Pneumatic and hydraulic systems are two of the most common systems utilized in B2B : B2B companies always consider operational needs, costs, and performance to determine the most suitable solution. When integrating systems in a factory, performance and operational requirements must also be considered. This piece aims to provide the necessary information to arrive at an accurate conclusion.
Pneumatic systems are a type of system that are able to do work from the application of compressed air. The work done in these systems is achieved by the release of compressed air which is stored in a reservoir and channeled through a number of devices. These systems are most applicable when work is fast and effective, and also where mechanical effort is minimum.
Some of the basic components of pneumatic systems are as follows:
- Generator: This is where the compressed air is developed.
- Compressed Air Storage Tank: The tank is also utilized when compressed air is at a later period of time needed.
- Valves: Controls the direction and flow of compressed air.
- Actuators: Changes the pressurized air into mechanical action.
These systems find specific use within warehouse systems and in the automation of an entire system.
What are Hydraulic Systems?
On the other hand, hydraulic systems perform work using pressurized liquids, most commonly oil, and sometimes even water. Due to the higher power output in a hydraulic system, they are suitable for applications that require high force and high precision. An example of such would be being used in heavy construction and lifting equipment, as well as industrial presses.
Key Components of Hydraulic Systems
- Hydraulic Pump: Machine that changes mechanical power to fluid power.
- Hydraulic Fluid: Form of liquid used for transmitting energy.
- Actuators: Similar to pneumatic actuators but built for higher force output.
- Valves: Smoothen the controlled circulation of the liquid and the pressure of the liquid.
High force systems are prevalent in construction, heavy machinery, automobile designing, and aerospace fields, owing to the necessity of the systems.
Key Differences Between Pneumatic and Hydraulic Systems
Identifying the crucial differences between pneumatic and hydraulic systems can help the businesses to know what the most suited systems are.
Power Source and Efficiency
- Pneumatic Systems**: The system runs on compressed air, which is abundant and easily handled. Despite this, they are the most energy inefficient systems, as the air is compressible and power is lost for the system.
- Hydraulic Systems: Operates with pressurized and concentrated fluids, which denotes higher efficiency and better force output as compared to air, albeit requiring more intricate maintenance.
Force and Speed
- Pneumatic Systems: Speed is their forte, although these systems lack ability to generate heavy lifting or high pushing force.
- Hydraulic Systems: As much as these systems move slowly, their ability to lift and move heavy loads dictates their value more than pneumatic systems.
Maintenance and Durability
- Pneumatic Systems: Given that the only airborne contaminants are dirt, systems that operate with air are easier to maintain, albeit frequent checks for leaks and condensation in the air lines are a must.
- Hydraulic Systems: Fluid leaks and contamination pose a significant issue, hence more regular checks and maintenance are needed. Due to the high-pressure fluids, these hydraulics systems are more elaborate and complicated to maintain.
Pneumatic systems do not require the application of great pressure to operate, unlike the hydraulic systems. The use of the pneumatic unit and power packs in pneumatic systems enables the efficient delivery of air. These systems are designed to operate very efficiently to accomplish light weight tasks. Pneumatic systems are commonly employed in the food and beverage industry, in the packaging, assembly lines and food processing, due to their competitive pricing and simplicity of use.
Primarily Used in Pneumatic Systems
- Automated retrieving and storing systems
- Packaging systems
- Material handling systems
- Assembly and sluicing systems
In most cases pneumatic systems are deployed when there is the need to optimize the speed of the process at the same time minimizing the cost and processes needed to complete the task.
When there is an application that requires more strength, the pneumatic system is more useful. These systems are primarily designed for tasks that require the application of great pressure, such as operating heavy duty machine systems. Tasks such as operating an industrial press or lifting device require the use of such systems. These systems, although their cost is higher and require more frequent maintenance, provide the needed power and control to accomplish the desired tasks.
Ideal Applications for Hydraulic Systems
- Press Machines
- Lifting and Hoisting Equipment
- Construction Machinery
- Aerospace and Automotive Manufacturing
In any business that works with heavy materials that require lifting, and you need the process to be controlled expertly no matter the weight, a hydraulic system will be crucial.
How to Choose the Right System for Your Factory
Given the options between pneumatic and hydraulic, the choice boils down to a few.
1. Power and Force Requirements
Evaluate the kind of force expected of the machinery. If it involves light works such as sorting or packaging, a pneumatic system will suffice. Lifting and Heavy pressing however, will require a hydraulic system.
2. Speed vs. Force
Which one do you need more: speed or force? Pneumatic systems balance speed and force, but with a compromise the force will be lower. Hydraulic systems balance speed and force, but with a heavy compromise the speed will be lower. Ask yourself, what do the machines need to do?
3. Energy Efficiency and Operating Costs
While powerful and more energy efficient, hydraulic systems have much higher initial and maintenance expenses. On the other hand, pneumatic systems have cheaper installation and maintenance prices, although they may end up being more costly in the long run due to energy expenses.
4. Maintenance and Downtime
Evaluate the maintenance requirements and potential inductions of downtime for each of the systems countered. While pneumatic systems have simpler maintenance, they may need more upkeep to minimize condensation or leakage issues. Hydraulic systems, on the other hand, need more careful maintenance, especially when it comes to leaks and contamination of the fluid.
5. Safety Considerations
If not done carefully both of the systems could have certain safety issues. Hydraulic systems have the potential to cause serious accidents because of the high pressure under which they work, and the potential leaks or failures of the system. Pneumatic systems, although much safer, are still able to injure someone if there is improper management of the system, or if pressure leaks give sudden bursts of air.
Integration with Other Automation Systems
Both pneumatic and hydraulic systems can be added components of more extensive systems of factory automation, like automated warehouse systems. This addition allows the machines to work on their own, reducing the need for human effort while increasing overall effectiveness and productivity.
Automation parts suppliers sell all of the required parts and have the knowledge necessary for the function of these systems onto a fully automated assembly line. If you’re seeking any type of actuators, valves, pumps, or even compressors. A reputable company will make sure all systems will integrate properly.
Conclusion
The choice of the two systems within the factory and their use pertains to the type of operation the factory is engaged in. Pneumatic systems operate best in applications that need speed and efficiency with less force. On the other hand, hydraulic is used for heavy duty work that requires high power and precision.
For B2B companies, having the supplier for automation parts enhances productivity due to the seamless integration of the systems. Determine the required force, speed and maintenance of the factory in order to make the choice that is right for the factory. There is no need to hesitate when it comes to the implementation of these systems as parts of the complete automation system.
