Basic Principles of Vacuum Technology, Brief Overview: P (Pa) P (Mbar)

Basic principles of vacuum technology, brief overview
Introduction
Basic principles of vacuum technology

What is a vacuum? Vacuum ranges Units of measurement
A vacuum is a space entirely devoid of P P There are a large number of national The vacuum level is often expressed
[pa] [mbar]
matter (absolute vacuum). and international units of as a % value. However, these are
In practice we talk about a vacuum GV measurement. The most commonly always relative values.
when the air pressure in a space lies FV
used units are Pascal (Pa) and bar
below atmospheric pressure.
HV 100 Pa = 1 hPa GV = Rough vacuum
1 hPa = 1 mbar FV = Medium vacuum
UHV
1 mbar = 0.001 bar HV = High vacuum
UHV = Ultra-high vacuum
What is a vacuum used for? Measuring the pressure or vacuum Atmospheric pressure
The vacuum plays a vital role in In the rough vacuum range, the h [km] 1 Mount Everest
research in the fields of chemistry, pressure gauges used are mainly 2 Festo
biology and physics. mechanical, but some digital pressure 3 Sea level
It is also indispensable in many gauges are also used.
industrial processes. In the high and ultra-high vacuum
range, highly sensitive pressure
gauges are used.
p [hPa]
Understanding vacuum Vacuum specification options Effects of changes on vacuum

technology
Air is a gas mixture with approx. A vacuum can be specified as an As altitude increases, the air pressure
1025 particles per m3 of air at one bar absolute value, i.e. with a positive in the atmosphere falls. This same
air pressure. sign from 1 to 0 bar, with 0 as effect reduces the attainable vacuum
Particles exert pressure or force on the absolute zero. Or it can be specified level of an ejector. Nevertheless, the
walls of a defined space. The fewer as a relative value with a negative performance level of 80% remains
particles there are in the space, the sign from 0 to 1 bar, with 0 as a unchanged in this case.
lower the force exerted on the walls. reference point, or as a %.
Pressure = Force
Area
100% vacuum would mean that there

are no particles present. Pressure = 0.
Subject to change Internet: www.festo.com/catalogue/... 1

Introduction
Components for vacuum generation

Vacuum ejectors Displacement vacuum pumps Kinetic vacuum pumps
These function according to the Air flowing into a space is Air is forced to flow in the delivery
venturi principle, i.e. they are driven mechanically shut off, compressed direction through the application of
purely pneumatically and have a and ejected. This allows a very high additional mechanical force. This
much simpler design compared with vacuum to be achieved at a very low method achieves only a relatively low
other vacuum generators. flow rate. vacuum level despite a high suction
rate.
Principle
The most important components Depending on the principle, air is 1 1 Pressure side
are the jet nozzle (venturi nozzle) either carried away in a flow by a 4 2 Suction side
and at least one receiver nozzle. rotating impeller on the suction 3 Inlet valve
Accelerated compressed air side or compressed using vaned 4 Exhaust valve
generates a suction effect between chambers. 5 Piston
both nozzles (vacuum). The pump types available
3
There are different design include vacuum blowers and 5
2
principles: single-stage and multi- vacuum compressors, for example.
stage ejectors.
Features
High vacuum level with relatively Low-weight, compact design Minimal maintenance expenses Large flow rates, low vacuum level
small flow rate Any mounting position Generally large dimensions and High maintenance costs
Maintenance-free and wear-free High vacuum level up to 0.98 bar high weight
Low-cost operating pressure Restricted mounting position
Application
Wide range of applications, Broad application spectrum in Used mainly for precision processes
e.g. handling technology and industry and research. in industry.
process engineering.
2 Internet: www.festo.com/catalogue/... Subject to change

Introduction
Vacuum in handling technology

Practical use of vacuum Important selection factors Benefits of a vacuum
The extensive range of vacuum Lifting Conveyance Weight, temperature, shape and Gentle handling
component variants makes them ideal Loading Turning roughness of the workpiece surface Compact, low-weight, space-saving
for use in many industrial Speed per unit of time design
Gripping
applications. Stroke travel and conveying Fast cycle times possible
Machining distances Low maintenance costs
Low-cost
Holding
Insertion
Moving
Feeding Repositioning
Transporting
Comparison of ejectors
Variables/criteria Single-stage Multi-stage
Suction flow rate Average High
At low vacuum level up to approx. 50%
Evacuation time Very short Very short
In higher vacuum range from 30 50% In lower vacuum range up to 30 50%
Initial costs Low Relatively high
Noise generation Relatively high Low
Both principles have their advantages components, both principles can

and disadvantages which are difficult cover a large number of different areas
to compare. With optimally adapted of application.
Important comparison variables

Evacuation time Air consumption Efficiency Suction flow rate
Evacuation time = Time (s) required to Air consumption = Air consumption The efficiency formula makes it easier The efficiency of an ejector is often
generate a specific vacuum. (l/min) of the ejector required to to compare the different principles: and incorrectly measured using the
generate a specific vacuum. Efficiency = Evacuation time, air suction flow rate at 0 bar.
consumption and volume dependent
on vacuum. Suction flow rate = Suction air volume
(l/min) that an ejector can draw in.

Introduction
Vacuum in handling technology

Energy cost comparison
To generate compressed air from Vacuum ejectors: Electric vacuum pumps: For a comparison of features, a
atmospheric air, you need to reckon High air consumption, but Very high vacuum (up to 99.99%) calculation example and an energy
on approx. 0.02 per m3 volume at compensated by its energy-saving attainable cost comparison following
7 bar pressure when calculating the function High suction rates (vacuum blower) sections.
costs involved (e.g. investment, Maintenance-free, no moving parts of up to 1,200 m3/hr. possible
material, labour, etc.). Low weight and component High current consumption because
dimensions and can be installed in of continuously operated pumps
any mounting position High initial costs and ongoing
No electrical connections required maintenance costs
Relatively high vacuum level (up to Large weight and unit volume as
85% vacuum) attainable well as fixed mounting position
Low initial costs
Leakage in vacuum systems

When a vacuum suction gripper This might be caused, for example, by Remedial actions to achieve the
cannot fully seal the system against rough and uneven workpiece surfaces required vacuum:
atmospheric air, we talk about leaking or air-permeable workpiece materials. Use of high-performance ejectors
systems. Reduction of the suction cup
diameter
Selection aid for vacuum generators

In all cases, it is recommended that Procedure: Determining the correct ejector size
you perform a test setup to determine Determining the leak rate Intersection of the leak rate (now
the leak rate, thereby enabling you to Perform the test setup known) with the curves of other
ascertain which vacuum ejector you Read the vacuum value achieved ejectors
need. Compare the result with the Determine the attainable vacuum
course of the curve in the by means of projecting
Suction capacity as a function of downwards from the
vacuum chart ( 28) intersections with the leak rate
Difference with respect to suction Select the ejector that reaches the
capacity = leak rate required vacuum level.

Introduction
Typical applications

Introduction
What is a vacuum?
In physics, a vacuum is defined as In practice, however, this state cannot Furthermore, every space contains
a state of emptiness that can be be achieved. We therefore talk instead particles of matter such as protons
achieved by experiment in other about a vacuum when the air pressure and electrons, as well as zero-mass
words, nothing. in a space is lower than the particles photons which transport
This definition refers to the state of a atmospheric pressure or when the energy at the speed of light.
space entirely devoid of matter density of air molecules is reduced.
(sometimes also referred to as an
absolute vacuum).
What is a vacuum used for?

Since the 17th century (Magdeburg In chemistry, reactions in substances Today, the vacuum plays a vital role in Vacuum technology has also played a
hemispheres) mankind has been are investigated in a vacuum, biology important industrial processes, many part in the development and
studying vacuum. Today, we cannot is interested in the effects of a of which would not be possible implementation of new ideas in
imagine modern research without it. vacuum on organisms, while some without it. Noteworthy examples handling technology, i.e. lifting,
areas of physics (quantum physics, include semiconductor manufacture holding, rotating and transporting all
field theory, etc.) are concerned with or mass spectroscopy. kinds of parts.
particles that can be examined more
accurately in a vacuum.
Understanding vacuum
Air is a gas mixture containing To attain a state of vacuum, a space Pressure gauge In reality, however, this is rarely
approx. 1025 particles per m3 at must be empty, i.e. devoid of all achievable. In an ultra-high vacuum,
one bar air pressure. gaseous material. the pressure may indeed be low
The consequence of this is that the (approx. 108 to 1011 mbar), but the
pressure in this space is very low, as it particle number density is still
Nitrogen
contains no or only a small number of approx. 2.5 x 1013 particles per m3.
particles, which exert a force on an Small number of particles The following rule therefore applies:
area as a result of their impact at constant temperature The fewer particles there are, the
Oxygen
against the walls. low pressure lower the pressure.
Pressure is therefore defined as

Pressure gauge
Other gases follows:
Pressure = Force
In the atmosphere, this gas mixture is Area
made up of the following gases and
proportions: In theory, in an absolute vacuum,
78% Nitrogen i.e. where there are no more particles
21% Oxygen of matter in the space, pressure = 0. Large number of particles
1% Other gases at constant temperature
(e.g. carbon dioxide and high pressure
argon)

Introduction
Vacuum ranges
In practice, the large vacuum range P P
that can technically be achieved [pa] [mbar]
which now consists of more than Handling range:
16 powers of ten is generally GV This vacuum range is used in handling
subdivided into smaller ranges. technology.
The vacuum ranges below are FV
classified according to physical
attributes and technical HV GV = Rough vacuum
requirements. FV = Medium vacuum
HV = High vacuum
UHV UHV = Ultra-high vacuum
Vacuum range Pressure range (absolute) Applications

Rough vacuum Atmospheric pressure 1 mbar Applications in industrial handling technology.
In practice, the vacuum level is often specified as a percentage, i.e. the vacuum
is defined in proportion to its ambient pressure. The material and the surface
finish of workpieces play a major role in vacuum applications.
Medium vacuum 103 1 mbar Steel degassing, light bulb production, drying of plastics, freeze drying of
foodstuffs, etc.
High vacuum 103 108 mbar Smelting or annealing of metals, electron tube manufacture.
Ultra-high vacuum 108 1011 mbar Spraying of metals, vacuum metallizing (coating of metals) as well as electron
beam melting.
Measuring the pressure or vacuum

Pressure is defined as the force per For this reason, all measuring The most common mechanical
unit area. Air is a gas mixture made instruments must be calibrated, function types are:
up of many particles (atoms and i.e. individual measuring instruments
molecules). These particles are in with the same function must be Bourdon tube pressure gauge
continuous motion. Wherever they adjusted so that they produce the Aneroid pressure gauge
meet, they exert a force. same result under the same Diaphragm pressure gauge
The pressure and vacuum are conditions. Digital pressure gauge
measured by taking a specific unit In order to be able to evaluate or
area and measuring the number and measure the vacuum medium, there In the high and ultra-high vacuum
intensity of this impact on this area. are a number of items of technical range, pressure gauges with highly
Measurements are necessary in order equipment that are indispensable for sensitive response mechanisms are
to be able to check and monitor applications in the fields of industry used. A great many additional factors
processes. and research. play a role in determining the 1 Bourdon tube
Pressure gauges (vacuum gauges) are measurement results in this case. 2 Spring support
used generally as well as in the rough 3 Spring end piece
vacuum range. These gauges are It is important to remember that there 4 Segment
scaled according to the level of are two different options for specifying 5 Tie rod
accuracy required. Pressure gauges or representing the same 6 Gearing
work according to many different measurement result. 7 Indicator shaft
operating principles and can function 8 Coil spring
mechanically or digitally. 9 Indicator
aJ Dial face

Introduction
Vacuum designations and specification options

It is important to mention at this point both colloquial and technical misunderstanding, these designations
that there a number of different language. need to be explained here.
designations for the term vacuum in In order to avoid any uncertainty or
Vacuum
Correct designation specified as %
only in the range 0 1 bar absolute
pressure.
Operating pressure Vacuum as an absolute value Vacuum as a relative value

