Engineering Tools as a Support in

Suction cups Applications in order to

increase Energy Efficiency
Ivana Ignjatović1, Dragan Šešlija2
University of Novi Sad, Faculty of Technical Sciences, Department of Industrial
Engineering and Management, Trg Dositeja Obradovića 6, 21000 Novi Sad, Serbia,
ivanai@uns.ns.ac.yu

University of Novi Sad, Faculty of Technical Sciences, Department of Industrial

Engineering and Management, Trg Dositeja Obradovića 6, 21000 Novi Sad, Serbia,
seslija@uns.ns.ac.yu

Vacuum technology is becoming even more popular for workpiece handling as an

alternative to mechanical grippers. In this paper possibilities of increasing the
energy efficiency in suction cups applications are presented. Today we can use the
vacuum selection programs in order to choose the optimal type of suction cup.
This paper contains the functioning principle of this kind of software. Suction cups
are great consumers of compressed air. Using vacuum selection programs we can
save energy and reduce the costs. There are two possible ways to increase the
energy efficiency in the suction cup applications: 1. We can use air saving circuit.
It is integrated part of vacuum generators and it comes from manufacturers of
pneumatic equipment; 2. The other way is changing the vacuum components and
simulating the new system. Changing the components we can see the effects which
they cause. In accordance with these conclusions we can make actions for
increasing the energy efficiency of the whole system. The first method will be
explained and the second will be presented on the particular system.

Keywords
energy efficiency, software for pneumatic system design, suction cups, vacuum

1. Introduction
The aim of the efficient pneumatic system development is to provide the minimum loss
of pressure in the distributive system. Inefficient pneumatic system could cause
increasing costs per unit of compressed air, unsuitable and unbalanced operation of
pneumatic equipment, decreasing life cycle of components, reducing capacity and
forming rust and sludge in the main and the lateral ducts. [1]
It is well known that pneumatic systems spend a significant energy for their operation.
According to some researches 10% of all electric energy which is used in industry, is
used for making the compressed air. For this reason it is necessary to pay attention on
their efficient work. By making the pneumatic system more efficient we can save
energy, extend life time of the pneumatic equipment, make whole system more reliable
and decrease the costs of working period of the system. [2]
The main objective of this contribution is to call attention of developers and all firms
which use suction cups in their processes on energy saving. There are a lot of
possibilities to implement different solutions. In the next chapters the possibilities of
increasing the energy efficiency in suction cups applications will be presented.

2. Suction cup grippers

In industrial processes grippers is using for taking, lifting and transferring workpice to
the certain position. The common term for these actions is pick and place. Many good
sides of vacuum technology are the reasons that this technology is becoming even more
popular for workpiece handling. The first thing that should be known about workpiece
handling using suction cups is that certain conditions must be fulfilled:
• gripping surface has to be as level as possible,
• workpiece surfaces should be non-porous and not too rough,
• a maximum gripping force should not be greater than 7N per cm2 of gripping
surface.
Number of suction cups which is used in certain application depends of the shape, size
and weight of the workpiece. We should pay attention on shape of suction cups and
even more on suction cups position in reference to workpiece. In the Table 1 are shown
the choices of various fixed configurations for the suction cups. [3]

One in the centre At both ends

Rectangular (corners) Rectangular (area)

Circular (circumference) Circular (area)

Linear (X) Linear (Y)

Table 1 Suction cup positioning

3. Vacuum selection programs

The vacuum selection programs allow us to choose suction cups, tubing and vacuum
generators. When we want to define vacuum components for our system we have to
pass through few steps in order to provide successful working process realisation. In the
next two chapters the example of using software which is developed by FESTO AG &
Co. KG will be shown with the goal of optimisation vacuum applications and
increasing energy efficiency.
At the beginning it is necessary to define the workpiece, its shape, dimensions and
mass. We can choose between cube, cylinder (x axis, y axis or z axis), and sphere or
pipe (also x axis, y axis or z axis). After that we should define the coefficient of friction
between suction cup and workpiece. This software has an integrated data base of
materials from which suction cups and workpieces are made by. Choosing the right
material we will automatically get its coefficient of friction.
The next step in suction cups selection concerns defining number of suction cups which
will be used in certain application and their position in relation with workpiece. The
possible choices are presented in Table 1. There are three things on which we have to
pay attention:
• Dimensions of the suction cups. Suction cup surface can not be bigger than
workpiece surface.
• The distance between suction cup and edge of the workpiece.
• The distance between suction cups.
After defining parameters, software calculates the maximal suction cup diameter which
we can use in the certain application. Besides defining suction cup diameter we also
have to define suction cup material, suction shape, the type of the air connection, stroke
compensation, angle compensator and filter.
When we choose shape, material, number and position of suction cups, we have to
choose the type of tube which we will use. That means that we have to specify material
and tubing length per suction cup and total tubing length. FESTO software has an
option to choose the tubes which can be used just in the food industry (Suitable for
food).
Next step includes defining the vacuum generators, type and number. All FESTO
vacuum generators have a single stage design and operate according to the venturi
principle. After that it is necessary to set operating pressure and vacuum. We can also
choose some remaining features such as silencer, filter, threaded connections, switching
output, integrated solenoid valve, etc. Very important feature is option Air saving. That
air saving circuit is a factory solution. Air saving is very important from energy
efficiency point of view. The importance of that will be described in the next chapter.
At the end we have to define the motion of suction cups after taking the workpiece. We
also have to choose drive unit. There are two possibilities: pneumatic or electric drive
(pneumatic cylinder or electric motor.
After defining the components of the whole system and the characteristic of the motion
the software can make the simulation and finally we get suction cup load. Also we can
see the exactly number and position of suction cups in relation with workpiece.
Software can simulate the conduct of suction cups in the real time. We can see total
suction cup load or load per suction cup. [3]
If we are not satisfied with the way of functioning of our system we can go back to
some previous step of suction cup selection and change any of the defined parameters.
After every change software can make a simulation. In that way we can see the effects
of change. It is a circle action and we can repeat it as much as we want until we get
desired work of our system. At the end software automatically generates a parts list. It
is a list of components which we have to use to achieve the goal so we do not have to
do that manually.

