Since the first factories in the 18th century, moving has been a major problem, and pneumatics solve current and future needs of automation.  Pneumatic valve has been part of the industry for a very long time and it has advanced a long way. Originally they were designed for simple tasks like opening and closing, but now they power countless mechanical processes.  With the start of industry 4.0, demand for smarter components is increasing. In the present time, many different industries, such as automotive, pharmaceuticals, food processing, and packaging, are shifting to Pneumatic valve innovations that focus on digital transformation and intelligent operations.    VS Pneumatics has put together this guide, which advances you through the latest pneumatics tech trends of the industry. 

Understand pneumatics: Traditional vs Smart

Pneumatic valves is a system which works by controlling air flow, directions etc in big automation systems. They were made for purely mechanical functions which use brute force, durability and simplicity. 

Traditional Pneumatic valves

• They were rugged, strong, lasting and straightforward to use. 
• You don’t get any feedback, diagnostics or alarms. 
• Electronic control of these is manual and basic. 

Smart pneumatic valves

• These are not that simple, and they come with sensors and communication models. 
• These are very advanced and can report real-time flow rate, status, and errors.  
• You can integrate this without much issue into automated control networks. 

What can make a Pneumatic valve smart

These are the additional components which make your normal pneumatics into smart one’s. 

• Sensor: Whether it be Pressure, temperature, flow, and position. Every data can be processed and shown at any moment.
• Communication protocols: You can transfer information in real time to PLCs and cloud platforms from IO-Link, EtherNet/IP, and Profinet. 
• Self diagnostics: The System itself can monitor how valves are wearing, check for air leaks, and review fault statuses. 
• Predictive Maintenance: Issues are spotted in advance so downtime is less likely to happen and your work won’t have to stop. 
• Edge Intelligence: Some valves are now able to check and analyze information for faster decision making. 

What are the benefits smart pneumatic valves have?

Main thing is why should anyone invest in Smart pneumatics valves. As an industry or factory they can give you these generous benefits:

• Reduce downtime: Real-time alerts from the machine support maintenance teams in avoiding problems before they happen.
• Energy reduction: You can keep watch over air use and properly time the valves so no extra energy is used or wasted. 
• Data Analytics: you can review how your products are used to improve the efficiency of resource planning and allocation. 
• Predictive maintenance: Service is made predictable so that you can plan ahead for any maintenance or repairs. Planned maintenance can help you to utilise time properly. 

What are the challenges in adopting Smart Pneumatic Valves?

Throughout history, every kind of change has many hurdles, and with pneumatic it is also similar. They have also seen many issues from installation to adaptation:

• Cost: As they are not common for the manufacturer,r they have higher initial costs but they balance it out with the benefits they provide. 
• Training: Normal labourers and technicians of the manufacturing field are not enough to handle them. You might need a capable tech savvy person to operate and interpret data. 
• Legacy compatibility: This is one of the major issues. Some systems are not flexible enough to incorporate new tech and they might need complete overhaul.
• Cybersecurity: You might need the help of experts as connectivity comes with both profits and risk of hacking. So ensure data is encrypted and access controlled. 

New real world applications of smart pneumatic valves

• Automotive: In the Automotive industries smart valves control robotic arms which helps in lifting heavy objects and precise movements. Pneumatic valves also help detect leaks in brake line tests. 
• Pharmaceuticals: Valves helps with enabling sterile and cleanroom-compatible air systems. You can track the cycle times and monitor valve status remotely for improved efficiency. 
• Food and Beverage: This can help to maintain the health standards for food and drinks and also gives you a controlled filling system which ensures proper tracking.
• Logistics and packaging: You can set the system conditions so that air-powered conveyors are used at their best, handle packages on time, and keep track of how they are used.

Conclusion

Simply stating pneumatic valves started as reliable parts and have now become intelligent systems. The new design of pneumatic valves makes factories more effective, lowers the number of breakdowns, and gives you access to real-time information. Even though installing and training them costs some upfront effort, the results in the future are very rewarding. If you wish to elevate your equipment, smart pneumatic valves are the right choice in the future.   You’d like to find out which works best for your company? Get assistance from VS Pneumatics whenever you need it.  

Glossary 

• Pneumatic valve: A Device that controls air flow in machines using compressed air. 
• Industry 4.0: The Shift we have seen in industries toward smart, connected and automated industries. 
• Automation system: Machines and setups that can work without humans controlling them. 
• Sensors: A device that can detect movements, air pressure, flow, etc. 
• Communication protocol: These are the methods used by smart devices to share data. 
• PLC: Programmable logic controller. 
• Self diagnostics: The Process with machine checks itself which of its components are working. 
• Downtime: A Period in which work is not progressing and has stopped or is stalled.