Product category:
Pneumatic Valves and Controls
News Release from: Asco Numatics | Subject: Pre-engineered systems
Edited by the Engineeringtalk Editorial
Team on 02 May 2006
Pre-engineered systems improve
competitiveness
Steve Meadows, Senior Marketing Engineer at Asco Joucomatic, outlines the benefits of pre-engineered systems for all areas of industry.
Today, many products are designed around common platforms, with component systems (or modules) for each major subsystem This means that they can be configured and assembled more quickly and efficiently
This article was originally published on Engineeringtalk on 27 Feb 2007 at 8.00am (UK)
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The automotive industry is a good case in point.
One of the pioneers of pre-engineered assemblies with wheel hubs and steering systems, the industry is now successfully applying the technology into other areas of vehicle design, as evidenced by a recent example where one major manufacturer found that modular assembly could cut almost 10% off the cost of a vehicle cockpit.
Cost savings are, of course, the main driver behind the move to pre-engineered, modular systems; however, there are a number of other factors that are also driving the adoption of the technology.
First, manufacturers are finding that pre-assembled modular systems give them quicker design turnaround, reducing the "time to market" for new products.
Secondly, companies that have access to a wide variety of supplier modules improve their ability to meet changing customer demands, because product differences can now be more easily incorporated into a product's final design.
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Thirdly, pre-engineered systems demand less effort on the part of the end user, allowing him to focus more efforts and resources on the success of his core business.
Fourthly, companies require fewer expensive design personnel as a result of adopting pre-assembly, exploiting instead the unique design skills of specialty vendors.
Fifthly and finally, there is an increasing emphasis on safety issues.
For an OEM, the process of assembling discrete components from several manufacturers into complete assemblies is one that always has the potential for pitfalls.
However, the risks of parts incompatibility and incorrect assembly can avoided, and the subsequent responsibility for achieving the necessary level of safety provision can often be transferred, using pre-assembled systems.
A case that highlights the safety benefits of pre-assembly is Asco Joucomatic's provision of pre-assembled tank/valve systems for dust collection.
In the past, OEMs have assembled their own systems from discrete parts; however, with the introduction of a new European directive (European Pressure Equipment Directive 97/23/EEC), certification of these systems has become more onerous and costly.
The result of this is a move away from the component approach to pre-assembled, fully tested and certified tank systems from a single source supplier.
The Asco Joucomatic tank system is a good example of a pre-engineered system, where actual machining of components is required to achieve the assembly.
This is essentially what differentiates pre-engineered systems form pre-assembled systems, the latter generally being an assembly of existing components.
A simple example is the mounting of a control valve and flow control elements actually onto a pneumatic cylinder body using solid pipework.
In contrast, the bespoke manifold systems, as produced by Asco Joucomatic for use in general automation, medical, biomedical and analytical applications, dust collector applications, packaged control systems - and even petrol vending, use standard components, but require machining of the subbases on which the components mount.
In both cases, though, the assemblies are designed and delivered as fully functional units, which speed-up the construction time of machines to which they are applied.
With its traditional links to the OEM market, the UK pneumatics industry is a particular engine of growth for pre-engineered and pre-assembled systems.
This growth is recognition; not only of the traditional benefits of pre-assembly, but also that the complexity of modern machine designs cannot always be satisfied with standard fluid control and fluid power products.
The requirements for machine designs are becoming ever more demanding, and to meet these demands specialised products are often required.
This could involve producing a totally individual design, or, more simply, modifying an existing product.
Companies such as Asco Joucomatic offer a specialised product service, with a special team of engineers and technicians to produce these designs: the objective being to provide the most cost effective solution, and the closest correlation between market demands and equipment performance.
The specialised, pre-engineered product service provided by Asco Joucomatic delivers solutions in four key areas: distributors (manifolds) and distribution islands; actuators; solenoid valves and general valves and filters - regulators and lubricators.
All of the products in these areas are characterised by their reduced size and integrated functions, for easier integration into machines, and by their specialised mechanical and/or electrical interfaces that, by facilitating simplified design, reduce production time.
Distributors and distribution islands provided under the specialised service are available with multiple integrated pneumatic functions such as flow reducers, progressive starters, isolation valves, rapid purge, pressure switches, specific mounting plates and input modules (etc).
Specialised actuators are offered in corrosion resistant materials such as stainless steel, with impact resistant (induction-hardened) piston rods where required.
They can be fully integrated, space-saving units, incorporating flow reducers, or versions with displacement sensors, air saving systems and scraper seals to protect piston rods.
Other variations include telescopic units, versions with anti-rotation rod devices and proprietary welding clamp actuators that combine compactness with high power.
Manifolds are available with multiple functions, integrating several solenoid valves, circuit selectors, pressure sensors and metering.
In addition, the optimised specification also includes: KV, DeltaP, consumed power; special connections and mounting plates; integration of several pressure controlled valves in a single body; double action heads; control from 0.1 to 40bar and miniature pressure controlled valves with 3mm opening diameters.
In the final area of filters, regulators and lubricators, Asco Joucomatic offers specialised products for operation up to 16bar.
These include units with pneumatic and electrical control, and versions with special bowls for compactness, and for use in aggressive environments.
Also included are units with frontal regulation valves or modified-position isolation valves, and regulators with special springs adapted to specific working pressures to provide greater accuracy and reduced levels of hysteresis.
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