Correct designation, operating Applications: Applications:
pressure of 0 bar relative pressure is In the field of science as well as in the In the rough or operating vacuum
equivalent to 1 bar absolute pressure. medium-high and high vacuum range (e.g. for Festo applications).
A vacuum is generally specified as ranges. Principle:
relative operating pressure, i.e. with a Principle: Vacuum is specified as a relative
negative sign. Vacuum is specified as an absolute value in proportion to ambient
value in proportion to absolute zero, pressure, i.e. the specified vacuum
Operating pressure can be specified i.e. 0 bar is the lowest value and value has a negative sign, because
correctly in two different ways, i.e. as corresponds to 100% vacuum. In the the ambient pressure (atmospheric
a relative or an absolute value. Both vacuum range, 1 bar is thus the pressure) has been assumed as the
specification options are also applied highest value and corresponds to the reference point with a value of 0. The
to vacuums and are explained in more average ambient pressure. lowest value, i.e. also 100% vacuum
detail below. Feature: corresponds to 1 bar relative
Vacuum values have positive signs. operating pressure.
Vacuum range 1 0 bar Feature:
Vacuum values have negative signs.
Vacuum range 0-1 bar
Specification options for the pressure or vacuum

Operating pressure Vacuum Absolute pressure
[bar] [%] [bar]
6 7
5 6
4 5
3 4
2 3
1 2
0 0 1
0.1 10 0.9
0.2 20 0.8
0.3 30 0.7
0.4 40 0.6
0.5 50 0.5
0.6 60 0.4
0.7 70 0.3
0.8 80 0.2
0.85 85 0.15
0.9 90 0.1
0.95 95 0.05
1 100 0

Introduction
Units of measurement
As already described in the section It should be mentioned here that the Vacuum specifications that use bar as For the sake of simplicity, vacuum is
Designations and specification current official unit of measurement the unit of measurement are always generally expressed as a percentage
options, there are two ways of for the vacuum is the pascal (Pa). considered as relative values in the range 0 to 100%.
representing a vacuum: However, this is rarely used in (described under Vacuum as a This is always a relative value.
practice. In reality, the preferred units relative value). The conversion tables (international
As a pressure unit of measurement are bar, mbar or %, The most commonly used pressure vacuum/pressure conversion tables)
(relative or absolute) particularly in the rough vacuum units bear the following ratios to one below are a useful aid for expressing
As a percentage range (e.g. handling technology). another: these values relative to the other units
In the following pages also, only the of measurement.
There are a large number of national units of measurement bar and % are 100 Pa = 1 hPa
and international units of used. 1 hPa = 1 mbar
measurement in common use that can 1 mbar = 0.001 bar
be used to specify a vacuum as a
pressure unit.
These units of measurement are listed
in the conversion table (international
vacuum/pressure conversion table)
below.
International vacuum/pressure conversion table

Unit bar N/cm2 kPa atm, kp/cm2 m H2O torr, mm Hg in Hg psi
bar 1 10 100 1.0197 1.0197 750.06 29.54 14.5
N/cm2 0.1 1 10 0.1019 0.1019 75.006 2.954 1.45
kPa 0.01 0.1 1 0.0102 0.0102 7.5006 0.2954 0.145
atm, kp/cm2 0.9807 9.807 98.07 1 1 735.56 28.97 14.22
m H2O 0.9807 9.807 98.07 1 1 735.56 28.97 14.22
torr, mm Hg 0.00133 0.01333 0.1333 0.00136 0.00136 1 0.0394 0.0193
in Hg 0.0338 0.3385 3.885 0.03446 0.03446 25.35 1 0.49
psi 0.0689 0.6896 6.896 0.0703 0.0703 51.68 2.035 1
International vacuum/pressure conversion table with absolute and relative value comparison
Relative vacuum Residual Pressure, N/cm2 kPa atm, kp/cm2 m H2O torr, mm Hg in Hg
pressure, relative
absolute
[%] [bar] [bar]
10 0.9 0.101 1.01 10.1 0.103 0.103 76 3
20 0.8 0.203 2.03 20.3 0.207 0.207 152 6
30 0.7 0.304 3.04 30.4 0.31 0.31 228 9
40 0.6 0.405 4.05 40.5 0.413 0.413 304 12
50 0.5 0.507 5.07 50.7 0.517 0.517 380 15
60 0.4 0.608 6.08 60.8 0.62 0.62 456 18
70 0.3 0.709 7.09 70.9 0.723 0.723 532 21
80 0.2 0.811 8.11 81.1 0.827 0.827 608 24
90 0.1 0.912 9.12 91.2 0.93 0.93 684 27

Introduction
Atmospheric air pressure

Definition
Our planet which includes us as On average, the air pressure at sea If, starting at sea level, we now begin To make things simpler, the air
well as everything on the earths level is 1,013.25 mbar. If we imagine to climb higher, this imaginary air temperature and mass are considered
surface is surrounded by a layer of an air column with a cross-section column becomes shorter and the air as constants when deriving the
air several kilometres thick. This layer area of 1 m2, which extends from the mass is reduced. Because the air formula.
of air is known as the earths earths surface (sea level) to the pressure falls as the air mass In the derivation of the formula, the
atmosphere or, more simply, the outermost edge of the atmosphere, decreases, we can conclude that density of the layer of air () as well as
atmosphere. Gravity causes the the air exerts pressure on this 1 m2 of atmospheric air pressure falls as the pressure at the earths surface
weight of this mass of air to exert the earths surface with a mass altitude increases. This is why we say (p(h=0)) are based on assumptions
pressure on the earths surface. of 10,000 kg approx. that the air is getting thinner. from empirical values.
The pressure generated is known as These courses of action and
atmospheric pressure or air pressure. Air pressure dependent on altitude simplification of the formula
Our atmospheric conditions can also
-H- Note
can be calculated using the derivation are an idealisation.

be compared with conditions under Boltzmann barometric equation. This
NASA describes an altitude of gh
water. We live at the bottom of a sea calculation is affected by a wide p(h) = p (h=0) exp p (h=0)
of air. approx. 120 km above the earths variety of factors.
The gravitational force of the air above surface as the outermost edge of the p(h) = Air pressure dependent
us generates pressure which we call atmosphere. Air molecules can, In order to achieve accurate results, it on altitude
air pressure. however, be found at much greater is important to consider not only the p(h = 0) = Pressure at the earths
At present, the official unit of altitudes. It is therefore impossible output altitude, but also factors such surface (1.013 bar)
measurement for air pressure is hPa. to definitively identify the edge of as local gravitational force, = Density of the layer of air
This abbreviation stands for the atmosphere. atmospheric density and (1.29 kg/m3)
hectopascal (1 hPa = 1 mbar). temperature. h = Altitude
g = Acceleration due to
gravity
Generally applicable statements
At sea level, atmospheric pressure At the summit of Mount Everest h [km] 1 Mount Everest
is approx. 1,013 mbar. (8,848 m), atmospheric pressure is 2 Festo
By 2,000 m above sea level, the only 330 mbar. 3 Sea level
pressure has fallen by approx. 1% At an altitude of 16,000 m the
per 100 m to 763 mbar. pressure is 90 mbar, while it is
At approx. 5,500 m, the pressure is 15 mbar at 30,000 m and approx.
only 50% of the value at sea level. 8 mbar at 50,000 m.
p [hPa]

Introduction
Effect of changes in air pressure on vacuum technology

The pressure drop that occurs with As described earlier, air pressure at 0.4026 bar (402.6 mbar). PB
sea level (0 m) is approx. 1,013 mbar. Assuming that we take the same [bar]
increasing altitude does, of course,
At sea level, a vacuum generator with vacuum generator and go higher than 1,013 mbar
have an effect on vacuum technology
PA
or even on the vacuum generators a performance level of 80% vacuum the previous 2,000 m above sea level
themselves. achieves absolute pressure of in order to generate or use a vacuum,
763 mbar
Because the air pressure in the approx. 0.2 bar (200 mbar). the maximum attainable vacuum level
atmosphere falls with increasing This air pressure falls with increasing would continue to fall while the
altitude. Up to a height of 2,000 m, performance level would remain
altitude, the maximum attainable
there is a linear drop in pressure by unchanged at 80% because the
differential pressure and, [p]
approx. 12.5 mbar per 100 m to ambient pressure in the atmosphere
consequently, the maximum
763 mbar. continues to drop.
attainable holding force of a vacuum
However, although the same vacuum At a height of approx. 5,500 m above
suction gripper are also reduced. In
generator still has the same sea level, the air pressure is only
other words, the attainable vacuum performance level of 80% vacuum, approx. 50% of the pressure value at
level of a vacuum ejector reduces with 0m 2,000 mm
this figure of 80% refers to the sea level (506 mbar). (sea level) (height above
increasing altitude. Nevertheless, the ambient pressure that has fallen to The possible holding force of a sea level)
performance level of 80% vacuum, for 763 mbar because of the increase in vacuum suction gripper falls p = Performance of vacuum
example, remains unchanged altitude. This vacuum generator can proportionally with the attainable generator X = 80%
( Figure on right). therefore only achieve a maximum vacuum value.
absolute pressure of approx.
Valid standards and guidelines

In accordance with Festo standard FN Scaling factor: measurement results. Example:
942 011, the standards and When measuring characteristics (air The measurement results are therefore A current air pressure
guidelines have been defined for the consumption, pressure, evacuation related to the reference pressure. They pamb = 975 mbar produces a scaling
vacuum range. time and suction capacity), are converted using a scaling factor S = 1.039. The required
fluctuations in the ambient pressure factor (S), which is calculated on the vacuum is therefore produced at a
Vacuum: must be taken into account. Given that basis of the following equation. measured value of 750 bar
All vacuum generators based on this all pressure values measured in the (0.75 mbar) absolute to P = 780 bar
standard that are covered in this research laboratory are relative p (0.78 mbar).
S = p ref
system description operate exclusively pressure values referring to the amb
in the rough vacuum range. In current ambient pressure, the
accordance with the Festo guideline, fluctuations in ambient pressure (pref = 1,013 mbar)
the average air pressure at sea result in a degree of dispersion in the
level (1,013.25 mbar) must always be
taken as the reference value when
specifying and calculating pressure
values.
DIN standards, research reports and Festo guidelines

DIN 1 314 DIN 28 401 FB 190 FR 970 003
Pressure, basic definitions and units Graphical symbols (summary) Vacuum Guideline Basic Principles Fluid Units and Variables
(Research Report, Festo Research,
DIN 28 400 DIN 28 402 Dr. Berger) FR 970 004
Vacuum technology Quantities, symbols and units Flow Rate Measurement
Part 1 General terms (summary)
Part 2 Vacuum pumps
Part 3 Vacuum gauges
Part 8 Vacuum systems, components

Introduction
Vacuum generator
Introduction
Generating a vacuum in a closed 1. The gas is evacuated from the The range of vacuum generators is A direct comparison of these vacuum
space means dropping the air or gas closed space into an external very extensive. All work according to generators would not be objective
pressure. To do this, the gas particles space or into the atmosphere. different technical principles and enough, as they differ fundamentally
must either be removed or reduced in 2. The gas is combined within the methods and are often categorised from one another in terms of their
quantity. vacuum system, i.e. condensed, under the umbrella term vacuum technical construction, their mode of
There are basically two ways of doing absorbed or chemically pumps. operation, their ranges of application
this: combined. We need to categorise the vacuum and their efficiency.
generators into three types here and In this section we will describe the
classify them according to their mode various types of vacuum generator
of operation: referred to here based on their
Vacuum ejectors, functionality and focus on their
Gas-absorbing vacuum pumps, technical features and benefits.
Gas-feeding vacuum pumps.
Vacuum ejector High vacuum, relatively low flow rate

General
Compared with the often highly Vacuum ejectors basically function or low pressure with a relatively low they have in common is the fact that
complex and unwieldy mechanical according to the venturi nozzle flow rate. the venturi principle is applied
designs used to generate a vacuum, principle, i.e. the vacuum is generated They operate according to two different wherever the vacuum is generated.
the operating principle of ejectors is using pneumatically driven nozzles design principles using very different,
extremely simple. Yet despite its without moving parts. often complex equipment such
simplicity, this principle offers Vacuum ejectors are characterised by as valves, filters, silencers, switches,
enormous potential as an extremely their ability to generate a high vacuum etc. However, the crucial element that
practical solution.
Function principle
A classic ejector consists of a jet nozzle) accelerates the air to up to compressed air from the jet nozzle Single-stage ejector
nozzle (venturi nozzle) and, 5 times the speed of sound as it flows creates a suction effect at the gap to
depending on the design principle, at through the jet nozzle. the receiver nozzle, which in turn Venturi nozzle
least one receiver nozzle. There is a short gap between the exit creates a vacuum at the output (jet nozzle)
Compressed air enters the ejector. The from the jet nozzle and the entry in the (vacuum port).
narrowing of the jet nozzle (venturi receiver nozzle. The expanded Receiver nozzle
Vacuum port

