The development trend of pneumatic technology in China

Pneumatic technology is a specialized technology that uses compressed air as a medium to drive and control machinery. Because it has the advantages of energy saving, pollution-free, high efficiency, low cost, safety and reliability, and simple structure, it is widely used in various machinery and production lines. In the past, pneumatic systems and components on production lines such as automobiles and tractors were designed, manufactured and repaired by each factory.

The expansion of the application of pneumatic technology is a sign of the development of the pneumatic industry. The application of pneumatic components is mainly in two aspects: maintenance and matching. In the past, the sales of domestically produced pneumatic components were used for maintenance. In recent years, the sales share directly for the main supporting products has increased year by year. The application of domestic pneumatic components ranges from tens of millions of metallurgical equipment to chairs of only 1-2 yuan. Railway troughs, machine wheel rail lubrication, train braking, street cleaning, lifting equipment in special workshops, military command vehicles, etc. all use specially developed domestic pneumatic components. This shows that pneumatic technology has “infiltrated” into all walks of life and is expanding.

Although China's pneumatic industry has reached a certain scale and technical level, compared with the international advanced level, the gap is very large. The output value of China's pneumatic products only accounts for 1.3% of the world's total output value, only 1/21 of the United States, 1/15 of Japan, and 1/8 of Germany. This is very disproportionate to the big country with a population of more than 1 billion. In terms of varieties, there are 6,500 varieties in a Japanese company, and only one-fifth of them in China. The gap between product performance and quality levels is also large.

As pneumatic technology is increasingly used in the automatic assembly and automatic processing of small parts and special items in various industries, the performance of the original traditional pneumatic components is constantly improving, and at the same time, new products adapted to market requirements are developed. The variety of pneumatic components is increasing, and its development trend mainly includes the following aspects:

Smaller in size, lighter in weight and lower in power consumption. In the manufacturing industry of electronic components and pharmaceuticals, the size of the workpiece is limited, which is bound to limit the size of pneumatic components. Miniaturization and light weight are the first of pneumatic components. Development direction. Ultra-small solenoid valves with a size of only a large thumb and an effective cross-sectional area of ​​0.2 mm2 have been developed abroad. It is more desirable to develop components with small outline sizes and large flow rates. For this reason, the flow rate of the valve of the same size has been increased by 2 to 3.3 times. There is a series of small solenoid valves with a valve body width of only 10mm, an effective area of ​​up to 5mm2, a width of 15mm, and an effective area of ​​up to 10mm2.

The power consumption of foreign solenoid valves has reached 0.5W, and will be further reduced to accommodate the integration with microelectronics. The gas source treatment assembly is mostly made up of block-type block structures at home and abroad, which is not only compact in size, but also convenient in combination and maintenance. The positioning accuracy of the actuator is improved, the rigidity is increased, the piston rod is not rotated, and the use is more convenient. In order to improve the positioning accuracy of the cylinder, the cylinder application with the brake mechanism and the servo system is more and more popular. A cylinder with a servo system can achieve a positioning accuracy of ±0.1 mm even if the supply pressure and the negative load change.

At the international exhibition, there are many cylinders of various shaped cross-section cylinders and piston rods. Since these pistons do not rotate when they are used on the main engine, they can maintain a certain precision without additional guides. In addition, a number of cylinder and cylinder slide assemblies with various guide mechanisms have been developed, such as cylinders with two guide rods, double cylinder double cylinder cylinders, and the like. The shape of the cylinder barrel is not limited to a circular shape, but a square shape, a square shape or the like. The guide groove, the sensor and the mounting groove of the switch are opened on the profile, so that the user can install and use more conveniently.

Multi-functional, composite. In order to facilitate users, to adapt to the needs of the market, a variety of small pneumatic systems with multiple pneumatic components combined with control devices have been developed. For the component used to move small items, the two cylinders with the guide are combined according to the X-axis and the Z-axis. The assembly can handle 3kg heavy objects, equipped with solenoid valve and program controller. It has compact structure, small space and adjustable stroke. Another example is an upper and lower material module, which has seven different functional module forms, which can complete the upper and lower material operations on the precision assembly line, and can arbitrarily combine different modules according to the operation content. There is also a robot which is a combination of a oscillating cylinder and a collet having a small outer shape and capable of changing the swing angle, and a plurality of types of collets are available at the chuck portion.

