The Digital Evolution of Pneumatic Technology

Where does the digital evolution of pneumatic technology fit into smart factories?

With the rise of Industry 4.0 and smart factories, find out how pneumatic technology is evolving towards a new digital era of manufacturing.

Pneumatic technology has been a mainstay in manufacturing processes for decades, powering everything from factory automation to transportation systems.

Now, it's evolving to stay in pace with the digital overhaul of the industry.

In recent years, pneumatics manufacturers have been enhancing their devices to make them not only more efficient but truly connected, following the broad trend of digitalisation in industrial equipment.

Today, it’s extremely common to see pneumatic products featuring industrial ethernet and IO-Link interfaces – a clear shift from fieldbus products.

Why are companies choosing to embrace these advanced digital interfaces, and how is this digital evolution reshaping pneumatic technology as we know it?

In this article, we’ll dive into the benefits of ethernet and IO-Link in industrial processes, how pneumatic technology has joined the digital evolution, and where pneumatics will fit into the smart factories of the future.

How do industrial ethernet and IO-Link benefit industrial processes?

The integration of industrial ethernet and IO-Link technology has transformed pneumatic systems and opened up new possibilities for manufacturers.

Enhanced connectivity and monitoring

Industrial ethernet and IO-Link interfaces provide monitoring in unprecedented detail. Providing insights into performance metrics like movement, position, and flow allows operators to closely monitor efficiency and equipment health – essential for maintaining high performance and system reliability.

Advanced sensor integration

While protocol connectivity from fieldbus-based systems provides only basic diagnostics, sensors take it a step further by allowing comprehensive system performance monitoring and predicting potential issues.

As a result, we’re seeing a significant uptake in the integration of sensors across manufacturing operations.

Using real-time and historical data is particularly important for predictive maintenance, helping to reduce unplanned outages and increase productivity. For example, by storing and analysing historical machine data, operators can spot trends, anticipate maintenance needs, and prevent unplanned downtime.

Improved decision-making and efficiency

Measuring, monitoring, and having the ability to use data from digital systems all support smarter, more strategic decision-making.

Insights into machine performance give operators the power to optimise performance, carry out effective preventative maintenance, and boost operational efficiency. This data-driven approach helps manufacturers meet their productivity goals more consistently, and adjust their strategies based on live feedback from connected systems.

The digital evolution of pneumatic technology

Digitalisation in industrial settings has seen a shift towards performance insights and advanced data measurement in pneumatics.

One key example of this overall shift towards digital technology is “smart dashboards”. These allow operators to access real-time data streams and interact with their pneumatic systems in new ways.

But while data collection is one thing, understanding that data is another thing entirely. That’s why technology and pneumatic system manufacturers need to collaborate closely together to pool their expertise and allow system users to unlock actionable insights from these data streams.

In addition, while control and sensing connectivity on pneumatics is almost entirely wired today, more wireless installation and data communication is set to enter the fray. As technology becomes more robust, the industry will need advancements in security and reliability to pave the way for seamless, wireless pneumatic networks.

Machine builders will also need to foster strong partnerships with pneumatics suppliers that can provide a scalable, flexible platform for future product development, and support them as technology moves forwards.

We collaborate closely with our customers and continually assess the market to always stay in the know, shaping our ongoing product development strategy.

Where do pneumatics fit into the factories of the future?

With the rise of Industry 4.0 and digitalised manufacturing, smart factories are booming. Driven by technological advancements like artificial intelligence, IIoT, and robotics, they promise to be the ultimate in efficient manufacturing. The global market for these “factories of the future” is expected to grow by over 10% every year, up to a forecasted $164 billion in 2029.

So where does pneumatic technology fit into this?

There are two key areas that represent both opportunities and challenges for pneumatic systems in these smart factories – automation and sustainability.

Automation

Automation is revolutionising factory floors, and pneumatics is a critical part of this transformation. By automating some of the tasks traditionally performed by human operators, automation enhances consistency, quality, and workplace safety.

But there’s a problem. The inherent variation in production lines – which can differ by product size, shape, and weight – poses an enormous challenge for automation.

However, advances in AI and flexible machines are already making headway in tackling this issue.

Advanced AI-driven control systems – along with programmable proportional valves, positioners, and actuators – provide the flexibility and precision needed for pneumatics to adapt to these varied demands.

Sustainability in manufacturing

Another key challenge – and opportunity – for pneumatic systems in manufacturing is in sustainability. With manufacturing a typically energy-intensive sector, sustainability has become a top priority in recent decades, with increasing pressure to reduce their carbon footprints.

For instance, many factories use compressed air extensively. Yet this resource is often used inefficiently, with leaks and inefficiencies commonly found in compressors, actuators, and filter regulator lubricators (FRLs).

Connected devices can help operators map out machine performance, identify areas where compressed air is wasted, and allow them to make adjustments that minimise inefficiencies.

By making the use of compressed air more efficient and lowering energy consumption, pneumatic systems can help factories achieve sustainability goals, cut carbon emissions, and improve their operational footprint.

This commitment to sustainability isn’t just good news for the planet – it’s also a great opportunity for manufacturers. Lower electricity consumption and optimised use of compressed air can yield enormous cost savings, with pneumatic technology helping factories become both more sustainable and profitable.

Be part of the digital journey in pneumatics

Are you a manufacturer or OEM looking to boost efficiency, cut costs, and reduce the carbon footprint for your production plant?

Our expert team is committed to helping you embrace greener, more efficient practices to protect the planet and your profits. Get in touch today to find out how we can help you save money and stay competitive in a digital manufacturing era.