Introduction
Vacuum ejector High vacuum, relatively low flow rate

Design principles
Single-stage ejector: Multi-stage ejector: falling air pressure. The drawn-in air Again, the air is generally discharged
The design principle for a single-stage This design principle also includes a from the first chamber, combined with via a silencer at the end of the last
ejector includes a jet nozzle and only jet nozzle. Behind the first receiver the compressed air from the jet receiver nozzle.
one receiver nozzle. After exiting the nozzle there are additional nozzle nozzle, is thus used as a propulsion
receiver nozzle, the exhaust air is stages, each of which has a bigger jet for the other chambers.
generally discharged via a silencer or nozzle diameter in proportion to the
directly into the atmosphere.
Features
Completely maintenance-free and No heat build-up Small line lengths between vacuum Multiple functions possible in a
wear-resistant because there are no Compact design, smallest possible generation and application single device
moving parts dimensions Easy to install, can assume any Dry and filtered compressed air is
Low initial costs Suitable for pulsed applications mounting position useful
Low energy costs, as the ejector is Fast reacting Low weight Supply port 4 6 bar optimal
only switched on when in use
Applications
Part feeding systems in the Industrial robot applications in all Process engineering Transport of liquids and bulk
automotive industry sectors material
Packaging industry

Introduction
Displacement/kinetic vacuum pumps

General
Another component for generating a In order to come up with a useful Vacuum pumps
vacuum is the vacuum pump. classification of the pump designs
and operating principles used in
vacuum technology, it is best to Gas-absorbing Gas-feeding
subdivide them according to their Vacuum pumps Vacuum pumps
method of operation.
Displacement Kinetic
Vacuum pumps Vacuum pumps
Gas-absorbing vacuum pumps

Function principle
As their name suggests, gas-absorbing them into a liquid, solid or sorptive closed space is reduced and a vacuum
vacuum pumps do not discharge the state within the vacuum system. In is created.
gas particles, but instead convert this way, the volume of gas (air) in the
Gas-feeding displacement vacuum pumps High vacuum, low flow rate

Function principle
In displacement vacuum pumps, the The figure on the right is a simplified 1 1 Pressure side
gas (air) freely enters an expanding illustration of how the principle of a 4 2 Suction side
space, and is then mechanically shut displacement vacuum pump works. 3 Inlet valve
off, compressed and ejected. The main Although there is a wide range of 4 Exhaust valve
feature of vacuum pumps of this type solutions with varying designs, the 5 Piston
is the fact that they can achieve a very operating principle of all pumps is the
3
high vacuum with very low flow rates. same. 5
2
Features
High vacuum level of up to 98% Minimal maintenance expenses Generally restricted mounting Larger dimensions
attainable positions
Applications
Packing machines Manual vacuum handling Clamping devices Research

Introduction
Gas-feeding kinetic vacuum pumps Low vacuum, high flow rate

Function principle
With kinetic vacuum pumps, the gas Vacuum blowers are categorised as Vacuum compressors are another type
particles (air) are forced to flow in the kinetic vacuum pumps. of kinetic vacuum pump with similar
delivery direction through the These vacuum generators operate features.
application of additional force during according to the impulse principle, The drawn-in air is compressed in the
1
evacuation. i.e. during the transfer of kinetic vaned chambers of an impeller in
3
The main feature of these vacuum energy to the air by a rotating multiple stages with low pulsation by
pumps is that only a relatively low impeller 1, the air is drawn in and means of centrifugal force. As with the
vacuum can be generated. However, compressed 4 on the suction blower, high suction rates can be
they do achieve very high flow rates side 2 by the blades 3 on the achieved here with limited vacuum
2 4
(high suction capacity) at the same impeller. performance.
time.
Features
Vacuum blowers and compressors Large volumes extracted in a very High maintenance costs Only low vacuum performance
short time possible
Applications
Vacuum blowers Handling of extremely porous Where large suction rates per unit
materials such as clamping plates of time are important
or cardboard boxes, etc.
Compressors For precision industrial

applications

Introduction
Practical use of vacuum

Handling is a subfunction of material technology are feed technology assembly processes today. Vacuum technology has proven to be
flow and is subdivided into the areas components and systems, pick-and- Vacuum technology is now an extremely effective in the handling of a
of storing, changing quantities, place devices, manipulators and important part of this handling wide variety of materials and parts
moving, securing and checking. robots. technology and has become and has thus opened up entirely new
Handling requires the availability of The way in which parts are handled indispensable in many of the areas of application and solutions for
specific geometric bodies (component has a major influence on productivity industries and fields of application in handling technology.
parts or assemblies). Among the in automated production and which it is used.
equipment used in handling
Handling tasks
The following keywords and symbols Lifting Conveyance All of these tasks combined cover an Industrial fields of application of
illustrate the significance of vacuum Loading Turning almost unlimited range of vacuum technology include,
technology in handling technology as applications in industry. for example:
Gripping
well as the various tasks that it is Special machine construction
used to perform. Machining Packaging industry
Food industry
Holding
Woodworking industry
Insertion Metalworking industry
Automotive industry
Moving
Electrical engineering industry
Feeding Repositioning
Transporting
General
Vacuum technology generally tends to Nevertheless, there are also a great
come under the umbrella term of many applications where this
gripper technology. technology is being pushed to its
limits.
In handling technology, a large
number of applications use This is where vacuum technology
mechanical gripper technology to frequently comes into play and,
great effect. indeed, is creating entirely new
concepts and possibilities.
Advantages
Vacuum in handling technology Simple component and system Low weight, i.e. suitable for Low-cost
means: design extremely dynamic movement Low maintenance costs
Gentle handling of fragile parts Compact, space-saving design Fast cycle times possible Can be adapted to suit many
requirements
Important factors to consider

The decision to use vacuum Weight of the workpiece Having such a wide range of vacuum Festo provides a software tool which
technology or another handling Temperature of the workpiece or its component variants makes it easy to helps you select or find the right
technology depends on a number of surface find the right components for just vacuum components for your specific
different factors. Some of the most Speed per unit of time for cycle about any application, taking into applications.
important factors to consider are completion account the above factors, with
described here. Shape of the workpiece surface product features such as heat
Roughness of the workpiece surface resistance, speed, suction capacity
Stroke travel and conveying etc.
distances for handling

Introduction
Single-stage and multi-stage ejectors

General
Nowadays, wherever vacuum There are, of course, still a great many arguments in favour of ejectors are As already explained in the section
technology is used, you will also find special applications in which the their low initial costs, low Components for vacuum generation
increased use of vacuum ejectors. vacuum pump is as indispensable as maintenance costs and greater 2, there are two different design
ever. Nevertheless, many applications flexibility in terms of application principles for vacuum ejectors. How-
in handling technology favour the use compared with other vacuum ever, the venturi operating principle
of ejectors. The most convincing generators. applies to both types.
Function principle
As described earlier, all ejectors work All ejectors based on this principle depending on the design principle, at
according to the venturi operating have a jet nozzle (laval nozzle) and, least one receiver nozzle.
principle.
Design principle
Single-stage ejector: Single-stage ejector: Multi-stage ejector Multi-stage ejector
This ejector principle includes a jet Like the single-stage ejector, this
nozzle (laval nozzle) and one receiver design principle also includes a jet 1
nozzle. nozzle (laval nozzle), in which the
1 3
The extraction of ambient air and the compressed air flowing in is
generation of a vacuum therefore take accelerated to up to five times the
place within a chamber and the gap speed of sound, followed by a receiver 2
between the jet nozzle and receiver 2 nozzle.
nozzle. 1 Supply port/jet nozzle Behind the first receiver nozzle there
The compressed air or drawn-in 2 Vacuum/suction cup connection are additional nozzle stages, each of
ambient air is generally discharged 3 Exhaust air/receiver nozzle which has a bigger nozzle diameter in 3
into the atmosphere (environment) via proportion to the falling air pressure.
a silencer connected directly after the The drawn-in air from the first
receiver nozzle. chamber, combined with the
compressed air from the jet nozzle, is
thus used as a propulsion jet for the 1 Supply port/jet nozzle
other chambers. 2 Vacuum/suction cup connection
After exiting the last receiver nozzle, 3 Exhaust air/receiver nozzle
the exhaust air is generally
discharged into the atmosphere
(environment) via a silencer.

Introduction

Basic information
A direct comparison of the design Manufacturers of vacuum ejectors Viewed objectively, handling vacuum generator can be measured or
principles of single-stage and multi- tend to favour one of the two design technology using a vacuum comes evaluated.
stage ejectors frequently gives rise to principles, thus making it difficult to down to a few important variables,
discussions regarding the advantages get an objective opinion. with which the performance of a
and disadvantages of both principles.
Efficiency as a function of vacuum pu

Evacuation time = Time (s) required These variables evacuation time, air (pu) = 1
t(pu)Q
to generate a specific vacuum. consumption and the volume depend- 1 + V60smin
ent on the vacuum produce a
Air consumption = Air consumption formula, which can be used to (pu) = Efficiency of the vacuum
(l/min) of the ejector required to calculate the efficiency of a vacuum generator in relation to

generate a specific vacuum. generator. This is the most objective low pressure
criterion that can be used to assess t(pu) = Evacuation time [s]
the performance of different vacuum Q = Air consumption [l/min]
generator types. V = Volume to be evacuated
(standard volume) [l]
pu [bar]
In practice, the job of a vacuum

generator is to generate a specific
vacuum in the shortest time possible,
using as little air (energy) as possible.
Misapprehension
Suction flow rate = Suction air In practice, the performance of an sure and the result is then used as the Performance comparisons of vacuum
volume (l/min) that an ejector can ejector is often and incorrectly ejector rating. In fact, the suction flow ejectors based on the suction flow rate
draw in. measured on the basis of the suction rate falls progressively with an in- therefore have only a limited level of
flow rate. The misapprehension lies in creasing vacuum, i.e. a high suction accuracy. Apart from this, the suction
the fact that the suction flow rate is flow rate does not necessarily result in flow rates of the specimens are
often measured at atmospheric pres- a short evacuation time. compared at the same vacuum level.

Introduction

Comparison
The aim of this comparison of single- Evacuation time Variables such as noise level, air A comparison of single-stage and
stage and multi-stage ejectors is to Air consumption supply time or attainable vacuum also multi-stage ejectors in practice
evaluate variables or criteria that Efficiency play an important role. produces the following general
occur in practice and that can be used observations, which should be borne
to measure the performance of the in mind before proceeding any further.
ejectors.
General findings
Variables/criteria Single-stage Multi-stage
Suction flow rate Average High
At low vacuum level up to approx. 50%
Evacuation time Very short1) Very short1)
In the higher vacuum range from 30 50% In lower vacuum range up to 30 50%
Initial costs Low Relatively high
Noise generation Relatively high Low
1) see diagram below
Evacuation time
In general, the multi-stage ejector Looking at the chart illustrating this Operating pressure p as a function of the evacuation time t
can, up to a pressure range of approx. comparison, it is obvious that single-
30 50% vacuum, generate this stage ejectors have a clear advantage
pressure faster or evacuate the over multi-stage ejectors in this case.
volume faster than the single-stage The higher the vacuum level, the more
ejector. time the multi-stage ejector takes to
p [bar]
However, a pressure of generate it.

