Vacuum technology for the digital factory

Compact Terminal SCTMi: Thanks to its modular design, up to 16 individual ejectors can be controlled and configured independently. The parameterization is done via app. (Image: J. Schmalz GmbH)

The electric vacuum generator ECBPi with IO-Link and NFC was developed for mobile robotics and stationary handling tasks with collaborative robots (cobots). (Image: J. Schmalz GmbH)

The vacuum components are quickly integrated into the application environment via interfaces such as IO-Link, Ethernet, or NFC. They enable seamless process monitoring, early fault detection, and timely, planned maintenance. (Image: J. Schmalz GmbH)

To make electric vacuum generators, grippers, or compact actuators visible for the smart factory, they must provide real-time digital energy and process data. Schmalz integrates interfaces such as IO-Link, Ethernet, or NFC into its vacuum components to create the intelligent foundation for networked manufacturing.

Cyber-physical systems are the protagonists of the fourth industrial revolution. They connect real objects with virtual ones, i.e., machines with information processing systems. The level of innovation compared to the automation wave driven by electronics and IT since the 1970s is cross-system communication. Through this, energy and process control as well as predictive maintenance can be realized — provided the devices have the appropriate interfaces.

Specifically developed for networking in vacuum automation, J. Schmalz GmbH creates vacuum components that not only capture and send energy- and performance-relevant data to the cloud but also monitor and analyze them. Thanks to interfaces like IO-Link or Industrial Ethernet, the Smart Field Devices enable seamless communication from the sensor and actuator level to the higher-level control (PLC) and further to the supervisory level. The communication works in both directions: in addition to transmitting data about the condition or energy consumption, parameters can be changed via the control and transferred to the intelligent field device.

In addition to the IO-Link and Industrial Ethernet interfaces, Schmalz integrates an NFC interface (Near Field Communication) into its intelligent vacuum components. To exchange information wirelessly over short distances, a point-to-point coupling occurs between the Smart Field Device and the NFC-enabled mobile device of the user. No separate power supply is needed for transmission; instead, a coil is embedded that is energized via the smartphone. The coil induces a voltage in a processor, which then sends its information via an antenna. The user can thus read process data as well as maintenance and service information directly on the smartphone. The device communicates in plain language with the user: in case of a standstill, it provides clear hints about the source of the error instead of cryptic error codes. The component can also be parameterized via the smartphone. For this purpose, Schmalz has programmed the app ControlRoom. Parameter changes made via NFC can be directly transferred to the device or copied from one device to another.

Another advantage of NFC is the direct association of the product with the smartphone. Two devices are only connected over a very short distance of a maximum of two centimeters. This ensures that the user does not unintentionally parameterize neighboring devices.

From Airflow to Data Stream

The benefits of digitization at the component level for vacuum applications are exemplified by the view into the compact terminal SCTMi. This consolidates up to 16 individual vacuum generators into a compact unit that only has one electrical and one compressed air connection. Schmalz thus enables the simultaneous, independent handling of different parts with just one system. Vacuum is generated with a Venturi nozzle and detected by a sensor. The exact vacuum value can be read by the user via the IO-Link process data or on the display of the generator.

Through cyclic process data, the ejectors are also controlled, and current information is fed back from the SCTMi. Likewise, the user has access to set values, parameters, as well as measurement and analysis data via the IO-Link connection. Additionally, the diagnostic and prognosis functions of the vacuum components derive information about the condition of the system and detect trends in quality and performance. When transmitted to an internal or external cloud, the data are processed and analyzed, generating real added value: if the system detects ongoing values within tolerance or gradual changes, these can be quickly and clearly displayed to the user. For example, the system checks for leaks and backpressure for predictive maintenance evaluations.

Condition monitoring events are triggered, for example, when the backpressure values deviate, the evacuation times of the ejectors exceed their limits, or sensor voltages fall outside the working range. The energy monitoring function keeps an eye on the energy consumption of the connected vacuum systems. This monitoring is based on the measured air consumption, which is calculated considering system pressure and nozzle size. Users can specify an externally measured pressure value via the IO-Link process data. When this value is available, the ejector can additionally measure the absolute air consumption besides the percentage.

Quick Integration

Thanks to these various functions, users can keep their systems efficient, avoid machine downtime, and increase system availability. But IO-Link also offers significant advantages during the integration of the compact terminal into the system environment: Schmalz provides the user with a comprehensive IO-Link configuration file, IODD (IO Device Description), which includes information on identification, device parameters, process and diagnostic data, as well as communication properties. The exchange of devices is also simplified, as the IO-Link protocol includes an automation for data transfer. When replacing a device with a new one of the same type, the old device's settings are automatically stored in the master and transferred to the new device.

The compact terminal SCTMi is part of the continuously growing program of intelligent field devices. Their process and condition data enable Industry 4.0 concepts. Users benefit from quick commissioning, reliable operation, and reduced failure risks. In addition to special compact actuators, Schmalz also offers the electronic vacuum pressure switch VSi — which measures and monitors under- and overpressure in automation and handling systems — as well as the SNGi-AE special gripper and the ECBPi electric vacuum generator with IO-Link and NFC for the digital factory.