio : Small diameter nozzle S Pressure loss: Small ø6 P Pump head (electric power) Pump capacity Previous rate Discharge rate Pump outlet Pressure Pressure loss: Small Nozzle outlet Effect of Energy Saving Improvement Electric power consumption % 75% Reduction Before After Main Points Improve pressure loss. Improve the effective area ratio with the upstream side by using a small diameter nozzle. Nozzles for blowing Series KN Page 8 Related Equipment High precision digital pressure switch for general fluids -color display digital pressure switch Digital pressure switch with backlight Energy Saving Program Ver. Industrial filter Low maintenance filter Series ZSE5F/ISE5 Series ISE7/75/75H Series ZSE5B/ISE5B Series FG Series FN P Front matter

25 Before Improvement For bed washing (chip washing), coolant is discharged constantly without any restraint. For cutting For jig (Blade cooling) (Reference surface cleaning) Bed washing (Washing chips) Nozzle KN Coolant flow/cycle For cutting For jig Flow rate For cutting For cutting For jig P Bed washing Bed washing cycle After Improvement Bed washing is stopped when blowing for cutting or jig. Coolant flow/cycle For cutting For jig Flow rate For cutting For cutting The amount of reduction is shown by the shaded area. P Bed washing Bed washing For jig cycle Bed washing Coolant valve Main Points Improve pressure loss. Supply and stop coolant for bed washing. Coolant valve Series VNC Page 68 Effect of Energy Saving Improvement Electric power % consumption to 5% Reduction Before After Related Equipment High precision digital pressure switch for general fluids Series ZSE5F/ISE5 -color display digital pressure switch Series ISE7/75/75H Digital pressure switch with backlight Series ZSE5B/ISE5B Energy Saving Program Ver. Industrial filter Series FG Low maintenance filter Series FN P Front matter

26 Proposal Cooling Water Purpose Reduction of electric power consumption for cooling water pump Before Improvement Regardless of operating or non-operating state of a welding gun, cooling water is constantly discharged. Header IN P P Pump OUT Cooling water tank Welder After Improvement Stop cooling water supply when not welding. Header port solenoid valve IN P P Pump OUT Cooling water tank Welder Effect of Energy Saving Improvement Electric power consumption % to 5% Reduction Main Points Stop the supply of cooling water when not welding. Zero differential pressure operated port solenoid valve Series VXZ Page 55 Before After Related Equipment Digital flow switch for water Series PFW P. 8 Front matter

27 Proposal Hydraulic Clamp Purpose Reduction of electric power consumption for hydraulic clamp Before Improvement A hydraulic unit is used for workpiece clamping when cutting is performed. Hydraulic cylinder Hydraulic control valve M Hydraulic cylinder Workpiece Hydraulic control valve Hydraulic pump P After Improvement By performing air-hydro conversion for the clamping process, the use of the hydraulic unit is eliminated. Cutting feed is electrically driven. Air-hydro converter M M Air-hydro booster Workpiece Hydraulic cylinder Effect of Energy Saving Improvement Electric power consumption % to 5% Reduction Main Points Convert to high output hydraulic drive. Air-hydro booster (Made to Order) Page Before After Air-hydro converter Series CCT Page 5 Front matter 5

28 Proposal Low Power Consumption/Long Service Life Purpose Reduction of power used for solenoid valve energization, and service life improvement After Improvement Electric power used for solenoid valve energization is reduced by using low power consumption solenoid valves. Also, the use of a metal seal construction improves the service life. Main Points 5 port solenoid valve Series SY.5 W/. W (with energy saving circuit) 5 port solenoid valve Series VQ/Metal seal.5 W( ma, VDC) million cycles port solenoid valve Series VQ/.5 W( ma, VDC) million cycles These values are based on SMC life test conditions. For more details refer to Best Pneumatics catalog Vol. //7. Front matter 6

29 Front matter 7

30 Actuators Actuators Non-rotating double power cylinder Guide table PFC/QFC valves Air saving valves Hollow rod cylinders Free mount cylinder for vacuum Water resistant air cylinders Air cylinder with heavy duty scraper Air cylinder with coil scraper Air-hydro booster Air-hydro converter Series Application Page MGZ MGF PFC/QFC valves ASR/ASQ (Made to Order) ZCUK (Made to Order) (Made to Order) (Made to Order) CCT Actuator Actuator Actuator Actuator Air blow Air blow Air leakage Air leakage Air leakage Hydraulic clamp Hydraulic clamp