0.4 0.8 bar or a vacuum of
between 40 and 80% is normally
required in practice.
1 Multi-stage ejector
2 Single-stage ejector
t [s]
Air consumption
Multi-stage ejectors have, on average, clear advantage over single-stage the advantage is not so clear-cut. considerably reduces the energy-
a much lower level of air consumption ejectors . Although multi-stage ejectors have a saving benefits.
and thus consume less energy than However, if we look at this information lower level of air consumption, their
single-stage ejectors, giving them a in context with the evacuation time, evacuation time is higher. This
Suction flow rate

Single-stage ejectors have a lower draw in higher volumes over the same this progressive curve falls off rapidly rate fall below the values achieved
suction flow rate than ejectors based amount of time. for multi-stage ejectors (see chart). In with single-stage ejectors.
on the multi-stage principle. Multi- However, as the vacuum level other words, as pressure increases,
stage ejectors in the low vacuum increases (from approx. 30 50%), the initial gains of a higher suction
range of approx. 30 50% can thus

Introduction

Noise level, vacuum level and air supply time
In comparison, single-stage ejectors atmosphere in weakened form in however, counteracted with suitable There are very few differences in air
have a relatively high level of noise the case of multi-stage ejectors, the silencers. supply time, although a single-stage
generation. Because the compressed noise level is, accordingly, lower than Both design principles reach the same ejector has a smaller volume to supply
air is slowed down by the series of with single-stage ejectors. The noise vacuum level, although single-stage with air, which gives them a minimal
nozzle stages before it reaches the levels in single-stage ejectors are, ejectors do so in a shorter time. time advantage.
Summary
The cause of the somewhat poorer considerably less efficient than a another, are changed. This example illustrates how all of
evacuation time of the multi-stage single-stage ejector. It is important, Although increasing the laval nozzle these variables are dependent on
ejector lies in the fact that although however, to remember that these diameter while maintaining a constant each other. If one variable changes,
the second and subsequent nozzle findings must be viewed as generali- operating pressure increases the this affects the other variables as well.
stages generate a high suction sations and should therefore be used suction rate, it also extends the
capacity, these are decoupled at a for reference purposes only. Irrespec- evacuation time and, in extreme
Laval Evacuation
relatively low vacuum level. This tive of the design principle, different cases, the desired vacuum cannot be
nozzle time
means that when the pressure is results are obtained when the initial reached without increasing the
higher, only the first nozzle stage values, which interact with one operating pressure.
Vacuum Operating
draws in air. This first nozzle stage is
level pressure
Conclusion
The comparison shows just how exist on this basis. possess attributes that defy any more manageable than the multi-
difficult it is to reach an objective It is also easy to see how minor generalisation. In conclusion, it can stage principle.
conclusion about the pros and cons of technical adjustments affect the be said that the single-stage ejector The multi-stage ejector, on the other
both operating principles. ejectors and how both operating achieves its best results in applica- hand, achieves its best results
And thats to say nothing of deciding principles can be optimised to suit the tions with average or higher pressure wherever a relatively low vacuum (up
on a preferred operating principle or a relevant application (e.g. by varying (vacuum). The simple design makes to approx. 0.3 bar) needs to be
test winner. Basically, the benefits the laval or receiver nozzle diameter). this operating principle more cost- generated quickly and wherever
of both principles lie in very specific Both operating principles can thus effective and, in terms of dimensions, energy costs play an important role.
areas and they justify their right to achieve degrees of efficiency or

Introduction
Energy cost comparison between vacuum ejectors and vacuum pumps (electric)
Given that energy is a scarce, valuable cannot be overlooked. You should compressed air from atmospheric air, range (10 20 bar), the costs for
and, above all, expensive resource, therefore remember one golden rule at taking into account all costs such as compressed air increase by
energy costs play an important role in all times: air is expensive. material, depreciation, labour costs, approx. 100%.
choosing a suitable vacuum system. etc., with electricity tariffs (industry) of
The air consumption of a vacuum With electrically driven vacuum 0.10/kWh, you must reckon on costs Before proceeding any further, it is
system might not initially seem to be a pumps, on the other hand, energy of approx. 0.02 per 1 m3 volume at important that we mention some of
particularly important consideration. costs can be measured and assessed 7 bar (normal supply pressure). These the criteria that should be considered
However, the amount of energy that is much more easily on the basis of costs apply in the low pressure range when making a comparison of vacuum
necessary to operate a pneumatic current consumption. up to 10 bar. In the high pressure ejectors and vacuum pumps.
vacuum ejector with compressed air The fact is that in order to generate
Vacuum ejector
For
Energy consumed only as required. Circuit diagram 1 Energy-saving function: Circuit diagram 2
Compressed air or energy is only Many ejectors (compact ejectors)
consumed during the suction have this function. Compressed air
operation and during workpiece is only consumed during generation
handling in an operation cycle. of the vacuum. Once the vacuum
The vacuum generator remains level has been reached, the ejector
switched off for the rest of the time is switched off. The vacuum is
(discharge, return). Ejectors have maintained and monitored using
fast response times (start and stop valves and switches
times) and can therefore be ( circuit diagram 2).
switched off when no vacuum is 1= Compressed air connection Energy-saving function = 1= Compressed air connection
required ( circuit diagram 1). 2= Suction cup connection 4 2/2-way valve + 2= Suction cup connection
Vacuum ejectors require absolutely 3= Exhaust port 5 Switch + 3= Exhaust port
no servicing apart from the prefilter 4 2/2-way valve 6Non-return valve 4 2/2-way valve
and have no moving parts. 6 Non-return valve Their low weight/mass ratio and 5 Switch
their small unit volume, not to 6 Non-return valve
mention the fact that they can be
installed in any mounting position,
are also worth noting.
A relatively high vacuum of up to
85% can be attained.
Against
With Festo ejectors, the suction rate Higher compressed air consumption
is relatively limited at per m3 vacuum increases energy
approx. 16 m3/hour. costs dramatically. However, this is
compensated by the air/energy-
saving functions.

Introduction
Vacuum pump
For
With some designs a very high High suction rates of up
vacuum level (up to 104 mbar to 1,200 m3/hr. possible.
= 99.99999%) can be attained.
Against
Electro-mechanical vacuum pumps High initial costs and ongoing Large weight/mass ratio and large
are almost always in continuous maintenance costs. unit volume as well as fixed
operation, the vacuum require- mounting positions.
ments are regulated by means of
valves. This means that current
consumption and, consequently,
energy costs are very high.
Energy cost comparison/sample calculation

In this example, we are comparing a The electricity price is based on The costs for compressed air refer Additional assumed numerical
vacuum ejector (pneumatic), both industry tariffs ( 0.10/kWh). to, as mentioned earlier, a 1 m3 values such as time specifications,
with and without an air-saving volume with 7 bar pressure. All for example, may apply depending
function, with a vacuum pump costs such as material, depreci- on the application.
(electrical) of similar performance. ation, labour costs, etc. are taken
Using a calculation example, we want into account in the calculation
to create a cost or energy cost ( 0.02/m3).
comparison over a period of one year.
Electricity price Compressed air costs System capacity Remarks

[/kWh] [] [kW]
0.05 0.02 approx. 1,100 Large system
0.10 0.02 approx. 1,100 Large system
0.10 0.03 approx. 20 Small system

Introduction
Calculation base
Ejector operation cycle
Ejector with air-saving function: The figure on the right shows an tE tE = Evacuation time
Air consumed (energy consumption) operation cycle for a vacuum system. 1 t1 = Transport
only while the workpiece is being The individual work steps of the t1 ta = Discharge
received (picked up) (= 0.5 s). system are subdivided into time ta t2 = Return
Ejector without air-saving function: sectors. The amount of time allocated 1 = Pick-up
pu [bar]
Air consumed (energy consumption) to the work steps depends on the 2 = Time saved
for reception (pick-up) and vacuum generator. t2
transport of the workpiece (= 2 s).
Vacuum pump: t [s]
2
Energy consumed for the entire
operation cycle, as the pump is not
normally switched off (= 5 s).
Variables/criteria Assumed numerical values

Initial costs for vacuum pump [] 715
Initial costs for ejector [] 337
Maintenance costs/year for vacuum pump [] 306
No. of operating days/year 250
No. of operating hours/day 16
Time per operation cycle [s] 5.0
Time for pump ON [s] 5.0
Time for ejector ON1) [s] 2.0
Time for ejector ON2) [s] 0.5
Price per kWh (industry tariff) [] 0.10
Price per m3 for compressed air at 7 bar [] 0.02
Supply pressure for ejector [bar] 6
Energy used to generate compressed air (1m3 at p = 7 bar) [kWh/m3] 0.095
1) Without air-saving function

2) With air-saving function
General calculations
When comparing the energy costs for
both vacuum generators, the following
calculations must first be performed:
Number of products per year Proportion of pump operation to Proportion of ejector operation Proportion of ejector operation with
(hours) operation cycle (%) without air-saving function to air-saving function to operation
Formula: Formula: operation cycle (%) cycle (%)
Total running time (s)/Time per Time for pump ON (s)/ Formula: Formula:
operation cycle (s) Time per operation cycle (s) x 100 Time for ejector ON1) (s)/Time per Time for ejector ON2)(s)/Time per
= 250 x 16 x 3,600/5 s = 5/5 x 100 operation cycle (s) x 100 operation cycle (s) x 100
= 2,880,000 hours = 100% = 2/5 x 100 = 0.5/5 x 100
= 40% = 4%


Introduction
Vacuum ejector calculation

The calculations for the vacuum (air consumption at P = 6 bar:
ejector with and without the air- 505 l/min)
saving function give us the following
partial results:
Running time per year Air consumption per year Energy costs per year
Formula: Formula: Formula:
No. of products (units) x Time for Running time per year (min)/ Air consumption (m3)
ejector per unit (s) Air consumption (l/min) x Price per m3 for compressed
2,880,000 unit x 2 s 96,000 min/505 l/min air ()
1) = 5,760,000 s (96,000 min) 1) = 48,480 m3 48,480 (12,120) m3 x 0.02
2) = 1,440,000 s (24,000 min) 2) = 12,120 m3 1) = 969.60
2) = 242.40

Air consumption at P = 6 bar [l/min] 505
Total air consumption per year at P = 6 bar1) [m3] 48,480
Total air consumption per year at P = 6 bar2) [m3] 12,120
Air saving per year2) [m3] 36,360
Air saving per year2) [%] 75
Energy costs per year1) [] 969.60
Energy costs per year2) [] 242.40
Energy saving per year2) [] 727.20

Electric vacuum pumps calculation

The calculations for the vacuum pump
give us the following partial results:
Running time per year Energy consumption per year Energy costs per year
Formula: Formula: Formula:
Operating hours per day Running time per year x Energy Energy consumption per year
x Operating days per year consumption per hour x Costs per kWh
16 hours x 250 4,000 hours x 0.55 kW 2,200 kWh x 0.10
= 4,000 hours = 2,200 kWh = 220

Energy consumption/operating hour [kWh] 0.55
Energy consumption/year [kWh] 2,200
Energy costs/year [] 220

Introduction
Cost comparison of the vacuum ejector and vacuum pump

The costs of the vacuum system are Investment costs Investment costs are one-off costs,
made up of three cost types: Maintenance costs while maintenance and energy costs
Energy costs are incurred annually.
Result
A direct cost comparison shows that The ejector without the air-saving and investment costs into account,
the vacuum pump has the lowest function has considerably higher this reduces the advantage that the
energy costs, closely followed by the energy costs than the other vacuum vacuum pump has over the other
ejector with the air-saving function. systems. If we also take maintenance systems due to its low energy costs.
Cost type Vacuum pump Ejector Ejector

without air-saving function with air-saving function
Investment [] 715 337 337
Maintenance1) [] 306
Energy1) [] 220 969.60 242.40
1) annual costs for a vacuum pump after approx. 4,000 to 6,000 hours
Conclusion
The calculation example shows that maintenance costs associated with their simple design keeps initial costs dominated by the vacuum pump and
ejectors more than justify their their continuous use and wearing and maintenance costs to a minimum. where ejectors are not used. This is
existence. parts confirm this conclusion. There are, of course, a great many not the case, however, with handling
The high investment costs for vacuum While ejectors may use more energy, areas of application that are technology.
pumps as well as the annual

