Blog

There is a lot of discussion surrounding Industry 4.0, but its overall goal is the Smart Factory and Smart Manufacturing.

Many technologies are included in these broad definitions, and what are now commonly known as Smart Components, are core building blocks.

Smart Components are increasingly being deployed by OEMs to help them satisfy the evolving demands of customers who are looking to facilitate a shift from mass production to mass customisation. Production flexibility is also required so that the end manufacturer can quickly adapt to rapidly changing market and customer requirements. The bigger picture of deploying Smart Components sees an improvement in overall digitisation, which in turn helps to achieve sustainability goals and pollution reduction.

To facilitate the above, machines must be able to collect and analyse huge quantities of data, which then feeds back into the Manufacturing Execution System (MES) to inform decision making. It’s therefore the machines that make the greatest contribution that will be the best fit with the evolving demands of Smart Factories and Smart Manufacturing.

Actuation Technology

So let us now consider some of the technology choices facing design engineers in their quest for greater machine efficiency. When it comes to motion control applications in OEM machines, there’s no one dominant actuation technology.

For example, traditional pneumatics provide an ‘on-off’ motion solution, based on air flow regulation to control speed, and pressure adjustment to control force. These are manual adjustments, but components are typically simple to install and provide a low-cost linear motion solution.

At the other end of the spectrum, there are electric actuators which increase flexibility and motion control capabilities. While standard pneumatic actuators are not designed for mid-stroke positioning or controlled velocity, electric actuators, or servo pneumatic actuator solutions (which include proportional valves) are.

However, striving for Smart Manufacturing doesn’t just mean using innovative technologies, but choosing the optimal motion control technology for the specific application. It also means reducing Total Cost of Ownership throughout the lifecycle of the machine by considering the acquisition, utilisation and disposal phases.

Integration into a Smart Environment

Another key consideration for design engineers, when choosing technology, is how can it be integrated into a Smart Environment? The technology has to be able to communicate back to the MES or ERP of the factory so that the machine it’s integrated into can then be monitored in real time.

The collection of data is also important, so that an operating history can be built up. Algorithms can then be used to prevent system failures by harnessing the power of predictive maintenance.

Camozzi has developed Smart Components to do just this, using a technology called CoilVision, which integrates an algorithm into the electronics of, for example, a traditional on-off pneumatic valve to measure its health status. The algorithm monitors the valve over time and sends information back to a central system to prevent failures, by predicting issues before they arise. With this solution, engineers are presented with health status indicators, on a dashboard, which work in the same way that a fuel gauge would in a car.

The Importance of Data

In summary, new Smart Components allow OEMs to monitor the operation of their machines in real time and allow the collection of operating data which can then help to troubleshoot. This real time data can then be compared with statistical data to build predictive models through the use of machine learning and AI algorithms. The benefits of predictive maintenance as opposed to routine maintenance are then available.

The integration of Smart Components into machines enable the goal of the Smart Factory and Smart Manufacturing to be achieved. The availability of the data generated, once processed, and converted into intelligence, is the bedrock for more informed decision making, leading to measurable commercial benefits.

Do you ever need pneumatic cylinders quickly?

For example, to fix a production line breakdown?

Whatever the reason may be, many types, including non-standard stroke lengths, are made in the UK. Here’s how we do it:

Our UK Express Build Service includes:

• Mini-Cylinders ISO 6432 – Series 16, 24 and 25
• Large Bore Cylinders ISO 6431 – Series 40
• Large Bore Cylinders/ Aluminium Profile ISO 6431– Series 41
• Aluminium Profile Cylinders ISO 6431 – Series 61
• Aluminium Tube and Profile Cylinders ISO 15552 – Series 63
• Compact Cylinders ISO 21287 – Series 32
• Compact Cylinders – Series 31
• Guide Units ISO 6431/ 6432 – Series 45
• Roundline Cylinders – Series 27
• Rodless Cylinders – Series 50
• Rodless Cylinders – Series 52

If you have any application specific questions before ordering your cylinder, then our technical team is available to help. Just sales@camozzi.co.uk.

Machinery maintenance and repairs can be time-consuming and frustrating, but there's a way to improve the whole ordeal!

Many companies are turning to predictive maintenance to aid their operations. This helps them save time, money, and frustration when dealing with their equipment. Here are a few facts about predictive maintenance to help you get started.

What Is Predictive Maintenance?

Predictive maintenance focuses on intervening in machines before anything breaks or goes wrong. This is achieved by considering the physical parameters of individual components. The idea is to replace the part before it fails. This lets you save maintenance time and prevent costly, unplanned machinery downtime.

How Does It Differ from Other Maintenance?

The biggest difference is that this type of maintenance is 100% proactive. Many companies have a "use it until it breaks" approach to their maintenance. This can often cause a lot of cascading effects and incur extra repair costs!

Even regularly scheduled maintenance and inspection can have its drawbacks. For example, more preventative approaches, that are based on statistical, historical data, run the danger of replacing good components, incurring unnecessary replacement costs.

That's why companies have begun moving to predictive maintenance. With computer analysis, they can plan exactly which machines or parts need work.

