Secure and highly absorbent connection: Multi-stage vacuum generators of the ZL series with IO-Link increase efficiency in Industry 4.0

The highly efficient multi-stage vacuum generators of the ZL series from SMC increase efficiency and safety in pick-and-place applications thanks to new IO-Link. (Photo: SMC Deutschland GmbH)

Whether for clamping, suction, or transportation: The multi-stage vacuum generators of the ZL series from SMC are the first choice industry-wide for pick-and-place applications – and now make them even safer and more efficient thanks to IO-Link expansion. Combined with high suction performance and low weight, the ZL3/ZL6 models thus offer an economical and well-networked all-round solution for vacuum applications in Industry 4.0: easy to integrate, efficiently usable, safely controllable, and suitable for mounting on industrial robots in sectors such as food, automotive, or life sciences.

Modern pick-and-place applications often require small, lightweight, and powerful vacuum generators that perform reliably both on large workpieces and on moving robot parts. To further improve processes, safety, and connectivity, automation specialist SMC has equipped the two multi-stage vacuum generators ZL3/ZL6 of its ZL series with an IO-Link interface. Both models continue to impress with a maximum suction volume flow of 300 l/min (ZL3) and 600 l/min (ZL6), complemented by the ZL1 model (100 l/min, each ANR). The IO-Link communication increases automation level and process safety: in addition to remote monitoring and real-time data utilization, malfunctions can be detected more quickly. Overall, the ZL series provides an economical all-round solution that, thanks to IO-Link expansion, also helps reduce application errors and IT costs. The high suction power shortens cycle times as usual and thus increases output, while the low weight enables lightweight machine designs. In short: the ZL series offers flexible all-round vacuum generators for Industry 4.0 – saving space, weight, and costs while enhancing efficiency, safety, and connectivity.

Simple integration for increased automation

In operation, the IO-Link expansion of the ZL series allows for better control of device status and manufacturing processes. Thanks to sensor monitoring, malfunctions can be detected more quickly, which is an advantage for process safety. Vacuum generation can also be remotely controlled via optional pilot valves mounted on the housing, depending on the need. This allows the compressed air supply to be shut off on the control side, reducing energy costs.

The weight, which has already been reduced compared to previous models (e.g., by 44% from 700 g to 390 g for ZL3), ensures a lower moment of inertia when using the vacuum generator in moving applications (e.g., robot arm). Additionally, this enables the design of particularly small and cost-effective machines.

Efficient suction power with energy-saving functions

The air consumption and thus energy costs can be controlled with special features: all models of the ZL series feature a nozzle design with a 3-stage diffuser, which can more than double the suction volume flow at constant compressed air supply (simple design for ZL1, ZL3; double design for ZL6).

The ZL3/ZL6 models can optionally be equipped with a digital vacuum switch including an energy-saving function. The resulting self-regulating control loop reduces air consumption by up to 91%: vacuum is generated only as needed, and the compressed air supply is automatically shut off once the desired vacuum level is reached. This not only saves money but also benefits the climate.

Ready for the future of Industry 4.0

The installation of the ZL series remains quick: the double threaded connection (vacuum connection 1/2") allows direct connection of the ZL3/ZL6 models without additional T-fittings – saving time and costs. An optional adapter is available for bottom mounting, for example, for machine upgrades without changing the mounting holes (ZL1/ZL3). Additionally, an adjustment needle for damping the blow-off pulse enables gentle release of sensitive components or workpieces. This increased process safety reduces time and costs associated with potential production errors.

The even more versatile all-round vacuum generators of the ZL series with IO-Link make pick-and-place applications in numerous industries safer and more efficient – from the food industry to automotive and life sciences. Small, lightweight, and powerful, they are ideally suited for mounting on moving robot applications, for suctioning glass sheets (e.g., ZL1), clamping workpieces (e.g., ZL3), or transporting cartons (e.g., ZL6).