4. The possibilities for increasing energy efficiency

In this chapter the two possibilities of increasing energy efficiency in suction cup
applications will be presented. The first one uses intended equipment manufactured for
that purpose. The second one increasing energy efficiency achieves by choosing the
optimal work pressure.

4.1 Increasing energy efficiency with specific components

One of the possible methods for increasing energy efficiency in suction cups
applications is with equipment for that purpose manufactured. Air saving is realized
with a vacuum generators. They have an integrated vacuum switch with an air saving
function. It is well known as Air saving circuit.
It is integrated part of vacuum generators and it comes from manufacturers of
pneumatic equipment. Its function principle is: the vacuum range to be used to hold the
workpiece is set on the vacuum switch. The switch generates a pulsating signal which
actuates the solenoid valves for vacuum when the vacuum pressure has fallen below the
selected upper limit value (due to leakage etc.). At all other times, the vacuum is
maintained with the non-return valve, even when the vacuum generator is not switched
on. [4] We will compare work of vacuum generator and work of vacuum pump. That
will be presented on the example. Also on the same example we will see the principle
of energy efficiency achievement.
On the Figure 1 are presented working curves of vacuum pump and vacuum generator
with integrated air saving function. We can see that vacuum generator switches off
when it reaches vacuum value which is demanded. That means that vacuum generator
does not generate vacuum while is vacuum on the demanded level. When vacuum falls
down bellow demanded level vacuum generator will switch on and continue with
vacuum generation until he reaches demanded level. During the period while vacuum
generator is switched off it does not spend compressed air for vacuum generation.
If we have on mind that vacuum producing in that manner is expensive and that suction
cups are great consumers of pressurised air, option air saving could lead to increasing
energy efficiency of the system. With the air saving circuit we can use vacuum more
rational because it is not necessary to produce vacuum during the whole period when
suction cups are engaged. Vacuum will be generated only when it falls down bellow
demanded level which is indispensable for successful realisation of assignment
(catching and replacing the workpiece).
Air savings is in proportion to participation of time Δt from Figure 1 in total holding
time of workpiece. This solution is especially suitable in applications in which
particular holding time of workpiece significant takes part in total material handling
cycle.

Figure 1 Curves of Vacuum pump and Vacuum generator

4.2 Increasing energy efficiency with simulation

The great advantage of vacuum selection programs is that they automatically generate
diagrams on which we can see how the concrete parameters of our system work, e.g. air
consumption, suction capacity, vacuum etc. If we change some of those parameters we
can see the effects which they cause on those diagrams. In accordance with obtained
diagrams we can take actions in order to increase energy efficiency of the system. This
procedure will be presented on example.
We have cylindrical (z axis) workpiece with dimensions: diameter 150 mm and height
40 mm and mass 200 g. In this vacuum application we will use 6 suction cups, standard
shape and diameter 30 mm. Suction cups are in circular (circumference) positioning.
Working pressure is 6 bars. Three vacuum generators are supplied suction cups with
necessary quantity and value of vacuum. After defining those parameters in vacuum
selection program we will obtain diagrams which are presented on Figure 2.

Figure 2 Vacuum values for working pressure 6 bars

We can see that the biggest value of vacuum is in situation when working pressure is
5,4 bars. If we change the working pressure from origin 6 bars to 5,4 bars we will
obtain diagrams like on Figure 3.
 Figure 3 Vacuum values for working pressure 5,4 bars

When we change the working pressure vacuum and suction capacity will be used on the
most effective way. In the case when the working pressure is 6 bars we have air
consumption 27,60 litres per minute and in the case when the working pressure is 5,4
bars, 23,28 litres per minute. In this manner we can save 4,32 litres per minute of air or
0,072 litres per second. In some longer period air savings could be significant. The
importance of that will be illustrated on example from real process.
If suction cups work 30 seconds every minute, 8 hours per day, 250 days per annum,
we have total working time 60.000 minutes per annum or 259.200 litres per annum
pressurised air savings. This is savings while just one suction cup works on one
working operation. But this situation is very rare in real processes so the total air
savings is much, much bigger.

5. Conclusion
Rapid development of IT lead to massed usage of engineering tool as a support in
suction cups applications. In the present developers of pneumatic systems could use
software to help them to choose equipment and develop pneumatic systems. Those
software have integrated mechanisms for calculating all necessary parameters of the
system. Also they save time and effort to developers and the possibilities of making
mistakes are less.
From increasing energy efficiency of vacuum applications using engineering tools point
of view we can conclude that there are a lot of economical and technical potentials for
energy saving in this field. It is enabled by:
• choosing intended equipment manufactured for that purpose which increases
energy efficiency and/or
• optimisation of working parameters of pneumatic system on the basis of
simulation in exploitation conditions.

References
[1] Šešlija D., Lagod B., “Condition of pneumatic systems in Serbian industry from
aspect of energy efficiency”, Centre for automation and mechatronics, Novi Sad,
2006.
[2] Šešlija D., “Production, preparing and distribution of air pressure”, IKOS, Novi
Sad, 2002.
[3] Ignjatović I., “Usage of the Engineering Tools in Pneumatics Systems
Development”, Master thesis, FTN, Novi Sad, 2006.
[4] FESTO AG & Co. KG, “The Pneumatic Catalogue 2004”, Esslingen (Berkheim),
2004.