How Does It Work?

A growing aspect of predictive maintenance is the use of smart pneumatic components. This equipment can self-diagnose health and make recommendations via a remote user interface before issues arise.

Although traditional pneumatic components can't collect very much data, there have been a lot of recent improvements. For example, Camozzi's Series D  smart pneumatic valve islands collect vast amounts of data which is then processed in real time, within the device itself, using what Camozzi calls CoilVision technology. This is edge computing, and because of it, the device only exchanges refined deterministic data when necessary, therefore reducing the total amount of data and calculations in the cloud.

Without getting into the complex analysis, just realise that the remote user interface is fed all the parameters about a part. Just like there are a lot of factors that can make your body healthy or sick, there are a lot of factors that will make your equipment healthy or broken.

When a determination is made for a component, a colour coded warning is indicated on the remote user interface, which can also be displayed on a smartphone. With the Camozzi Series D valve island, an animated gauge will show yellow, on the remote dashboard, when one of the island’s solenoid coils has reached a remaining lifespan of 10%. In the same way as how the fuel gauge warning on your car will turn on to inform you that you're running low. This lets you get to the component and replace it before it breaks completely.

Learn More About Predictive Maintenance and Smart Pneumatic Components

If you'd like to learn more about how smart pneumatic components can help you unlock the benefits of predictive maintenance, the technical team at Camozzi Automation Ltd is ready to help.

Manually adjusting an air cushion on a pneumatic cylinder can be time consuming. This blog explains the benefits of considering an auto-cushioning option.

In the industrial world, the primary goal is often to boost productivity whilst reducing costs.

Pneumatic cylinders  in particular have gained wide acknowledgement as being durable enough to withstand harsh environments alongside providing a high level of performance at a competitive rate.

However, they often require running actuators as fast as possible without introducing excessive shock or vibration to products and equipment, which can become demanding.

Due to operating at a higher speed and with potentially increased loads, engineers generally use an air cushion to avoid any lasting damage to the cylinder.

The issue is that the manual adjustment of these end-position cushions require time and using directly fitted flow regulators costs up to ten times more than a standard elbow or straight fitting.

Experienced maintenance technicians are required to adjust the air-cushion valves, depending on the cylinders operating pressure, speed and load. Once these parameters are changed, the air cushions then need to be reset for each job in order for the machine to run efficiently.

Manually adjusting the air cushion is not only time consuming but it can put pressure on the technicians to complete the task as quickly and efficiently as possible, as well as incurring unnecessary production costs.

With the introduction of a new type of air cushion which automatically adapts to changing conditions, the headache of manual adjustments is eliminated and productivity is increased, ultimately reducing maintenance costs.

Camozzi Automation's Series 23 ISO 6432 pneumatic cylinders embrace the innovation of 'auto-­cushioning'.

The 'auto-cushioning' system works the same as many conventional cushions, except instead of a needle valve, the air is exhausted with the use of shaped sleeves that have a number of holes accurately positioned with precisely set dimensions.

As the system cleverly adapts to various combinations of speed and applied mass, the self-­adjusting cushion is a 'fit-and-forget' feature. Eliminating the need to regulate settings, the Series 23 pneumatic cylinders are ultimately tamper proof, offering a long, maintenance-free service life.

Whilst the cylinder benefits from a smooth, jolt-free movement, the reduction in vibrations and noise is also noticeable. Despite appearing less intrusive, the cushions guarantee higher reliability and constant performance over time.

If the parameters such as friction and pressure change, the self-adjusting cushions ensure proper deceleration every time. Reducing the acceleration forces acting on components and workpieces, the appearance of wear and tear is reduced and time-consuming vibration is minimised.

The series 23 is suitable for use in many industrial applications, especially if working conditions vary. Reducing the installation and commissioning times, the 'auto-cushioning' system provides a cost-effective alternative to manually adjustable cylinders.

If you need to replace a pneumatic cylinder there are some key measurements that will help to identify an equivalent. This video explains the keys steps.

The video is mainly applicable to ISO pneumatic cylinders , using an ISO 15552 cylinder as an example.

Please contact us with any cylinder related questions (024 7637 4114 or sales@camozzi.co.uk). We are here to help.

We thought it would be useful for you to be able to put faces to some of the Camozzi UK team who you may deal with. Take a look at our new video to hear what they have to say.

The whole team is here to provide whatever support you require. Here are some quick links to make it easier to find what you are looking for: :

• Pneumatic Cylinders
• Pneumatic Valves and Solenoid Valves
• FRLs
• Pneumatic Fittings and Tubing

Pneumatic cylinders with an integrated scraper seal to remove debris from the piston rod. Watch the video to see how pneumatic cylinder life can be extended.

When used in harsh conditions the piston rod of a pneumatic cylinder is exposed to the build up of debris which will, if left unchecked, ultimately result in a shorter working life. 

A more efficient solution is to use a pneumatic cylinder with an integrated scraper seal, as demonstrated in the video above.