Introduction
Leakage in vacuum systems

Ideally, when using vacuum When a vacuum is generated, the Unfortunately, these ideal surface In these applications, the vacuum
applications in handling technology, sealing rim of the suction cup can conditions do not always exist on the suction grippers cannot completely
the workpiece surfaces on which the fully seal the system against external workpieces to be moved. The seal the system against atmospheric
suction cups have to rest should be atmospheric air. We therefore materials are often air-permeable air. If atmospheric air constantly
smooth and impervious. A suction cup describe this as a leak-proof system. (e.g. sheets of paper) or very rough enters the system during vacuum
fits tightly against this type of surface. The holding force of the suction and uneven. generation, we describe this as a
gripper on the workpiece increases as leaking system.
the vacuum level in the system
increases compared with the external
atmospheric pressure.
Leak-proof systems
In vacuum technology, the When a specific volume is being Evacuation time tE as a function of vacuum pu
performance of the vacuum generator evacuated, the course of the time/
for the handling of leak-proof material pressure curve travels upward
depends, among other things, on how proportionally, i.e. the higher the
quickly the system can generate a vacuum level, the stronger the fall in
specific vacuum. This rating is known the suction capacity of a vacuum
tE [s]
as the evacuation time of the vacuum generator and the longer it takes to
generator. attain an even higher vacuum level.
pu [bar]
Leaking systems
The requirements for handling porous continuously evacuating the air conditions (leak-proof system). performance level. To determine the
materials (leaking systems) are (leakage air) entering the system. However, in this case the leakage air leakage air volume, it is recommended
different. In order to attain or maintain The maximum attainable vacuum that entering the system prevents the that you carry out a test
the desired vacuum level, the vacuum a vacuum generator can produce is vacuum generator from reaching or ( 27, Selecting vacuum generators
generator must be capable of normally measured under ideal being able to attain its maximum according to leakage flow).
Remedy
In general, there are two options for Option 1: Option 2: To select the correct vacuum
optimising or increasing the vacuum Using a high-performance vacuum Reducing the suction cup diameter or generators for handling leakage flow,
level in leaking systems. generator. orifices. you need to perform a test setup as
Advantage: Advantage: outlined above. With the aid of charts,
Actual
Power transmitted as required Leakage is reduced (energy costs)

Target
Target
you can then select the right vacuum

Simple solution Disadvantage: generator.
Disadvantage: Power transmission may be below This selection aid is described in
Actual
Leakage remains high the required vacuum level. detail on page 27.
High energy costs

Introduction
Selecting vacuum generators according to leakage flow

A reliable method is needed to e.g. the selection of vacuum
determine the exact leak rate in generators with larger dimensions, be
vacuum systems or applications. Only taken and the functional reliability of
then can optimal remedial action, the vacuum system guaranteed.
Graphical representation as a tool

Graphical representation Suction capacity qn as a function of vacuum pu All curves in the chart have an almost
of the suction capacity in relation to linear downward course. The
vacuum/operating pressure in a maximum suction capacity of the
chart (all ejectors in a single chart). individual vacuum ejectors is reached
at atmospheric air pressure
(0% vacuum).
qn [l/min]
The higher the vacuum level, the lower

the suction capacity of a vacuum
generator, up to a maximum limit.
This chart is very useful for finding out
1 VAD-y quickly and reliably whether a
2 VAD- vacuum generator is needed to
3 VAD-x achieve the desired vacuum level with
4 VAD-M5 leaking materials.
pu [%]
Test setup
Perform a test setup The operating pressure (vacuum) of
with an ejector as the vacuum the system is now measured at a
generator, a vacuum gauge constant supply pressure. The
(pressure gauge) as the measuring performance of an ejector under
instrument as well as a suction 1 Supply port normal operating conditions, i.e.
gripper and workpiece as the 2 Suction cup connection without leakage, can be determined
leakage source. The test setup is 3 Exhaust port from its technical data as well as from
illustrated in the following figure. the Suction capacity as a function of
vacuum/operating pressure chart.
The measurement results from the test
setup are then compared with the
known data.

Introduction

Procedure
Where systems are clearly leaking The following procedure is with the relevant application and can
(e.g. because of porous or rough recommended for finding a suitable generate the required vacuum level:
workpieces), the leak rate must be vacuum generator that is compatible
determined.
Determining the leak rate

Perform the test setup In a test setup like the one illustrated In a leak-proof system, the value The leak rate can then be determined
Read the vacuum or operating earlier, a workpiece is picked up using indicated on the vacuum gauge must on the basis of the measured vacuum
pressure achieved a defined suction gripper size, a correspond to the value contained in value in conjunction with the chart
Compare the result with the course vacuum generator and pressure the technical data for the vacuum (Suction capacity as a function of
of the curve in the chart supply (5.5 6 bar). generator. vacuum/operating pressure).
Suction capacity difference = leak In a leaking system, the vacuum
rate attained is read from the vacuum
gauge.
Example
In a test setup using the ejector 2 residual airflow can be read from the Result:
VAD-, a vacuum level of 35% is suction capacity scale. The residual airflow or leak rate is
achieved at full pressure supply. This residual airflow corresponds to = 22 l/min.
Starting from this result, if we draw a the leak rate of the system, as in the The only disadvantage of this method
horizontal line and a vertical line case of a leak-proof system the lies in the fact that it is impossible to
intersecting the ejector curve 2, the residual airflow would be = 0. tell whether the leakage is caused by
the workpiece itself or by a rough
surface underneath the edge of the
suction gripper.
Determining the correct ejector size

Compare the intersection of the Conversely, with a known leak rate of If we now extend the horizontal line generators (at the same leak rate)
leak rate (now known) with the 22 l/min, we can now read the that we drew previously in the chart to from the intersection with the curves
curves of other ejectors. vacuum level attainable with other determine the leak rate (Procedure 1), of other ejectors and the subsequent
Determine the attainable vacuum vacuum generators from the Suction we can determine the vacuum level downwards projection to the vacuum
by projecting the intersections with capacity as a function of vacuum attained with other vacuum scale.
the leak rate downwards. chart.
Select the ejector that reaches the
required vacuum level.

Introduction

Example
If we extend this horizontal line, it Suction capacity qn as a function of vacuum pu Result:
must intersect another curve. In the In this application, the next largest
case of the next largest vacuum vacuum generator 1 would attain a
generator 1 VAD-y, the line vacuum level of 52%.
intersects at 52% vacuum. If this vacuum level were sufficiently
The curve for the next smallest high for the application, this would be
vacuum generator 3 is overshot and
qn [l/min]
the right choice of ejector. Otherwise,

there is no intersection. In other a higher-performance ejector should
words, the low performance value be chosen (curves not available in this
would mean that no vacuum is chart).
generated with this leakage flow, as 1 VAD-y
the quantity of air drawn in is lower 2 VAD-
than the quantity of air that is 3 VAD-x
discharged because of the leakage. 4 VAD-M5
pu [%]
Conclusion
This method is useful for determining However, it should be noted that Leakage, for whatever reason, should Energy costs
the correct ejector size where the leak leakage can occur at other positions, be avoided if at all possible. Where there is a leakage flow, the
rate is known. e.g.: Safety risk air consumption (energy
seals, A leakage flow increases the risk of consumption) of an ejector is much
tubing connectors, the vacuum system no longer being higher than that of a leak-proof
couplings able to attain the required pressure system.
in a vacuum system. and the workpiece being dropped Time
during handling. A leakage flow means it takes
longer to reach the required
vacuum level.

Introduction
Technical symbols
Vacuum ejector Vacuum gauge Filter
This system description uses technical The technical symbol used in the Measuring and checking device for the Filters the drawn-in air and prevents
symbols to represent individual function charts for all Festo vacuum analogue vacuum display. contamination of the ejector.
components in function charts as well generators.
as in component descriptions.
These symbols are illustrated and
described in this section.
Vacuum suction cups Non-return valve Reservoir container

Standard, extra-deep, round, oval. Prevents the drawn-in air from flowing Air reservoir to support the setting
In technical circuit diagrams, this back against the intake direction, down of a workpiece that was
symbol represents the complete i.e. the valve permits flow in one previously picked up.
suction gripper (suction cup direction only.
holder + suction cup + accessories).
Bellows suction gripper Solenoid valve Throttle

1.5 convolutions, 3.5 convolutions. In Different valve types (mostly 2-way For controlling the flow rate or
technical circuit diagrams, this valves) perform the ON/OFF or exhaust pressure.
symbol represents the complete function in vacuum technology.
suction gripper.
Silencers
Dampens the compressed air, which
flows from the venturi nozzle at
ultrasonic speed, before it is
discharged into the atmosphere.

Introduction
Circuit diagrams with vacuum components

Circuit diagrams help provide a system. The technical drawings below
general understanding of the mode of contain examples of pneumatic circuit
operation of vacuum components as diagrams. These are intended as a
well as a schematic representation of reference to help you understand the
their function within the overall symbols used in vacuum technology.
Basic vacuum circuit
Regulated vacuum circuit

Introduction
Vacuum ejectors
Vacuum generators are the central Festo only uses ejectors that operate Festo offers a wide selection of Basic ejectors
element of any vacuum system. according to the single-stage design ejectors of different types and with Inline ejectors
The mode of operation of vacuum principle. different equipment to suit a whole Compact ejectors
ejectors and the venturi principle host of application and performance
were already explained in the Basic requirements. Each group is, in turn, subdivided into
principles section ( 12). These vacuum generators are a wide range of performance classes
subdivided into the following ejector and equipment types.
groups:
Standard and inline ejectors

The functions of standard and inline The ejector design basically consists Control, monitoring and other Because they are so compact, ejectors
ejectors are essentially limited to the of just a single jet nozzle that functions depend on external and of this type can generally be used
basic function of an ejector, operates according to the venturi additional components within the directly wherever a vacuum is
i.e. generation of a vacuum. principle. vacuum system. required, even in large quantities.
These ejectors are therefore much They are also used in vacuum
1 3 smaller compared with other vacuum processes that do not require complex
ejectors. and sophisticated control technology.
VN- VAD-
2
Ejector/venturi nozzle 1
1 = Compressed air / nozzle

2 = Vacuum / suction port 2
3 = Exhaust air/receiver nozzle
3
1 Ejector
2 Suction cup holder
3 Suction cup

Introduction
Compact ejectors
In practice, demands on vacuum Vacuum ejectors are therefore capable Depending on the ejector and design, Solenoid valves
systems in terms of function, speed of much more than just vacuum these function units contain the Filter
(performance) and, increasingly, generation. Compact ejectors have a following components in addition to Non-return valves
economy tend to be extensive. number of components integrated in the vacuum generator: Silencers
or on the housing, which makes them Vacuum switch
complete function units.
Vacuum ejector VADMI-

Taking a vacuum ejector VADMI-- as The individual components are
an example, we can see the identified in the sectional drawing
components and functions of a (34). The functions, benefits and
complete function unit. special features are described in the
notes.

Introduction
General information
1 aA
aJ
2 9
8
7
4 6
5 6
Components
1 Solenoid valve for ejector pulse 3 Special silencer 7 Non-return valve aJ Manual override
(VADMI-, VAD-M-I-) 4 Vacuum switch 8 Supply port aA Solenoid valve for vacuum
2 Venturi nozzle (jet and receiver 5 Filter for air to be evacuated 9 Manual ejector pulse control generation
nozzle) 6 Two vacuum ports
Description Function Benefits

1 Solenoid valve for ejector pulse If the voltage is switched off at the valve for ejector pulse, the vacuum is Rapid purging of vacuum
3/2-way valve solenoid valve for vacuum generation rapidly purged at port 6 as a result Fast and precise setting down of
Controls ejector pulse aA and switched on at the solenoid of the application of pressure. workpieces
Short vacuum ejector operation
cycles
2 Venturi nozzle (jet and receiver When pressure is supplied to the receiver nozzle and directed into the Ejector performance can be
nozzle) supply port 8, compressed air flows silencer 3. A suction effect, which modified and controlled by varying
Most important ejector into the jet nozzle. The narrowing of evacuates the air from the filter 5, is the nozzle diameter or supply
component the nozzle accelerates the compressed created between the jet nozzle and the pressure
Used for vacuum generation air to up to 5 times the speed of receiver nozzle. A vacuum is created
sound. This air flow is collected by the at the vacuum port 6.
3 Special silencer (closed, surface The silencer is made from air- silencer dampens this air flow, thus Minimises the noise level from the
or round type) permeable plastic or a metal alloy. reducing the noise level before the exhaust air during ejector operation
For noise reduction in exhaust The air flow exits the jet nozzle at up compressed air (exhaust air) enters
air to 5 times the speed of sound. The the atmosphere.

