New Festo Modules Optimize Compressed Air Consumption, Detect Leaks Sooner

November 26, 2020

Festo is expanding its industry-leading technology for energy conservation and early leak detection in pneumatic production with two more intelligent energy efficiency modules – the MSE6-C2M and MSE6-D2M. They join the MSE6-E2M to form a comprehensive lineup of condition monitoring devices that optimize compressed air usage during normal operations and halt or reduce consumption during scheduled stoppages as a further economy. They will pay for themselves in fairly short order.

These MSE6 series modules can be fully integrated into the machine’s control system via fieldbus nodes to cyclically exchange important energy consumption and availability data regarding production. That data can inform more targeted preventive maintenance practices, or for even bigger cost savings, a predictive maintenance program. In the case of the -E2M, this data can be uploaded to the cloud via the Festo IoT gateway CPX-IOT and recorded and analyzed as long-term measured values to recognize consumption trends that can identify inefficiencies and deteriorating performance for possible remedial action.

The new -C2M is the most fully featured in the MSE6 series. It fully and automatically regulates the compressed air consumption of a pneumatic system. The -C2M combines a pressure regulator, on/off valve, flow and pressure sensors and fieldbus communications (PROFINET, with more protocols to come) in one unit. During production, the integrated proportional pressure regulator ensures optimum production by regulating the pressure according the user’s specifications. During non-production intervals, it shuts off the compressed air supply once production has stopped for a certain amount of time while maintaining sufficient pressure in the idling system for an immediate re-start.

While the system is in standby mode, the -C2M, like the -E2M and -D2M, will detect leaks by evaluating the rate of pressure drop.

Throughout industry, estimates of compressor capacity loss due to leaks runs from 10 to 30%, even in businesses with high maintenance standards. It usually starts with tiny trickles around joints or in hoses, and can grow into major problems that result in unscheduled shutdowns. When excessive air loss goes unrecognized, the compressor and associated components have to work harder to maintain required production pressure levels, potentially shortening their reliability or service life.

Conventional approaches for detecting air loss are reactive, like relying on pressure sensors on air preparation units to send a signal to the PLC or DCS that the pressure has dropped too low. At that point, the system often shuts down until engineering or maintenance diagnoses and fixes the problem. Festo’s MSE6 modules continuously monitor air flow and volumetric consumption. They can detect anomalies much sooner, so repairs can be done when issues are small, and during scheduled downtime.

The -C2M also can be incorporated into an air preparation environment, to create a service unit that also can perform functions such as soft start, filtering and exhaust/quick exhaust. The smaller, economical -D2M, is an efficient extension module of the -C2M to provide coverage of a second supply stream. It must be connected to a -C2M or to a CPX terminal.

The -C2M already has won an award – the Gold Medal in the pneumatics category at the 2020 LEAP (Leadership in Engineering Achievement Program) awards. The judges verdict: “Great energy saving product! Leveraging historical data, or data mining gives the customer situational awareness.”

The -E2M, introduced in 2015, is a standalone module that has won multiple awards and citations for both concept and technology; it’s the mid-priced choice in the MSE6 series.

All three MSE6 modules can be installed in existing or new systems.

For more information, visit www.festo.com.

Related Articles


Latest Articles

  • Tariffs – Can You Look Within? 

    February 12, 2025 OPINION By Swathi Mohan, Founder of Leanacle Inc. I was standing backstage at a company townhall, running through my talking points, but my mind was elsewhere. Will they be engaged? Will they relate to what I’m saying? What if I lose them halfway through?  The more I thought about it, the more anxious… Read More…

  • What is a Robotic Subsystem?

    What is a Robotic Subsystem?

    February 11, 2025 In robotics, a subsystem refers to a distinct functional unit within a robot, each responsible for specific tasks that contribute to the robot’s overall operation. Understanding these subsystems is crucial for designing, analyzing, and optimizing robotic systems. This guide delves into the primary subsystems commonly found in robots, detailing their components and… Read More…


Featured Article

Revolutionizing Material Movement with Autonomous Mobile Robots

Revolutionizing Material Movement with Autonomous Mobile Robots

In today’s fast-paced manufacturing and logistics industries, the need for efficient and flexible material movement solutions has never been greater. Traditional methods like conveyor systems, forklifts, and manual pushcarts have served us well, but they come with limitations.

That’s why Omron is thrilled to announce the launch of their game-changing MD Series of Autonomous Mobile Robots (AMRs). Read more


Products

  • POSITAL Announces Ultra-Heavy-Duty Absolute and Incremental Rotary Encoders

    February 12, 2025 POSITAL has introduced a new series of IXARC rotary encoders designed for applications where high shaft loadings may be encountered. With heavy-duty housings and shaft bearings, these units are designed to withstand radial shaft loads of up to 350 N (80 pounds) and axial loads as high as 250 N (56 pounds),… Read More…

  • POSITAL Announces Upgrades to IXARC Incremental Rotary Encoders

    February 12, 2025 Higher resolution opens possibilities in new application areas POSITAL has enhanced its IXARC family of incremental magnetic encoders, increasing the maximum resolution to 32,768 pulses per revolution (PPR). This upgrade includes new phasing options, offering a choice of wider index (Z) pulses, making it easier to replicate the features of older encoders… Read More…