31 Non-rotating Double Power Cylinder Series MGZ ø, ø5, ø6 Actuator Front end lock type and mounting brackets now available End lock holds the rod when extended Transaxial foot style, front flange style and rear flange style New Non-rotation guide is unnecessary! Employs a large bore tube rod up to 8% of the cylinder's external square dimension plus slide bearings. In addition, a built-in non-rotation mechanism using slide keys allows direct mounting of loads. Slide key x Tube rod diameter External square dimension Long stroke capability with space savings Strokes up to mm are possible. The overall cylinder length is not two or more times the stroke length, as is the case with conventional double output cylinders (tandem type). Double output power for extension! (Approx. % reduction) Air pressure supplied from A operates on surfaces q and w. (extension) q w A B Clean external appearance Auto switches are contained in grooves on four sides Air pressure supplied from B operates on surface e. (retraction) e A B Piping is centralized on the head cover. Mounting accuracy improved Positioning holes are provided on the workpiece mounting surface for easy alignment. Regulator with check valve is unnecessary A regulator with check valve normally required for a lifting circuit becomes unnecessary. Applications Pressing High strength with space savings Moment resistance is equal to that of a guide cylinder (cylinder + two guide shafts). Furthermore, the mounting cross section is reduced by approximately %. Gripping Pusher Shooter Lifter

32 Non-rotating Double Power Cylinder Series MGZ How to Order Standard Type MGZ Z Y7BW Nil L F G Mounting Basic style Transaxial foot style Front flange style Rear flange style 5 6 Bore size mm 5 mm 6 mm Number of auto switches Nil S pcs. pc. Auto switch type Without auto switch Nil (Built-in magnet cylinder) Select applicable auto switch models from the table below. Auto switches are shipped together, (but not assembled). Actuators Coil scraper Nil Z None Yes Stroke (mm) Refer to the standard stroke table. Applicable Auto Switches: Direct Mount Type Type Special function Electrical entry Indicator light Wiring (output) DC Load voltage AC Auto switch model Electrical entry direction Perpendicular In-line Lead wire length (m).5 (Nil) (L) 5 (Z) Applicable load Reed switch Solid state switch Diagnostic indication ( color indicator) Grommet Grommet -wire (NPN) Water resistant ( color indicator) -wire V Note ) Lead wire length symbols:.5 m... Nil (Example) Y59B m... L Y59BL 5 m... Z Y59BZ Note ) Solid state switches marked with a "" symbol are produced upon receipt of order. Note ) When later installing auto switches on a cylinder ordered without auto switches, the switch spacers in the table below are necessary. Yes Yes 5 V -wire V V -wire (NPN) 5 V, V -wire (PNP) -wire V -wire (NPN) V -wire (PNP) 5 V, V V Y69A Y7PV Y69B Y7NWV Y7PWV Y7BWV Z76 Z7 Y59A Y7P Y59B Y7NW Y7PW Y7BW Y7BA IC circuit IC circuit IC circuit Relay, PLC Relay, PLC Switch Spacer Applicable bore size (mm) Switch spacer Mounting Bracket Part No. Bore size (mm) Foot MGZ-L Flange MGZ-F, 5, 6 BMP- 5 6 MGZ-L5 MGZ-L6 MGZ-F5 MGZ-F6 Switch spacer

33 Series MGZ Specifications Bore size (mm) Action Fluid Proof pressure Maximum operating pressure Minimum operating pressure Ambient and fluid temperature Lubrication Piston speed Stroke length tolerance Cushion Thread tolerance Port size Mounting 5 6 Double acting, Single rod Air.5 MPa. MPa Standard stroke:.8 MPa Long stroke:. MPa Without auto switch: to 7 C (with no freezing) With auto switch: to 6 C (with no freezing) Non-lube Extending: 5 to 7 mm/s Retracting: 5 to 5 mm/s to 5, 5 to Rubber bumper JIS class Rc / Basic style, Transaxial foot style, Front flange style, Rear flange style Standard Stroke Bore size (mm), 5, 6 Standard stroke (mm) 75,, 5, 5, 75, 5, Long stroke (mm) 5,, 5, 5, 6 7, 8, 9, Intermediate strokes and strokes of less than 75 mm can also be manufactured. Weight Bore size (mm) Standard weight Additional weight per 5 mm of stroke Basic style Foot style Flange style All brackets (kg) Theoretical Output Model MGZ MGZ5 MGZ6 Bore size (mm) 5 x 55 x x 6 6 Rod size (mm) 5 Operating direction OUT IN OUT IN OUT IN Piston area (mm ) Operating pressure (MPa) (N)