Introduction
Components
Description Function Benefits
4 Vacuum switch with PNP or NPN On the vacuum switch, the vacuum status. If the vacuum range falls below Air-saving function: The vacuum
output range for holding the workpiece is set the required level, the signal controls generator is switched off within the
For pressure monitoring using two potentiometers. Once the the switching on of the vacuum required vacuum range
vacuum level is reached, a signal generator. If the required vacuum can Safety function: Control of vacuum
switches off the vacuum generator no longer be generated because of a generator if vacuum level goes
(air-saving function). The non-return malfunction, the vacuum generator is above or below the required values
valve 7 maintains the vacuum in this switched off.
5 Filter for air to be evacuated A large plastic filter is integrated operation, the air is filtered before it No contamination of the system
With contamination indication between the vacuum port 6 and the enters the vacuum generator. Protection of components
40 m grade of filtration vacuum generator 2 or non-return A removable display window shows Display ensures maintenance is
valve 7. During the suction the degree of filter contamination. carried out regularly
6 Two vacuum ports (V) or (2) Vacuum components can be Depending on the application, you
With female thread connected here (e.g. vacuum suction can use either one output or both
gripper). outputs simultaneously.
7 Built-in non-return valve After the vacuum generator is air, thus preventing a drop in The vacuum is maintained after the
switched off, this non-return valve pressure. vacuum generator is switched off
prevents a backflow of the drawn-in (air-saving function in connection
with the vacuum switch 4 ).
8 Supply port (P) or (1) The compressed air supply port (P) or
(1) for generating the vacuum is con-
tained in the ejector housing.
9 Manual ejector pulse control The intensity of the air flow and, suction gripper, can be adjusted The system can be optimised for the
consequently, the time taken to manually. vacuum application
remove the workpiece from the
aJ Manual override Stem on the solenoid valve that can that is already present cannot be Manual switching of the solenoid
be switched without an electrical disabled. valve
signal. However, an electrical signal
aA Solenoid valve for vacuum When the signal is activated, vacuum. The air flow is interrupted Air-saving function in connection
generation compressed air flows through the when the signal is turned off. with the vacuum switch 4 and the
3/2-way valve vacuum generator and creates a non-return valve 7
Controls vacuum generation

Introduction
Important variables
Selecting a suction gripper
The main criteria to consider when Total volume of the vacuum system Cycle time of an operation Ejector economy
selecting a suction gripper: Additional functions
Total volume
The sum of the volumes is needed to The volume to be exhausted from the Suction cup volume
calculate the cycle time of an system is made up of the following: Suction cup holder volume
operation. Tube volume
Cycle time of an operation

When defining quantities, the time Individual criteria for determining the Evacuation time tE for 1 l volume at 6 bar operating pressure pu
factor plays a decisive role. The duration of an operation cycle:
evacuation time is used to determine Evacuation time: Time taken for the
how economical an ejector is. ejector to generate the required
vacuum
tE [s]
Air supply time: Time taken to set

down the workpiece under suction 1 VN-05-H-
(purging of the vacuum) 2 VN-07-H-
Handling/return time 5 VN-05-M-
6 VN-07-M-
pu [bar]
Ejector economy
Factors for determining the energy Air consumption per unit of time Air consumption qn as a function of operating pressure p1
consumption of an ejector: (specified in the ejector technical
data)
Number of operation cycles per unit
of time
qn [l/min]
2 VN-07-H-
VN-07-M-
8 VN-07-L-
p1 [bar]
Comparison of vacuum generators

Efficiency is a criterion which The product section of this catalogue Efficiency as a function of vacuum puat Pnom 6 bar
facilitates an objective comparison of contains information to help you
various vacuum generator types. determine the efficiency of an ejector
( 18).
The chart allows you to compare the
efficiency curves of other vacuum

generators.
pu [bar]

Introduction
Suction grippers
General data
Vacuum suction grippers provide the They are a simple, low-cost and Festo offers a wide range of suction Universal suction gripper
link between the vacuum generator reliable solution for handling gripper designs: Flat suction gripper
and the workpiece being transported. workpieces, parts, packaging, etc. Bellows suction gripper
Special suction gripper
Mode of operation
When the suction gripper comes into draws in the air on the underside of atmospheric pressure holds the
contact with the workpiece surface, the suction cup. A vacuum is created. workpiece on the suction cup.
the same air pressure (atmospheric Given that air pressure within the The larger the vacuum, the greater the
pressure) prevails on the top side and vacuum is lower than that on the holding force pressing the suction cup Vacuum
underside of the suction cup. The outside of the suction cup, onto the workpiece.
activated vacuum generator now
Materials
The suction cups are available in Depending on the range of The criteria for selecting the right
different materials. application, the following conditions suction cup material are summarised
Nitrile rubber play an important role when deciding in a table ( 44).
Polyurethane on the quality of the materials to be
Polyurethane, heat-resistant used:
Silicone Resistance to wear
Fluoro rubber Intensity of stress
Butadiene rubber, anti-static Industry in which gripper is to be
used (food industry, electronics)
Workpiece quality (surface, weight,
sensitivity, etc.)
Environment (chemically aggressive
media, temperatures)
Shapes
Suction grippers can move a wide variety of products and materials Furthermore, it is possible to pick up
variety of workpieces. (shapeless, compact or porous) with a workpieces with masses ranging from
The range of workpiece surface wide variety of surfaces (even, uneven, a few grammes right up to several
structures and contours available round, sloping or undulating) to be kilogrammes.
demands versatile gripper technology. handled easily, cost-effectively and,
Vacuum technology allows a wide above all, reliably.
Accessories
For every suction cup there is a The suction cup holders are Suction cup holders are more than
suction cup holder to fit. characterised based on the following just mounting devices for suction
Depending on their design, these can criteria: cups.
be used for a variety of applications. Holder size
Suction cup connection
With or without height compensator
Position and type of vacuum port
Mounting thread

Introduction
Suction grippers
Advantages of a bellows suction cup
When the volume of a bellows suction In practice, this so-called flexible
cup is evacuated, the suction cup vertical stroke can be used as a short
shape contracts slightly. The work- vertical stroke to lift workpieces gently
piece is lifted gently in the process. from their supports.
The evacuation of a bellows suction Phase 1 Phase 2

cup is divided into 2 phases: The suction cup is positioned on top A vacuum is created within the
of the workpiece without the influence suction cup. The workpiece is drawn
of any external forces. in and a state of equilibrium is
achieved depending upon the size of
the vacuum and the weight of the
workpiece.
Workpiece
Workpiece
Suction gripper selection guidelines

When designing a suction gripper for
a specific handling task, there are
several criteria to be taken into
consideration:
Parameter Effects on
Required suction No. of suction cups Suction cup shape Suction cup material
force
Workpiece dimensions

Workpiece weight

Workpiece rigidity

Surface texture of the workpiece Harsh

Dry, wet

Round, diagonal, curved

Environmental influences such as

weather, cleaning agents, approval for
use in the food industry, temperature
Distribution of suction grippers on the

workpiece
Arrangement of suction gripper in

relation to direction of movement
Max. acceleration


Introduction
Physical variables
The physical variables described that are needed to calculate the main
below are components of the formulae criteria.
Coefficient of friction
The coefficient of friction is the friction In practice, it is very difficult to obtain In order to be able to select a design, Surfaces
factor between the suction gripper precise specifications for this value. the following theoretical guide values Oily = 0.1
and workpiece. It defines the Suitable experiments should therefore apply: Wet = 0.2 0.3
tangential forces. be carried out for the relevant Rough = 0.6
application. Wood, metal,
glass, stone = 0.5
Safety value S
The regulations for the prevention of In the case of critical, non-uniform or A higher factor should also be selected
accidents (UVV) stipulate a safety porous materials or rough surfaces, in the case of a vertical suction
factor of 1.5. This minimum value the factor should be increased to 2. gripper position or swivel motions. Fv
must be incorporated in the The safety value is also important for
calculations. the position of the suction gripper. Fh
With a horizontal suction gripper
position, where the applied load acts
vertically on the suction cup, a value
of between 1.5 and 2 may be used.
Fh
Fv
Theoretical holding force TH

This force is calculated with a dry Mass of the workpiece m Only the result from the most
surface for the various load conditions Coefficient of friction unfavourable application load
of the application. Acceleration of the system (m/s) condition is taken into consideration.
The following factors are taken into Acceleration due to gravity
account in this formula: (9.81 m/s)
Safety value S
Breakaway force FA
The breakaway force depends on the application, the result of the This allows you to determine the When selecting a suction gripper, you
suction cup diameter and suction cup theoretical holding force TH holding force of each suction gripper. can refer to the suction cup technical
shape. calculation must be divided by the The breakaway force of the selected data to find out its breakaway force.
If several suction grippers are used number of suction grippers. suction cup must always be greater
simultaneously in a vacuum than the determined holding force TH.

Introduction
General procedure based on a calculation example

Purpose & benefits
For safety and financial reasons, it is you create an optimal system design involved in selecting a vacuum The figure below illustrates step-by-
important that you design all for the application in advance, so that system. step the recommended in-house
processes and methods in accordance the system can be sized and selected A calculation example is provided to procedure at Festo, which is used for
with their intended application. This is in accordance with requirements. illustrate how the theory is applied in the design or selection of a vacuum
the only way of ensuring optimal To simplify this task, this section practice. You can follow the step-by- system.
deployment and utilisation of your provides a step-by-step description of step system design process with the
system. (This also applies to vacuum the basic procedure and theory aid of this example.
technology.) It is therefore vital that
Problem definition Suction cup selection Assembly/mounting attachments Vacuum generator

The problem definition produces To design a suitable suction cup you The following criteria should be When selecting a vacuum generator,
specifications as well as system need to calculate the masses, holding considered when selecting mounting the following values must be
requirements. forces and breakaway forces attachments: calculated:
Material/surface ( 43). Workpiece surface Total volume
Dimensions Workpiece surface finishes and Position of the vacuum port Cycle time
Directions of movement suction cup material requirements Type of vacuum port Energy costs
Cycle time/time allowed must also be taken into account Type of mounting
Design specifications ( 43). A table listing the available holders is
provided to help you select the right
holder.
Problem definition Assembly/mounting attachments

Description Retainer
Data Height/angle compensator
Suction cups Vacuum generator

Workpiece (mass, surface) Volume
Load conditions (forces) Cycle time
General conditions Energy costs
Vacuum General conditions

Introduction
Software tool
As a special service Festo offers you above all, quick way of designing your your system individually and select
free software. The software tool in vacuum systems. It allows you to suggested products from the Festo
question is a reliable, convenient and, specify the vacuum components of range. Vacuum selection software
www.festo.com/en/engineering
Software tool: Vacuum selection
Selection program for calculating the

mass of the workpiece
Program for selecting the suction

gripper

Introduction
Problem definition
Problem Assembly/
definition mounting components
Suction Vacuum
cups generator
A workpiece of mass X is to be
transported from point 1 to point 2
using a vacuum system.
Specifications for the workpiece and
general conditions for the vacuum
system are listed in the section below
(assumed values) and should be
referred to when performing the 2
necessary calculations.
Vacuum system, comprising:

Suction cups
Assembly/mounting attachments
Vacuum generator
We need to find out which vacuum 1

system from the Festo product range
is the right one for this application. To
do this, we need certain values or
forces (required values).
Assumed values Required values

For the workpiece For the handling system
Material Sheet steel Compressed air supply 6 bar The values specified below must be
Surface Even, smooth, slightly oily Directions of movement Lift vertically calculated to determine the correct
(e.g. from the press) Travel horizontally vacuum system.
Dimensions Length: 200 mm 90 Rotate Other general conditions must be
Width: 100 mm Travel vertically taken into account here.
Height: 2 mm Max. acceleration 5 m/s2 The following sequence is
Cycle time max. 3.5 s recommended:
Time requirements For picking up: < 0.5 s Mass (weight) of the workpiece
For setting down: 0.1 s Holding force and force of
Safety factor 1.5 acceleration
Design Total volume
conditions 2 suction grippers for Cycle time
vibration-free transport;
spring-action picking up/ Other general conditions
setting down of the workpiece; Material and surface finish
vacuum line ports at side; Height and angle compensation
suction grippers mounted Costs
using male threads.

