Maintenance and Use of SMC Pneumatic Components in Japan

August 08, 2024

The positioning accuracy of SMC actuators is improved, the stiffness is increased, the piston rod does not rotate, and it is more convenient to use. In order to improve the positioning accuracy of pneumatic cylinders, the application of pneumatic cylinders with braking mechanisms and servo systems is becoming increasingly common. For pneumatic cylinders with servo systems, a positioning accuracy of ± 0.1mm can still be achieved even if the supply pressure and negative load change.

At international exhibitions, there are many cylinders, cylinders, and piston rods with various irregular cross-sections. Due to the non rotating piston rods of these types of cylinders, they can maintain a certain level of accuracy when applied to the host without the need for additional guiding devices. In addition, many cylinders and cylinder sliding components with various guiding mechanisms have been developed, such as dual guide rod cylinders, dual piston rod dual cylinder cylinders, etc.

The shape of the Cylinder Barrel is no longer limited to circular, but square, meter or other shapes. The profile is equipped with guide slots, sensor and switch installation slots, etc., making it more convenient for users to install and use.

Multi functional and composite. In order to facilitate users and meet market demand, various small pneumatic systems have been developed, which combine multiple pneumatic components and are equipped with control devices. For example, the component used to move small items consists of two cylinders with guide rails along the X-axis and Z-axis, respectively. This component is capable of moving a 3kg weight and is equipped with solenoid valves and program controllers. It has a compact structure, small footprint, and adjustable stroke. Another example is the loading and unloading module, which has seven different functional module forms and can complete loading and unloading operations on precision assembly lines. Different modules can be combined according to the operation content. There is also a type of robotic arm that is a combination of a swing cylinder and a smaller shaped clamp, which can change the swing angle. There are several types of chuck parts to choose from.

Combining electronic technology, utilizing a large number of sensors, and intelligentizing pneumatic components. Cylinders with switches have been widely used in China, with smaller switch sizes and higher performance, making the system more reliable. Using sensors instead of flow meters and pressure gauges can automatically control the flow and pressure of compressed air, thereby saving energy and ensuring the normal operation of equipment. The pneumatic servo positioning system has entered the market. The system uses a three position five pneumatic servo valve to compare the predetermined positioning target with the detection data of the position sensor and achieve negative feedback control. When the maximum speed of the cylinder reaches 2m/s and the stroke is 300mm, the positioning accuracy of the system is ± 0.1mm. A new type of intelligent solenoid valve has been successfully developed in Japan. The valve is equipped with a logic circuit with sensors, which is a product of the combination of pneumatic components and optoelectronic technology. It can directly receive signals from sensors, and when the signals meet specified conditions, it can perform actions on its own without the need for an external controller to achieve control objectives. It has been applied to the conveyor belt of objects, which can recognize the size of the objects to be carried, so that large items can be directly sent or small items can be transferred.

Higher security and reliability. From the international standards of pneumatic technology in recent years, these standards not only require interchangeability, but also emphasize safety. The pressure test pressure for pipe joints, gas source processing shells, etc. should be increased to 4-5 times the working pressure, and the pressure resistance time should be increased to 5-15 minutes. The test should be conducted at high and low temperatures. If these international standards are implemented, it will be difficult for domestically produced cylinders, end caps, air source processing castings, and pipe joints to meet the standard requirements. In addition to the pressure testing site, there are also certain regulations for the structure. For example, the exterior of a transparent casing treated with a gas source needs to be equipped with a metal protective cover.

Many applications of pneumatic components, such as rolling mills, textile production lines, etc., cannot be interrupted during working hours due to the quality of pneumatic components, otherwise it will cause huge losses. Therefore, the reliability of pneumatic component operation is very important. There are many pneumatic components used on sailboats, but there are not many pneumatic component factories that can enter this field. The reason is that they have particularly high reliability requirements for pneumatic components and must pass relevant international mechanical certifications.

Developing towards high speed, high frequency, high response, and long lifespan. In order to improve the production efficiency of production equipment, it is necessary to increase the working speed of actuators. At present, the working speed of cylinders in China is generally below 0.5m/s. According to Japanese market makers' predictions, in five years, the working speed of most cylinders will increase to 1-2 m/s, and some may even need to reach up to 5 m/s. The improvement of cylinder working speed not only requires improving the quality of the cylinder, but also corresponding structural improvements, such as configuring hydraulic shock absorbers to increase buffering effect. The response time of the solenoid valve will be less than 10ms, and its service life will increase to over 50 million times. There is a gap sealing valve in the United States. Due to the suspension of the valve core in the valve body, it does not contact each other and does not require lubrication, with a service life of up to 200 million times.

Oil free lubrication technology is widely used to meet some special requirements. Due to environmental pollution and requirements from industries such as electronics, healthcare, and food, oil is not allowed in the environment. Therefore, oil-free lubrication is the development trend of pneumatic components, which can simplify the system. The lubricators in the European market are outdated products that typically achieve oil-free lubrication. In addition, in order to meet certain requirements

To meet specialized demands, we are continuously developing deodorization, sterilization, and precision filters with a filtration accuracy of 0.1-0.3 μm and a filtration efficiency of 99.9999%.

There is widespread consensus that enhancing and developing pneumatic products can secure market share and yield significant economic benefits. Pneumatic Components Co., Ltd. has tailored its cylinders and valves to the specific needs of railway marshalling and wheel-rail lubrication, earning significant attention from railway authorities.

By utilizing new materials and integrating advanced technologies, membrane dryers have been developed internationally. These dryers employ high-tech reverse dialysis membranes to remove moisture from compressed air. They offer energy efficiency, a long lifespan, high reliability, compact size, and lightweight, making them ideal for low-flow applications.

Pneumatic seals crafted from polytetrafluoroethylene-based composites are resistant to heat (260°C), cold (-55°C), and wear, finding increasing applications in various fields.

To enhance quality, emerging technologies like vacuum die casting and hydrogen-oxygen explosion deburring are being progressively integrated into the manufacturing of pneumatic components.

These components are easy to maintain, repair, and operate. Research is underway internationally to equip pneumatic components and systems with sensors for predictive fault diagnosis and self-diagnostic capabilities.

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