34 Non-rotating Double Power Cylinder Series MGZ Dimensions Basic style -RcP GA GB ød Y Y -MM depth M øxa H7 depth XL +. Actuators øi x -J E KA C B K H MC N S + Stroke ZZ + Stroke N MA MB Allowable angle displacement of E to B is ±.5. (mm) Bore size (mm) Stroke range B C D E KA GA GB H I J K M 5 6 to to to M6 x. M8 x.5 M8 x Bore size (mm) Stroke range MA MB MC MM N P S XA XL Y ZZ 5 6 to to to M6 x. M8 x.5 M8 x / / /

35 Series MGZ Dimensions: With Mounting Bracket Transaxial foot style: (L) -øld through (mm) X Y z LH LT LX LY LZ LS ZZ 5 6 to to to Front flange style: (F) (mm) B FD FT FX FY FZ Rear flange style: (G) -øfd FY B LT LH LY X/ X X LX Y LS + Stroke LZ ZZ + Stroke Bore size (mm) Stroke range -øfd FY B FX FZ FT Bore size (mm) Stroke range to to to FX FZ ZZ + Stroke FT (mm) Bore size (mm) Stroke range B FD FT FX FY FZ ZZ to to to

36 Non-rotating Double Power Cylinder Series MGZ Construction q i w!6!5!!! With coil scraper Component Parts No Description Rod cover Head cover Cylinder tube Piston rod Tube rod Tube rod cover Piston Stationary piston Bushing Thrust plate Holder Pin Tie-rod Material Aluminum alloy Aluminum alloy Aluminum alloy Aluminum alloy Carbon steel pipe Carbon steel Aluminum alloy Aluminum alloy Lead bronze casting Lead bronze casting Aluminum alloy Carbon steel Carbon steel Note Clear anodized Clear anodized Hard anodized Hard anodized Hard chrome plated Electroless nickel plated Chromated Chromated Chromated Zinc chromated Corrosion resistant chromated No Description Tie-rod nut Hexagon socket head cap screw Spring washer Bumper Wear ring Magnet Rod seal A Rod seal B Piston seal Piston gasket Tube rod gasket Cylinder tube gasket Coil scraper Material Carbon steel Chrome molybdenum steel Steel wire Urethane Resin Magnetic material NBR NBR NBR NBR NBR NBR Metal Note Nickel plated Nickel plated Nickel plated Replacement Parts: Seal Kit Bore size (mm) Kit no. MGZ-PS 5 MGZ5-PS 6 MGZ6-PS Content A set of above nos. and 5. Seal kits consist of a set of items and 5, which can be ordered using the seal kit number for each bore size. 7

37 Series MGZ How to Order With End Lock MGZ R Y7BW Nil L F G Mounting Basic style Transaxial foot style Front flange style Rear flange style 5 6 Bore size mm 5 mm 6 mm With front end lock Stroke (mm) Refer to the standard stroke table. Number of auto switches Nil S pcs. pc. Auto switch type Without auto switch Nil (Built-in magnet cylinder) Select applicable auto switch models from the table below. Auto switches are shipped together, (but not assembled). Applicable Auto Switches: Direct Mount Type Type Reed switch Solid state switch Special function Diagnostic indication (-color indicator) Electrical entry Grommet Grommet Indicator light Wiring (output) -wire (NPN) Water resistant (-color indicator) -wire V Note ) Lead wire length symbols:.5 m... Nil (Example) Y59B m... L Y59BL 5 m... Z Y59BZ Note ) Solid state switches marked with a "" symbol are produced upon receipt of order. Note ) When later installing auto switches on a cylinder ordered without auto switches, the switch spacers in the table below are necessary. Yes Yes DC Load voltage 5V -wire V V -wire (NPN) 5 V, V -wire (PNP) -wire V -wire (NPN) V -wire (PNP) 5 V, V AC V Switch spacer Auto switch model Electrical entry direction Perpendicular In-line Y69A Y7PV Y69B Y7NWV Y7PWV Y7BWV Z76 Z7 Y59A Y7P Y59B Y7NW Y7PW Y7BW Y7BA Lead wire length (m).5 (Nil) (L) 5 (Z) Applicable load IC circuit IC circuit IC circuit Relay, PLC Relay, PLC Switch Spacer Applicable bore size (mm) Switch spacer Mounting Bracket Part No. Bore size (mm) Foot MGZ-L Flange MGZ-F, 5, 6 BMP- 5 6 MGZ-L5 MGZ-L6 MGZ-F5 MGZ-F6 8

