At the Hanover Trade Fair "Factory Automation", Schmalz presented the new product series X-Pump (vacuum generators/ejectors) for the first time.

The excellent characteristics of these vacuum generators can be grouped into three categories.

The ejectors are "eXtra strong" In other words, they have a very high suction capacity and generate very powerful blow-off pulses, and thus guarantee maximal availability.

The attribute "eXtra robust" stands for features such as their compact design, simple connection facilities, insensitivity to dirt and dust, degree of protection IP65, etc.

But it is the functions grouped under the slogan "eXtra intelligent" which distinguish these ejectors from all other currently available compact ejectors.

...eXtra intelligent...
Fault detection before the system breaks down!

Manifold diagnostic functions are integrated as standard features in the new X-Pump and permit preventive maintenance.

A concrete example serves to show the immense benefits of this to the user.

Example: a press transfer line in the press shop of an automobile manufacturer with industrial robots for the transfer operations

How did this run until now?

The system runs in three shifts, 24 hours a day, and is set up for new parts two or three times in each shift. If the vacuum spider of a robot develops a fault, i.e. the leakage in the system becomes so large that workpieces can no longer be transported, this becomes evident only when the damage occurs.
In the worst case, there is a system crash and the entire system grinds to a halt!
This incurs enormously high costs!

Assumption:

The press shop is equipped with the X-Pumps from Schmalz.
Each robot is equipped with a double X-Pump.

The new situation when the X-Pump is used:

The X-Pump has an integrated condition-monitoring function, a diagnostic function which permits preventive maintenance.
The X-Pump thus detects any impending fault in the vacuum spiders, evaluates it and displays it!
For this purpose, the X-Pump has an optical status indicator in the form of easily visible indicator LEDs which work rather like miniature traffic lights.
These indicators permit the operator of the press to see the status of the vacuum spider or the entire vacuum system at a glance.

For example:
The following states are indicated directly on the ejector...

• Steady green light: no leaks in the vacuum system. Everything is OK.
• Blinking green light: the system has a minor leak, but can still be used without problems...
• Blinking red light: the system is taking too long to reach the required vacuum value. In other words, there is a serious leak and the system should be checked as soon as possible, since there is a high risk of imminent failure.
• Steady red light: the vacuum at the spider is too low or absent. The spider must be checked and repaired immediately.

In the past, the entire system had to be stopped in order to identify and repair the defective component (spider) in the vacuum system.

This situation cannot occur with the new X-Pump!

Why not?

• Defective spiders can be identified unambiguously, quickly and easily with the aid of the status indicators.
• If the press is stopped for conversion to another workpiece or tool, the current/last status of the vacuum spider is still indicated.

The press operator sees the status indicators on the vacuum generators and can act accordingly. In other words, the defective spider is not used again after the tool change!
The operator informs the maintenance department of the status indicated on the X-Pump, and repairs can be started while the system is stopped for the tool or workpiece changeover.
This reduces the maintenance work and, of course, the costs!

In addition to making the status of the vacuum spider easily visible to the operator, the X-Pump has further condition-monitoring functions:

• Deactivation of the automatic air-saving function:
  If the vacuum deteriorates during production (i.e. if the permissible leakage rate is exceeded), the condition-monitoring system indicates this with the status indicator (blinking green light) and, at the same time, deactivates the automatic air-saving function. The ejector thus continuously generates the full vacuum in order to compensate for the leakage and to permit continued operation of the system. The defective vacuum spider can then be identified unambiguously and can be repaired during the next planned idle period of the press.

• Diagnostic output for external monitoring
  The information provided by the manifold diagnostic functions of the X-Pump can be transmitted to an external controller, such as that for the robot or a higher-level system (process control room). The external controller thus has a complete overview of the system status, permitting better process reliability.

Most down times in production shops are caused by defective or faulty vacuum systems. With the X-Pump and its integrated condition monitoring, such faults can be detected in good time and the necessary actions initiated.

Are you interested? Would you like a personal consultation?
We are at your service.

Send us a letter or an email, or call us at +49(0)7443/2403-392. Walter Dunkmann will be glad to provide any information you desire.