Did you know that a leak in a compressed air pipe equivalent to a 2 mm hole costs R12 500 a year? And did you know that if you mounted a small economiser that costs R70 on a cylinder you would save R1150 a year? And that if, instead of the old array of 10 solenoid valves with a 10 W coil, you used a modern HDM island with a 0,6 W pilot, you would avoid releasing 120 kg of CO2 into the environment each year?
Metal Work has a solution
BMG Hydraulics places great emphasis on environmental issues. The company is an importer and distributor of Metal Work pneumatic products. Compressed air is a clean source of energy but producing it is an energy intensive process. Metal Work has therefore launched an information campaign to help its customers reduce energy wastage and save money.
The company proposes the following four pillars of energy saving:
Choose the correct cylinder size
Pneumatic actuators consume an amount of air that depends on the pressure and the bore. Using the right cylinder at the right pressure results in considerable savings. A smaller cylinder allows associated valves, fittings and pipes to be of a smaller size.
Metal Work has developed easy to use software called Easy Sizer for sizing pneumatic cylinders, valves, pipes and units. It can be downloaded from www.metalwork.it
Use economisers
If a thrust is required in one direction only on a cylinder, for example a piston rod extension, and a lower thrust and pressure is sufficient in the other direction, a significant amount of energy can be saved by mounting an economiser valve.
Metal Work proposes the RML-RMS-RMC series of miniature economisers or reducers which can be mounted straight onto the cylinder port or inline on the pipe. See Figure 1.
Eliminate air leaks
Air leaks in the system waste a large amount of money and put unnecessary stress on the compressor. To reduce this wastage, check periodically for leaks and fit solenoid valves on each machine. These cut-out devices seal off the flow of air when the machine is off.
Metal Work proposes V3V shut-off solenoid valves with instant opening or the APR type with progressive start-up. See Figure 2.
Design and operate the air distribution system correctly
When designing a pneumatic system, size pipes to minimise load losses. Use the minimum required pressure. A booster should be used only when a higher pressure is required. Deactivate unused compressors. Even when not in use, they consume 30% of the full power.
Metal Work proposes high efficiency pressure multipliers – boosters – that can be used to increase the air pressure only for components that effectively require this. See Figure 3.
Low operating power
To reduce electricity consumption, Metal Work has modified all the most common types of solenoid pilot (DIN 43650 shape B, 22 mm wide) to reduce the operating power from 5 W to 2 W. In addition all new generation valves are designed with 0,6 W solenoid pilots. Metal Work will soon have a series of solenoid valves operated at a mere 0,2 W.
Miniaturisation
Metal Work is also making breakthroughs in the miniaturisation of valves. For example Multimach valve islands, with the same flow rate, occupy a volume one ninth that of conventional ones and weigh just one third. Miniaturisation can be seen in the push-in fittings, which are much smaller than in the past, and are often made of technopolymer rather than brass, giving a 75% reduction in weight.
These innovations make it possible to reduce the dimensions of other mechanical parts and the machinery containing them, leading to reduced overall dimensions and weight. Besides advantages in machine design, this also has a positive effect on energy saving and the consumption of materials.
For more information contact Mark Johnson, BMG Hydraulics, +27 (0)11 614 2004, [email protected], www.bmgworld.net
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