38 Non-rotating Double Power Cylinder Series MGZ Cylinder Specifications Bore size (mm) Action Fluid Proof pressure Maximum operating pressure Minimum operating pressure Ambient and fluid temperature Lubrication Piston speed Stroke length tolerance Cushion Thread tolerance Port size Mounting 5 6 Double acting, Single rod Air.5 MPa. MPa. MPa Without auto switch: to 7 C (with no freezing) With auto switch: to 6 C (with no freezing) Non-lube Extending: 5 to 7 mm/s Retracting: 5 to 5 mm/s to 5, 5 to Rubber bumper JIS class Rc / Basic style, Transaxial foot style, Front flange style, Rear flange style Except for the lock section, the minimum operating pressure is.8 MPa (. MPa for long strokes). Actuators Lock Specifications End lock position Holding force (maximum) N Backlash Manual release ø 77 Front only ø5 69 mm or less Non-locking type ø6 6 Adjust an auto switch's position so that it operates for movement to both the stroke end and backlash ( mm) positions. Standard Stroke Bore size (mm) Standard stroke (mm) Long stroke (mm), 5, 6 75,, 5, 5, 75, 5, 5,, 5, 5, 6 7, 8, 9, Intermediate strokes and strokes of less than 75 mm can also be manufactured. Weight Bore size (mm) Standard weight Additional weight per 5 mm of stroke Basic style Foot style Flange style All brackets (kg) Theoretical Output Model MGZ MGZ5 MGZ6 Bore size (mm) 5 x 55 x x 6 6 Rod size (mm) 5 Operating direction OUT IN OUT IN OUT IN Piston area (mm ) Operating pressure (MPa) (N)

39 Series MGZ Construction qo#irt ue End lock Component Parts No Description Rod cover Head cover Cylinder tube Piston rod Tube rod Tube rod cover Piston Stationary piston Bushing Thrust plate Holder Pin Tie-rod Tie-rod nut Hexagon socket head cap screw Spring washer Bumper Wear ring Magnet Cap Material Aluminum alloy Aluminum alloy Aluminum alloy Aluminum alloy Carbon steel pipe Carbon steel Aluminum alloy Aluminum alloy Lead-bronze casting Lead-bronze casting Aluminum alloy Carbon steel Carbon steel Carbon steel Chrome molybdenum steel Steel wire Urethane Resin Magnetic material Bronze alloy Note Clear anodized Clear anodized Hard anodized Hard anodized Hard chrome plated Electroless nickel plated Chromated Chromated Chromated Zinc chromated Corrosion resistant chromated Nickel plated Nickel plated Nickel plated Electroless nickel plated No Description Lock holder Lock piston Stopper Collar Port block Pipe Lock spring Rubber cap Rod seal A Rod seal B Piston seal Piston gasket Tube rod gasket Cylinder tube gasket Lock piston seal A Lock piston seal B Lock piston seal C Lock holder gasket Port block gasket Pipe gasket Material Note Stainless steel Carbon steel Quenched, Hard chrome plated Carbon steel Quenched Lead-bronze casting Bronze alloy Electroless nickel plated Bronze alloy Steel wire Synthetic rubber NBR NBR NBR NBR NBR NBR NBR NBR NBR NBR NBR NBR Replacement Parts: Seal Kit Bore size (mm) 5 6 Kit no. MGZR-PS MGZ5R-PS MGZ6R-PS Content A set of above nos. 9,, 5, 6, 7, 8, 9 and. Seal kits consist of a set of items 9 and through, which can be ordered using the seal kit number for each bore size.

