Transformative Advancements in Pneumatic Systems

Trends, Technologies, and Industry Applications

By Scott Schipiour, Content Marketing Specialist, IMI.

The fluid power industry is witnessing a transformative era with rapid advancements in pneumatics. As an integral part of this evolution, pneumatic systems continue to play a crucial role in various industrial applications, driven by innovative trends and technologies. This article delves into the latest developments in pneumatic systems, shedding light on innovative technology, the latest trends, and industry applications that are shaping the future of the fluid power sector.

Emerging Trends in Pneumatics

1. Enhanced Efficiency

One of the most significant trends in the pneumatic industry is the drive toward enhanced efficiency. Modern pneumatic systems are being designed to optimize energy consumption while maximizing performance. Incorporating energy-efficient components, such as variable speed drives and advanced air compressors, helps reduce the overall energy footprint.

2. Integration of IoT and Smart Technologies

The Internet of Things (IoT) is revolutionizing the operational capabilities of pneumatic systems. By integrating smart sensors and connectivity solutions, pneumatic systems now offer real-time monitoring and predictive maintenance. This allows for early detection of potential issues, reducing downtime and maintenance costs. Smart pneumatics also enable remote control and automation, enhancing operational flexibility and efficiency. IMI has a complete portfolio of smart, connected products from air preparation to valves, switches, sensors, and proportional valves that provide feedback to help identify issues and failures to optimize performance.

3. Miniaturization and High-Precision Components

The demand for more compact and precise equipment is driven by several factors, including the need for space optimization, higher performance standards, and the push for more efficient processes in various industries. These factors necessitate smaller, yet highly efficient components that deliver the same or better performance in a reduced space. For example, the development of miniaturized pneumatic valves and actuators, such as IMI Norgren compact solenoid valves (diameters as small as 8mm) and the IMI Bimba Original Line® Cylinders (bore diameter as small as 5/16″), exemplifies how these innovations meet the demand by providing powerful performance in a small footprint. 

Technological Innovations

1. Advanced Materials and Coatings

The use of advanced materials and coatings is significantly improving the durability and performance of pneumatic components. Materials including stainless steel and specialized polymers enhance resistance to corrosion and wear, extending the lifespan of components. For example, the IMI Bimba stainless steel cylinders are particularly suited for use in aggressive chemical settings and in food and beverage processing. Hygiene and durability are critical to offering exceptional durability and longevity, making them suitable for demanding environments.

2. Electro-Pneumatic Actuation

Electro-pneumatic actuators combine the benefits of electrical control with the power and simplicity of pneumatics. These actuators offer precise control over motion, making them suitable for a wide range of applications, from industrial automation to robotics. The integration of internal transducers enhances their accuracy and responsiveness. IMI Bimba Servo Pneumatic Control System operates with an 0-10 VDC or 4-20 mA analog command signal, providing closed loop pneumatic proportional control for all IMI Bimba position feedback actuators, including the PFCN, PFCNL, PFCL, PTF. This ultimately delivers exceptional control and flexibility, enabling seamless integration into complex systems.

 3. Modular and Scalable Systems

Modular pneumatic systems are becoming increasingly popular due to their flexibility and scalability. These systems consist of interchangeable modules that can be easily configured and expanded to meet specific application requirements. This modularity simplifies maintenance and upgrades, reducing downtime and operational costs. IMI Norgren Excelon® Plus Series Quikclamp exemplifies this by offering fast removal, replacement, and expansion of system components.

Industry Applications

1. Automotive Manufacturing

In the automotive industry, pneumatic systems are extensively used for assembly line automation. From robotic arms to conveyor systems, pneumatics provides the necessary power and precision to streamline production processes. The integration of smart pneumatics enhances efficient operation and reduces the risk of production delays. IMI Bimba pneumatic actuators paired with IO Link Switches and IMI Norgren VR10/VR15 valve manifolds are a great option to enhance automotive manufacturing efficiency and reliability.

2. Food and Beverage Processing 

Pneumatic systems are vital in the food and beverage industry, where they are used for packaging, sorting, and material handling. The use of clean and dry compressed air is critical to prevent contamination and support compliance with hygiene standards. Proper filtration is required to maintain air quality, safeguarding product integrity. IMI’s air preparation equipment, including the IMI Norgren Excelon® Plus, offers high quality air to be used in these sensitive applications, promoting safety and consistency. Excelon® Plus filters provide exceptional particulate removal and water extraction, adhering to high industry standards. Including general purpose filters for particulate and water extraction, coalescing filters for removing oil aerosols, and vapor removal filters for eliminating oil vapors, ensuring clean, instrument-grade air.

3. Pharmaceutical and Medical Devices

The pharmaceutical and medical device industries rely on pneumatic systems for various applications, including fluid handling, dispensing, and automation of laboratory equipment. The trend towards miniaturization and high-precision components is particularly beneficial in these sectors, allowing for the development of compact and reliable medical devices. IMI miniature cylinders and precise control valves, such as the IMI FAS valves, are essential in driving innovation and reliability in medical technologies as they are compact and offer high precision in many life science applications.

Case Study

Transforming Printing Technology with Precision Solenoid Valves

A global leader in Continuous Inkjet (CIJ) printing required miniature solenoid valves with greater repeatability, higher reliability, and longer operating life. IMI Norgren collaborated closely with the OEM customer to develop a precision miniature solenoid valve in a 10mm body with the smallest possible overall footprint and internal volume. This valve featured repeatable specified operating times and leak rates, an increased valve life cycle, and higher reliability to withstand clogging during continuous operation with viscous ink.

The miniature solenoid valve design needed to be compatible with MEK (Methyl ethyl ketone) based inks to compensate for the “swelling” of elastomer seals and to allow precision control of highly aggressive media. The solution was an integrated dual 10mm solenoid valve in a single assembly and housing.

This miniature integrated precision solenoid valve assembly was 100% tested to OEM customer specifications, achieving the highest quality and inspection standards. This allowed for KANBAN shipments to arrive at the customer as “door to floor” with no incoming inspection. The product represented an extension of an existing product technology platform and was co-developed over 24 months between IMI Norgren and the OEM customer project engineering team. This collaboration enabled the OEM customer to focus on its core competencies, decrease development time, launch to market faster and realize sales revenues six months sooner.

Pneumatic systems are continuing to evolve to meet the demands of modern applications. Enhanced efficiency and the integration of smart technologies are driving this evolution, paving the way for more reliable and high-performing pneumatic solutions. As these trends and technologies continue to develop, pneumatic systems will undoubtedly play an increasingly vital role in various industries, offering exceptional levels of reliability efficiency, and flexibility.

By staying abreast of these advancements and adopting cutting-edge solutions from industry leaders like IMI Norgren and IMI Bimba, businesses can ensure they remain competitive in an ever-changing landscape. Pneumatics are not going anywhere; in fact, there are still plenty of exciting opportunities for growth and innovation.