Introduction
Selection of suction cups

Problem Assembly/
Suction Vacuum
cups generator
Check list
Load Workpiece surface Suction cup material Forces
What does the workpiece weigh? What kind of surface finish does the What requirements must the vacuum What kind of loads do the suction
workpiece have? generator fulfil? grippers have to carry?
Areas of application Holding forces load cases in the
Resistance requirements, various directions of movement
temperature Breakaway force determining the
breakaway force per suction cup
(definition of suction cup diameter)
Step 1: Calculating the mass m of the workpiece
m=LxWxHx Example: m = Mass [kg]

m = 20 cm x 10 cm x 0.2 cm L = Length [cm]
x 7.85 g/cm3 W = Width [cm]
m = 314 g H = Height [cm]
m = 0.314 kg = Density [g/cm]
Step 2: Selection of the suction gripper

According to the surface finish of the workpiece
Different suction cup shapes are Standard suction cup Oval suction cup Bellows
recommended for the suction gripper,
depending on the surface finish of the
workpiece: For flat and slightly undulating For narrow, oblong workpieces such
surfaces, e.g. sheet metal or as profiles and pipes For inclined surfaces, from 5 to 30
cartons. depending upon suction cup
diameter
Extra deep suction cup Undulating, round surfaces, flexible
workpieces with large surface areas
Fragile workpieces such as glass
For round or deeply undulating bottles
workpieces Use as a cost-effective height
compensator
Result
If, in the sample exercise, we were
using sheet steel with an even,
smooth surface, a standard suction
cup would be the best solution.

Introduction
Step 2: Selection of the suction gripper

According to the material quality of the workpiece
Depending on the application, the Life expectancy There are different material designs For high temperatures
following conditions need to be taken Environment (e.g. chemically available, such as: Antistatic design for electronics
into consideration: aggressive media, temperatures) For smooth or rough surfaces components
Continuous load in multiple shift
operation
Material properties Nitrile rubber Polyurethane Polyurethane Silicone Fluoro rubber Butadiene rubber
(heat-resistant) (anti-static)
Material code N U T S F NA
Colour Black Blue Red-brown White Grey Black with white
transparent dot
Resistance to wear/ ** *** *** * ** **

resistance to abrasion
Areas of application
Very high stress * * *
Food processing *
Oily workpieces * * *** * *
High ambient temperatures * *
Low ambient temperatures * * *
Smooth surface (glass) * * * *
Rough surface (wood, stone) * **
Antistatic *
Minimal marking * * *
Resistance
Weather * ** ** *** *** **
Resistance to tearing ** *** *** * ** **
Permanent deformation ** * ** ** *** **
Mineral based hydraulic oil *** *** *** ***
Synthetic ester based hydraulic oil * *
Non-polar solvents (e.g. white spirit) *** ** ** ***
Polar solvents (e.g. acetone)
Ethanol *** *** *
Isopropanol ** *** ***
Water *** ** **
Acid (10%) * ***
Alkaline (10%) ** * * *** **
Temperature range, long-term [C] 10 +70 20 +60 10 +80 30 +180 10 +200 10 +70
Shore hardness A [] 50 5 60 5 72 5 50 5 60 5 50 5
Special features Low-cost Wear resistant Oil resistant Approved for Chemical and Antistatic
use in the food temperature
industry resistant
Area of application Conventional Rough surface Automobile Food industry Glass industry Electronics
application industry industry
*** Very suitable * Suitable

** Fairly suitable Not suitable
Result
For the workpiece in the problem example we would choose a suction cup made from polyurethane (material code U).

Introduction
Step 3: Calculating the holding force and breakaway force

Determining the holding force
To determine the holding force you
need to know the mass of the -H- Note
workpiece, on the one hand, and the
The forces of acceleration that operate designing a suction gripper system.
acceleration, on the other.
in a fully automatic system must be
taken into consideration when
Case 1
Horizontal suction gripper position, Example:
F H = m x (g + a) x S
vertical direction of movement (best
F H = 0.314 kg x (9.81 m2 + 5 m2) x 1.5
case) s s
FH 7 N
Case 2
Horizontal suction gripper position, a) x S Example:
F H = m x (g + 5 m2
horizontal direction of movement s
F H = 0.314 kg x (9.81 m2 + ) x 1.5
s 0.1
FH 28 N
Case 3
Vertical suction gripper position, Example:
F H = (m
) x (g + a) x S
vertical direction of movement (worst 0.314 kg
FH = ( ) x (9.81 m2 + 5 m2) x 2
case) 0.1 s s
FH 93 N
Result:
In accordance with the problem This value must be used for designing
definition, the result of 93 N from the system.
Case 3 must be taken into account, as
the system also transports the
workpiece in a vertical suction gripper
position with vertical force.
FH = Theoretical holding force of the a = Acceleration of the system S = Safety factor = Friction factor1)
suction gripper [N] [m/s] (minimum value is a safety 0.1 for oily surfaces
m = Mass [kg] Note the emergency off acceler- factor of 1.5, for critical, non- 0.2 0.3 for wet surfaces
g = Acceleration due to gravity ation. uniform or porous materials or 0.5 for wood, metal, glass,
[9.81 m/s2] rough surfaces the factor stone
should be 2.0 or higher) 0.6 for rough surfaces
1) The specified friction factors are average values and should be verified for the workpiece in question.

Introduction
Step 3: Calculating the holding force and breakaway force

Determining the breakaway force
FA = Theoretical breakaway force F Example:
[N] F A = nH 93 N
FA =
FH = Theoretical holding force of the 2
suction gripper [N] FA 47 N
(Result 45)
n = Number of suction grippers
(2 suction grippers are
planned in the problem
example)
Breakaway force FA dependent on suction cup diameter and suction cup shape
Round suction cup FA Oval suction cup FA at
at 0.7 bar 0.7 bar
Ordering Suction Standard Extra deep Bellows, Bellows, Ordering Suction Oval
data cup 1.5 convol- 3.5 convol- data cup size
utions utions
[mm] [mm]
ess 2 0.1 N ess 4x10 2N
4 0.4 N 4x20 3.4 N
6 1.1 N 6x10 2.9 N
8 2.3 N 6x20 5.9 N
10 3.9 N 4.7 N 3.9 N 8x20 8N
15 8.5 N 9.8 N 8x30 10.9 N
Breakaway force FA too low 20 16.3 N 17 N 12.9 N 8.2 N 10x30 15.2 N
30 40.8 N 37.2 N 26.2 N 20.8 N 15x45 32 N
40 69.6 N 67.6 N 52.3 N 42.4 N 20x60 62.8 N
50 105.8 N 103.6 N 72.6 N 63.4 N 25x75 92.5 N
Reliable range
60 166.1 N 162.5 N 30x90 134.4 N
for the problem example
80 309.7 N 275 N 213.9 N
100 503.6 N 440.8 N
150 900 N
Suction cup diameter too big for 200 1,610 N
workpiece
In this example we opt for 2 suction

grippers: -H- Note
Round design The load capacity of the vacuum
Suction cup diameter 40 mm
suction gripper must be greater
Breakaway force of 69.6 N
than the calculated value.

Introduction
Selecting assembly/mounting attachments

Problem Assembly/
Suction Vacuum
cups generator
Check list
Workpiece Vacuum port Type of connection Type of mounting
Consideration of the workpiece Positioning of the vacuum tubing Selecting the vacuum port for the Mounting the suction cup holder on
surface top suction cup holder the handling unit, e.g. robot arm
Angle compensator for very uneven at side Thread, push-in connector, barbed Female/male thread
surfaces fitting
Spring-mounted holders for
sensitive workpieces as well as
varying pick-up heights
Selecting the suction cup holder

The suction cup holder as well as the The suction grippers should be Choice of vacuum ports 1: Vacuum port 1
angle compensator and vacuum mounted with external threads. top
filter accessories are selected on the Spring-loaded holders: at side
basis of the previously defined In the event of excess stroke and 3 connection types 1: Mounting
suction cup diameter. height tolerances, it is recom- Push-in connector QS threads for
According to the problem example, the mended that you use a holder with Barbed fitting PK holder 2
Suction cup
workpieces must be picked up and set a height compensator the same Thread G connection 3
down with the aid of a spring. applies for sensitive workpieces that Different mounting threads for
The vacuum lines should be attached need to be placed gently and with holder 2:
at the side using push-in connectors. the aid of a spring. Female thread
Male thread
Round suction cup

From problem example

Suction cup 2 4 6 8 10 15 20 30 40 50 60 80 100 150 200
[mm]
Holder size 1 2 3 4 5 6
Suction cup connection 3 mm 4 mm M4x0.7 M6x1 M10x1.5 M20x2
3
Ordering data esh
Oval suction cup

Suction cup size 4x10 4x20 6x10 6x20 8x20 8x30 10x30 15x45 20x60 25x75 30x90
[mm]
Holder size 4 5
Suction cup connection M6x1 M10x1.5
3
Ordering data esh

Introduction
Holder type
From problem example

HA HB HC HCL HD HDL HE HF
Height compensation
Vacuum port 1
Top
At side
Threaded connection G
Push-in connector QS
Barbed fitting PK
Mounting threads for holder 2

Female thread
Male thread
Result
Taking all requirements into account:
Suction cup holder HD, size 4

Introduction
Selecting vacuum generators

Problem Assembly/
Suction Vacuum
cup generator
selection
The criteria referred to in the check Total volume

list therefore play an important role in Cycle time -H- Note
the selection of a suitable ejector. Economy
Functions Almost all Festo vacuum ejectors
Design specifications achieve a vacuum level of approx. All ejectors can thus be used for
85%, with the exception of the new handling tasks involving light to
VN ejectors, which are specially heavy workpieces or loads.
designed for low pressure of approx.
50%.
Check list
Total volume Cycle time Economy Functions
How high is the total volume to be How long does an operation cycle How high are the energy costs? What additional functions should the
drawn in? take? Calculate the energy costs based on vacuum generator have?
Take into account the suction cup Calculate the evacuation time the air consumption and number of Filters, controls, non-return valves,
volume Determine the handling/return time operation cycles vacuum switches, exhaust function,
Take into account the suction cup Calculate the air supply time etc.
holder volume
Calculate the tube volume
Design specifications
What specifications exist?
Dimensions, weight, mounting
position, etc.

Introduction
Step 1: Determining the total volume of the system (volume to be drawn in)
The suction cup, holder and tube
volumes must be determined and
added together to form the total
volume.
Suction cup volume V1 Suction cup holder volume V2 Tube volume V3 Total volume VT
The suction cup volumes are specified Because of the huge range of different Once the suction cups, suction cup VT = V1 + V2 + V3
in the datasheet for the relevant holder types and connection options, holders and connection options have VT = 3,132 + 678 + 12,566
vacuum suction grippers ESG, VAS, tables listing all of the suction cups been defined, the tube volume can be VT = 16,376 mm3 (16.38 cm3)
VASB. and their relevant volumes have been determined.
The suction cup volume may be created in the datasheet for the ESG
specified in a table or chart, product family. Tubing PUN:
depending on the product family. Outside/inside [mm]
In our sample application we opted In our sample application we chose 3.0/2.1
for 2 suction grippers: the following suction cup holders: 4.0/2.6
6.0/4.0
Round design Suction cup holder HD 8.0/5.7
Suction cup diameter 40 mm Size 4 with QS connector 10.0/7.0
Breakaway force of 69.6 N
V2 = 678 mm3 The following formula must be used
For these suction cups, the datasheet when calculating the volume:
specifies a suction cup volume
2
of 1,566 mm3 per suction cup. V3 = x D x L
4
V1= 2 x 1,566 mm3 = 3,132 mm3 D = Tube inside [mm]

L = Tube length [mm]
In the sample application a suction

cup holder with QS-6 couplings is
used. A tube with an outside diameter
of 6 mm is therefore required.
In order to connect the vacuum
generator to both suction cups, a tube
length (L) of approx. 1 m (1,000 mm)
is required.
42
V3 = x x 1 000
4
V3 = 12 566 mm3