40 Non-rotating Double Power Cylinder Series MGZ Dimensions Basic style DL -Rc P GA GB -MM depth M øxa H7 depth XL øi ød Y Y WM Actuators +. WL LL LM HR x -J E MB KA MC MA C K NB N B H S + Stroke ZZ + Stroke (mm) Bore size (mm) 5 6 Stroke range to to to B C D DL E 6 GA GB H 5 5 HR I 78 9 J M6 x. M8 x.5 M8 x.5 K KA LL LM Bore size (mm) 5 6 Stroke range to to to M MA MB 5 5 MC 5 5 MM M6 x. M8 x.5 M8 x.5 N 5 56 NB P / / / S 68 8 XA 6 6 XL Y WL WM ZZ

41 Series MGZ Dimensions: With Mounting Bracket Transaxial foot style: (L) -øld through LT LH LY X/ LX LZ Y X LS + Stroke ZZ + Stroke X (mm) Bore size (mm) Stroke range X Y LD LH LT LX LY LZ LS ZZ 5 6 to to to Front flange style: (F) -øfd FY B FX FZ FT (mm) Bore size (mm) Stroke range B FD FT FX FY FZ Rear flange style: (G) 5 6 to to to øfd FY B FX FZ ZZ + Stroke FT (mm) Bore size (mm) Stroke range B FD FT FX FY FZ ZZ 5 6 to to to

42 Double Power Cylinder (Without non-rotating mechanism) Series MGZR ø, ø5, ø6 Actuator How to Order Standard Type MGZ R Y7BW Without non-rotating mechanism Nil L F G D Mounting Basic style Transaxial foot style Front flange style Rear flange style Double clevis style 5 6 Bore size mm 5 mm 6 mm Number of auto switches Nil S pcs. pc. Auto switch type Without auto switch Nil (Built-in magnet cylinder) For the applicable auto switch model, refer to the table below. Auto switches are shipped together, (but not assembled). Stroke (mm) Refer to Standard Stroke on the next page. Actuators Applicable Auto Switches Type Reed switch Solid state switch Special function Diagnostic indication (-color indication) Improved water resistance (-color indication) Electrical entry Indicator light Grommet Yes Wiring (Output) -wire (NPN equiv) -wire -wire (NPN) -wire (PNP) -wire Grommet Yes -wire (NPN) -wire (PNP) -wire Lead wire length symbols:.5 m Nil (Example) Y59A m L (Example) Y59AL 5 m Z (Example) Y59AZ Load voltage DC 5 V V V 5 V, V V V 5 V, V AC Auto switch model Perpendicular Lead wire length (m) Pre-wired.5 5 (Nil) (L) (Z) connector Retrofitting of an auto switch on a clinder that is originally ordered without one requires a switch spacer per the table below. V In-line Z76 V Y69A Y7PV Y69B Y7NWV Y7PWV Y7BWV Z7 Y59A Y7P Y59B Y7NW Y7PW Y7BW Y7BA Applicable load IC circuit IC circuit IC circuit Solid state switches marked are produced upon receipt of order. Relay, PLC Relay PLC Switch Spacer Applicable bore size (mm) Switch spacer, 5, 6 BMP- Mounting Bracket Part No. Bore size(mm) Foot Flange Note ) Double clevis MGZ-L MGZ-F MGZ-D 5 MGZ-L5 MGZ-F5 MGZ-D5 6 MGZ-L6 MGZ-F6 MGZ-D6 Note ) Double clevis bracket is provided with clevis pins and cotter pins. Switch spacer

43 Series MGZR Specifications Bore size (mm) Action Fluid Proof pressure Max. operating pressure Min. operating pressure Ambient and fluid temperature Lubrication Piston speed Stroke length tolerance Cushion Screw tolerance Port size Mounting 5 6 Double acting, Single rod Air.5 MPa. MPa Standard stroke:.8 MPa Long stroke:. MPa Without auto switch: to 7 C (With no freezing) With auto switch: to 6 C (With no freezing) Non-lube OUT: 5 to 7 mm/s IN: 5 to 5 mm/s Up to 5, 5 to Rubber bumper JIS class Rc / Basic style, Transaxial foot style, Front flange style Rear flange style, Double clevis style Standard Stroke Bore sizes (mm), 5, 6 Standard stroke (mm) 75,, 5, 5, 75, 5, Long stroke (mm) 5,, 5, 5, 6 7, 8, 9, Intermediate strokes and strokes shorter than 75 mm are also available. Weight Bore size (mm) Standard weight Weight per each 5 mm of stroke Basic style Foot style Flange style Double clevis style All mounting brackets (kg) Theoretical Output Model MGZR MGZR5 MGZR6 Bore size (mm) 5 x 55 x x 6 6 Rod size (mm) 5 Operating direction OUT IN OUT IN OUT IN Piston area (mm ) Operating pressure (MPa) (N)