Improving pneumatics bottom line

Here are some common-sense methods for making pneumatic systems more efficient. Taking a common-sense approach to pneumatic system design, such as eliminating leaks, lowering the air pressure, and maintaining filters substantially reduces compressed-air costs. The first step in properly sizing pneumatic systems is to calculate cylinder flow. Armed with this information, designers can correctly size tubing, fittings, valves, and FRLs. Judicious use of pressure regulators can reduce operating costs, for example, by lowering return air pressure when actuators are loaded in only one direction. Designers often oversize cylinders to account for stiction and breakaway forces. But this degrades actuator performance, wastes compressed air, and increases upfront costs. A common mistake involves sizing components to match cylinder ports. This tends to oversize components and increase operating costs. A better approach is to calculate flow coefficients (cv) for valves and connectors. Despite escalating energy prices, many industrial users of compressed air remain blissfully unaware of its true costs. In fact, the notion that compressed air is free is a common misconception — even though the largest single electrical appliance in a manufacturing plant is often the compressor motor. Here's a look at some commonsense ways to determine the operating costs of typical pneumatic circuits. By knowing the facts, designers can make better decisions that lead to more-efficient systems. Because compressed-air costs are typically hidden in the operating overhead of most companies, any cost reductions immediately fall to the bottom line as added profit. The first step to improving the bottom line is exposing three popular myths. In the past, most people would not take the time to find out the cost of the compressed air an actuator requires. Yet experts indicate that producing compressed air typically costs from $0.15 to $0.40 per 1,000 standard cubic feet (scf). Hydraulic-system designers must calculate the size