Combined with electronic technology, a large number of sensors are used, and pneumatic components are intelligent. Cylinders with switches have been widely used in China, the switch volume will be smaller, the performance is higher, and it can be embedded in the cylinder block; some also have two-color display, which can show the position error. To make the system more reliable. Using sensors instead of flow meters, pressure gauges, and automatic control of compressed air flow and pressure can save energy and ensure proper operation of the device. Pneumatic servo positioning systems have entered the market. The system uses a three-position five-way pneumatic servo valve to compare the predetermined positioning target with the position sensor detection data and implement negative feedback control. When the maximum speed of the cylinder is 2m/s and the stroke is 300mm, the system positioning accuracy is ±0.1mm. A new type of intelligent solenoid valve has been successfully produced in Japan. This valve is equipped with a logic circuit with a sensor, which is a combination of pneumatic components and optoelectronic technology. It can directly accept the signal of the sensor. When the signal meets the specified conditions, it can complete the action by itself without using an external controller to achieve the control purpose. It has been applied to the conveyor belt of the object, which can identify the size of the moving object, so that the large piece can be directly sent down and the small part can be shunted.

Higher safety and reliability. From the international standards of pneumatic technology in recent years, the standard not only proposes interchangeability requirements, but also emphasizes safety. The pressure of the pressure test of the pipe joint and the air source treatment casing is increased to 4 to 5 times of the use pressure, and the withstand voltage time is increased to 5 to 15 minutes, and the test is also performed at high and low temperatures. If these international standards are implemented, domestic cylinders, end caps, gas source processing castings and pipe joints are difficult to meet the standard requirements. In addition to the pressure test, there are some provisions on the structure. For example, the outer cover of the transparent shell for air source treatment is required to be equipped with a metal shield.

Many applications of pneumatic components, such as rolling mills, textile lines, etc., cannot be interrupted during the working hours due to the quality problems of pneumatic components, otherwise huge losses will occur, so the operational reliability of pneumatic components is very important. There are many pneumatic components used in marine vessels, but there are not many pneumatic components that can enter this field. The reason is that their reliability requirements for pneumatic components are extremely high, and they must pass the certification of relevant international machinery.

It is developing in the direction of high speed, high frequency, high response and high life. In order to improve the production efficiency of production equipment, it is imperative to increase the working speed of actuators. At present, the working speed of cylinders in China is generally below 0.5m/s. According to Japanese experts, most cylinders will increase their working speed to 1~2m/s after five years, and some require 5m/s. The improvement of the working speed of the cylinder not only requires the quality of the cylinder to be improved, but also the structure should be improved accordingly, for example, a hydraulic shock absorber is required to increase the cushioning effect. The response time of the solenoid valve will be less than 10ms and the life will be increased to more than 50 million times. In the United States, there is a gap-sealed valve. Since the spool is suspended in the valve body, it does not touch each other, and the life is up to 200 million times without lubrication.

Oil-free lubrication technology is commonly used to meet certain special requirements. Due to environmental pollution and the requirements of electronics, medical, food and other industries, oil is not allowed in the environment. Therefore, oil-free lubrication is the development trend of pneumatic components, and no oil lubrication. Make the system simple. Oil misters in the European market are already eliminated products, and oil-free lubrication is generally achieved. In addition, in order to meet certain special requirements, deodorization, sterilization and precision filters are being developed continuously, the filtration precision has reached 0.1~0.3μm, and the filtration efficiency has reached 99.9999%.

Aiming at certain special requirements, improving and developing pneumatic products, it is possible to occupy a market and gain considerable economic benefits. This has been agreed by everyone. Jinan Huaneng Pneumatic Components Co., Ltd. has developed cylinders and valves for the special requirements of railway grouping and wheel-rail lubrication, which has attracted the attention of the railway department.

The use of new materials, combined with new technology. Developed a membrane dryer abroad, the use of high-tech reverse dialysis membrane to filter the moisture in the compressed air, energy saving, long life, high reliability, small size, weight Light and other features, suitable for occasions with low traffic.

Pneumatic seals made of composite materials based on polytetrafluoroethylene are heat-resistant (260 ° C), cold-resistant (-55 ° C) and wear-resistant, and their use is increasing.

In order to improve the quality, new technologies such as vacuum die casting, hydrogen and oxygen explosion deburring are gradually being promoted in the manufacture of pneumatic components.

Easy to maintain, repair and use. Foreign countries are studying the use of sensors to achieve pneumatic components and systems with fault prediction and self-diagnosis.

From the above-mentioned development direction of pneumatic technology, we have a lot of work to do in the development of pneumatic products. Any pneumatic component factory, even if it is small in scale, can break through one aspect and maintain its technological leadership, and it can occupy a place in the market and survive and develop in the fierce competition.

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