Camozzi ISO 15552 & ISO 6431 pneumatic cylinders are available with optional scraper seals. Produced in the UK, with same day despatch available, these cylinders can be deployed rapidly, especially in breakdown scenarios. 

In addition, a chrome plated Stainless Steel AISI 420B piston rod is used to offer superior resistance towards corrosion compared to more typical market offerings. 

Using the scraper seal option ensures the piston rod is kept clean which will reduce your costs, as service life is extended, and save you time, as maintenance and repair tasks become less frequent. Watch the video above to see these cylinders in action.  

For free, application specific advice, call 024 7637 4114 or email sales@camozzi.co.uk. 

This free new guide is for anyone looking for an introduction, or just a refresher, into the key parts of a pneumatic system.

PNEUMATICS EXPLAINED

The easiest way to explain pneumatics in the simplest terms is to imagine a compressed air ring main. Within the ring main there are four main components operating the functionality of the system:

• Cylinders
• Valves
• FRLs
• Fittings and Tubing

The cylinder is the external output, the end result or the movement you are setting out to achieve.

The valve is the control element within the system. For example, how fast? How many movements do you require from the cylinder?

FRL’s refer to the preparation of the air. The air must be cleaned, filtered and regulated or maybe even lubricated before it is channelled into the system. To do this we use a filter, regulator lubricator (FRL).

Fittings and tubing are self-explanatory, they are the connections and pipes that connect the system together.

WHERE ARE PNEUMATICS USED?

95% of industries use some form of compressed air using pneumatic components. The most prevalent include:

• Packaging
• Food & Beverage
• Plastics & Rubber
• Fluid Control
• Automotive
• Electronic Systems
• Textile Machinery
• Assembly & Robotics
• Printing & Paper
• Woodworking Machinery

BASIC QUESTIONS TO SPECIFY PNEUMATIC CYLINDERS

1. What is the cylinder’s bore and stroke size?
2. Do you know if it is an ISO (industry standard) cylinder?
3. If so, what is the ISO reference?
4. Is the cylinder double-acting or single-acting?
5. What thread port size is it, i.e. M5, 1/8, 1/4, 3/8 or 1/2”?
6. Are cylinder mounting brackets required? E.g. rod fork end, rear clevis, swivel combination.
7. Are any additional accessories required? E.g. pneumatic fittings, proximity switches or flow controllers.

BASIC QUESTIONS TO SPECIFY PNEUMATIC VALVES

1. How is the valve operated? I.e. solenoid, pilot, mechanical or manually?
2. What is the configuration of the valve or put another way, how many positions does the valve have? For example:

• 3/2 = 3 Ports, 2 Positions
• 5/2 = 5 Ports, 2 Positions
• 5/3 = 5 Ports, 3 Positions

3. Is the valve normally open (NO) or normally closed (NC)?
4. What is the port size of the valve? I.e. M5, 1/8, 1/4, 3/8 or 1/2”?
5. Are any accessories required? For example, coils, pneumatic fittings or tubing? If coils are required, a voltage will also need to be specified.

BASIC AIR PREPARATION QUESTIONS

1. What is required? E.g. A filter? A regulator? A lubricator? Or a filter regulator*? Or a filter, regulator, lubricator (FRL)*? * These are pre-assembled kits.

2. What thread/ port size is required? I.e. 1/8, 1/4, 3/8, 1/2”?
3. What is the required pressure range? (0-15 Bar standard)
4. Are any accessories required? E.g. wall mounting brackets, tamper proof cap, pressure gauge or filter service kit?

BASIC QUESTIONS TO SPECIFY PNEUMATIC FITTINGS

1. Is a specific material required? I.e. brass nickel plated, technopolymer (plastic) or stainless steel?
2. What type of fitting is required? For example:

• Push in fitting
• Push on fitting
• Pipe fittings/ BSP adaptor
• Air brake fitting

3. What sort/ model of fitting is required? E.g. straight, elbow, tee, reducer etc.
4. What thread is required? E.g. M5, 1/8, 1/4, 3/8 or 1/2?
5. What port connection is required? E.g. 4, 6, 8, 10, 12mm?

BASIC QUESTIONS TO SPECIFY PNEUMATIC FITTINGS

1. Is a specific material required? I.e. brass nickel plated, technopolymer (plastic) or stainless steel?
2. What type of fitting is required? For example:

• Push in fitting
• Push on fitting
• Pipe fittings/ BSP adaptor
• Air brake fitting

3. What sort/ model of fitting is required? E.g. straight, elbow, tee, reducer etc.
4. What thread is required? E.g. M5, 1/8, 1/4, 3/8 or 1/2?
5. What port connection is required? E.g. 4, 6, 8, 10, 12mm?

In this short video learn how to configure a Camozzi Series F (multipole or fieldbus) pneumatic valve island in just a couple of minutes. In just a few steps you will be able to generate your required part number. Plus:

• Download CAD drawings in a selection of formats
• Preview 3D CAD drawings on screen
• View your bill or materials

We are here to help answer any questions you may have. For support please contact the Camozzi sales office on 024 7637 4114, ask@camozzi.co.uk or use the online chat tool located bottom left of the screen during office hours.