Introduction
Step 2: Determining the cycle time

TC = Evacuation time tE + handling (tE) tE = Evacuation time An operation cycle can be subdivided
time t1 + air supply time tS + return 1 t1 = Transport into individual time intervals, which
(t1)
time t2 tS = Discharge must be either measured or
(tS) calculated. The individual times
t2 = Return
p [bar] 1 = Pick-up added together produce the cycle
2 = Time saved time.
(t2)
t [s]
2
Evacuation time tE
The evacuation time, i.e. the time time can be found in the Calculation: Example 1: VADMI-45
taken for a volume to reach a certain datasheet of the relevant vacuum In Step 1 of the sample application we tE = VT x tE1/1,000
vacuum level, is very useful for generator. This example depicts charts determined a total volume for the tE = 17 cm3 x 25 s/1,000 cm3
assessing the performance of a for some of the vacuum generators of vacuum system of VT = 16.38 cm3 tE = 0.425 s (0.43 s)
vacuum generator. The evacuation the VN- product family. (17 cm3). Using a basic rule of three,
we can now calculate the evacuation Example 2: VADMI-70
time tE for this system with any tE = VT x tE1/1,000
Evacuation time tE for 1 litre volume at 6 bar operating pressure pu
vacuum generator. According to the tE = 17 cm3 x 11 s/1,000 cm3
problem definition, tE < 0.5 s, based tE = 0.187 s (0.19 s)
on a vacuum level of 80%.
Example 3: VN-07-H
tE = VT x tE1/1,000
tE [s]
tE = 17 cm3 x 8 s/1,000 cm3

1 VN-05-H-
tE = 0.136 s (0.14 s)
2 VN-07-H-
5 VN-05-M-
6 VN-07-M-
tE = Evacuation time (VT )
tE1 = Evacuation time (V = 1,000 cm3)
pu [bar]
VT = Total volume (from example)
Handling time t1
The time required to handle the process (e.g. determined using a
workpiece after the end of the suction stopwatch = 1.5 s).
Air supply time tS

Time needed by the vacuum system to The specifications apply to 1 litre Using a basic rule of three, we can tS = Evacuation time (VT)
tS1 = Evacuation time (V = 1,000 cm3)
build up the pressure (vacuum) again volume at 6 bar operating pressure at now calculate the air supply time tS VT = Total volume (from example)
and set down the workpiece. The air max. vacuum level. for this system.
supply time can be found in the
technical data for the relevant vacuum
Example 1: VADMI-45 Example 2: VADMI-70 Example 3: VN-07-H
generator.
tS = VT x tS1/1,000 tS = VT x tS1/1,000 tS = VT x tS1/1,000
tS= 17 cm3 x 1.9 s/1,000 cm3 tS= 17 cm3 x 0.59 s/1,000 cm3 tS= 17 cm3 x 1.1 s/1,000 cm3
tS = 0.03 s tS= 0.01 s tS= 0.02 s
Return time t2 Cycle time tC

The time needed by the vacuum Example 1: VADMI-45 Example 2: VADMI-70 Example 3: VN-07-H
system to return to the initial position tC = tE + t1 + tS + t2 tC = tE + t1 + tS + t2 tC = tE + t1 + tS + t2
after the workpiece has been set down tC = 0.43 + 1.5 + 0.03 + 1.5 tC = 0.19 + 1.5 + 0.01 + 1.5 tC = 0.14 + 1.5 +0.02 + 1.5
(e.g. determined using a stopwatch tC = 3.46 s tC = 3.2 s tC = 3.16 s
= 1.5 s).

Introduction
Step 3: Checking economy of operation

Energy costs are determined on the
basis of air consumption.
Determining the air consumption per operation cycle QC

These charts are also included in the When combined with the vacuum Air consumption Q as a function of operating pressure p
datasheet for the relevant vacuum switch it provides an air-saving
generator (e.g. VADM-, VADMI-). function, i.e. no air is consumed
The VADMI- vacuum generators have during transport of the workpiece.
a built-in non-return valve which The VN- vacuum generators do not
Q [l/min]
maintains the vacuum after the have this function. This means,
vacuum generator has been switched therefore, that the vacuum generator
off (prerequisite: there must be no remains in operation so that it can
leakage in the system). hold the workpiece during transport.
p [bar]
Qz = Air consumption per operation cycle Example 1: VADMI-45 Example 2: VADMI-70 Example 3: VN-07-H
tE = Evacuation time for application
Q Q Q
Q = Air consumption per vacuum generator QZ = tE x QZ = tE x QZ = t E + t 1 x
[l/min] 60 60 60
QZ = 0.43 s x 11 l QZ = 0.19 s x 31 l QZ = (0.13 s + 1.5 s) x 28 l
60 s 60 s 60 s
QZ = 0.08 l QZ = 0.10 l QZ = 0.76 l
Determining the number of operation cycles per hour Zh

Zh = Operation cycles per hour Example 1: VADMI-45 Example 2: VADMI-70 Example 3: VN-07-H
tZ = Time per operation cycle
3, 600 s 3, 600 s 3, 600 s
tE = Evacuation time for application Zh = Zh = Zh =
tZ tZ tZ
3, 600 s 3, 600 s 3, 600 s
Zh = Zh = Zh =
3.46 s 3.2 s 3.16 s
Zh = 1, 040 Zh = 1, 125 Zh = 1, 139
Determining the air consumption per hour Qh

Qh = Air consumption per hour Example 1: VADMI-45 Example 2: VADMI-70 Example 3: VN-07-H
QC = Air consumption per operation cycle
Ch = Operation cycles per hour
Qh = QC x Ch Qh = QC x Ch Qh = QC x Ch
Qh = 0.08 l x 1,040 Qh = 0.10 l x 1,125 Qh = 0.76 l x 1,139
Qh = 83.20 l (0.08 m) Qh = 112.5 l (0.12 m) Qh = 865.64 l (0.87 m)
Determining the energy costs per year KEA

KEA = Energy costs per year Costs for compressed air1):
Qh = Air consumption per hour
1 m at 7 bar: 0.02/m, t operating t operating
KEA = Qh x Compressed air costsm3 x x
at an electricity price of Day Year
0.10/kWh
Vacuum generator Air consumption per cycle QZ Cycles per hour Zh Air consumption per hour Qh Energy costs per year KEA2)
[l] [m3] []
VADMI-45 0.08 1,040 0.08 5.76
VADMI-70 0.10 1,125 0.12 8.64
VN-07-H 0.76 1,139 0.87 62.63
1) Material, depreciation and labour costs, etc. are reflected in the price
2) Energy costs for shift operation 16 hours/day and 220 days/year

Introduction
Step 4: Taking additional functions/components and design specifications into account

Selecting additional functions/components:
Selection of these components is and application of the system. All
guided by specific requirements in details regarding performance or
terms of performance and functional- components are provided in the
ity, as well as by the place of operation datasheet on the relevant product.
Solenoid valves Vacuum switch

A vacuum system needs solenoid Operation cycles can be accelerated Reliability through pressure
valves for controlling vacuum and optimised by adding an extra -H- Note monitoring
generation. These switch the vacuum valve as an ejector pulse generator. The nominal flow rate of the Adjustable switching point
on and off. Fast hysteresis adjustment
solenoid valve must not be lower
Vacuum generator Vacuum generator Digital/analogue signal output
than the suction capacity of the
VADM-, VADMI- VADMI- vacuum generator at atmospheric Display
VAD-M-, VAD-M-I- VADM-I- Ports
pressure. (Both specifications can
be found in the datasheet for the
relevant product.)
Filter Pressure gauge Silencers

Reliability: no contamination of the Extension of the product life cycle Manual pressure monitoring of the Noise pollution kept to a minimum
system and reduction of maintenance system
intervals Safety function
Taking design specifications into account

The following design specifications Size
must be taken into account when Weight
configuring a vacuum system: Resistance
Calculation example summary Selection of suction cups Selecting assembly and mounting Selecting vacuum generators
attachments
The cycle time and economy of the Taking the mass and force The result takes all system We compared three vacuum
ejectors were used as selection calculations plus all criteria into requirements into account: generators chosen at random from the
criteria. account, we get the following result: Festo product range:
Quantity 2 units Holder type HD Compact ejectors VADMI-45
Design round Size 4 VADMI-70
Suction cup 40 mm Inline ejectors VN-07-H
Breakaway force 69.4 N
Material Polyurethane
Result Cycle time Economy

Compact ejector VADMI-45 All three vacuum generators lay within The vacuum generator VADMI-45 came The VADMI-45, on the other hand, has
a reasonable timeframe in the sample off best in terms of energy consump- a smaller nozzle diameter and thus
application and were below the tion and, consequently, energy costs. significantly lower air consumption.
maximum time of 3.5 seconds The two compact ejectors VADMI-45 However, it cannot generate the
specified in the problem definition. and VADMI-70 produced almost vacuum as quickly as the VADMI-70.
identical results in relation to energy The number of cycles per unit of time
costs. Although the larger VADMI-70 and the quantities are almost
has a somewhat higher air consump- identical for all three vacuum
tion per unit of time, it can generate generators.
the vacuum faster.

Introduction
Products for vacuum technology
Vacuum generator Vacuum suction gripper

A vacuum ejector is the central The suction grippers are the connect-
element of any vacuum system. ing element between the vacuum
Festo offers an extensive range of system and the workpiece.
vacuum ejectors for all kinds of Given the huge variety of surface
applications and performance finishes, shapes and temperatures as
requirements: well as different workpiece masses, a
Basic and inline ejectors comprehensive range of suction cups
Vacuum generators and possible combinations is needed.
VN-, VAD-/VAK- With its suction cup range and the
Compact ejectors modular suction gripper ESG, Festo
Vacuum generators has a solution for every application:
VADM-/VADMI-, Modular suction gripper ESG-
VAD-M/VAD-M-I- Suction cups VAS-/VASB-
Vacuum accessories
Controlling, measuring, checking,
filtering, etc. are important functions
which, if not already included as
standard in a vacuum system, can be
added through an extensive range of
accessories.
Vacuum security valve ISV-
Vacuum gauges VAM-
Vacuum filters VAF-
Vacuum switches VPEV-
Other accessories:
Height compensators, adapters
Tubing
QS push-in fittings

Basic Principles of Vacuum Technology, Brief Overview: P (Pa) P (Mbar)

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Basic principles of vacuum technology, brief overview

Basic principles of vacuum technology

Understanding vacuum Vacuum specification options Effects of changes on vacuum

100% vacuum would mean that there

Subject to change Internet: www.festo.com/catalogue/... 1

Components for vacuum generation

2 Internet: www.festo.com/catalogue/... Subject to change

Vacuum in handling technology

Both principles have their advantages components, both principles can

Important comparison variables

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Vacuum in handling technology

Leakage in vacuum systems

Selection aid for vacuum generators

4 Internet: www.festo.com/catalogue/... Subject to change

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What is a vacuum used for?

Pressure is therefore defined as

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Vacuum range Pressure range (absolute) Applications

Measuring the pressure or vacuum

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Vacuum designations and specification options

Operating pressure Vacuum as an absolute value Vacuum as a relative value

Specification options for the pressure or vacuum

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International vacuum/pressure conversion table

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Atmospheric air pressure

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Effect of changes in air pressure on vacuum technology

Valid standards and guidelines

DIN standards, research reports and Festo guidelines

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Vacuum ejector High vacuum, relatively low flow rate

12 Internet: www.festo.com/catalogue/... Subject to change

Vacuum ejector High vacuum, relatively low flow rate

Subject to change Internet: www.festo.com/catalogue/... 13

Displacement/kinetic vacuum pumps

Gas-absorbing vacuum pumps

Gas-feeding displacement vacuum pumps High vacuum, low flow rate

14 Internet: www.festo.com/catalogue/... Subject to change

Gas-feeding kinetic vacuum pumps Low vacuum, high flow rate

Compressors For precision industrial

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Practical use of vacuum

Important factors to consider

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Single-stage and multi-stage ejectors

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Single-stage and multi-stage ejectors

Efficiency as a function of vacuum pu

In practice, the job of a vacuum

18 Internet: www.festo.com/catalogue/... Subject to change

Single-stage and multi-stage ejectors

1) see diagram below

However, a pressure of generate it.

Suction flow rate

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Single-stage and multi-stage ejectors

20 Internet: www.festo.com/catalogue/... Subject to change

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Energy cost comparison/sample calculation