A global manufacturer of high-value industrial components required a bespoke pneumatic control solution for a new automated production cell. The application demanded highly accurate pressure regulation to control pneumatic actuators responsible for positioning, clamping, and testing precision-engineered parts.
To improve product consistency and reduce cycle times, the customer required a compact assembly capable of delivering repeatable pressure control while integrating seamlessly with the existing PLC-based automation system.
The Challenge
The production process required pneumatic pressure to be adjusted dynamically throughout each manufacturing cycle. Variations in pressure could lead to inconsistent clamping forces, inaccurate positioning, or component damage, directly affecting product quality and increasing scrap rates.
The customer required a solution that could:
- Deliver precise closed-loop pressure control.
- Respond rapidly to changing process demands.
- Integrate with existing PLC and control architecture.
- Operate continuously within a high-volume production environment.
- Reduce manual adjustment and maintenance requirements.
The Solution
SG Controls designed and assembled a bespoke pneumatic pressure control package using Proportion-Air components, including:
- QB2SANEEZP15BRG electronic pressure regulator for high-precision proportional pressure control.
- PSR2PN precision pressure regulator to provide stable, conditioned air supply.
- DSTEX00ZP15BRGA electronic pressure transducer to provide continuous pressure feedback for closed-loop control.
The complete assembly was configured to interface directly with the customer's automation system, allowing pressure setpoints to be adjusted automatically throughout the production cycle. Real-time pressure feedback enabled continuous monitoring and rapid correction of any deviations, ensuring consistent actuator performance.
Results
Following installation, the customer achieved significant operational improvements:
- Improved repeatability of pneumatic actuator positioning and clamping force.
- Reduced product variation through precise pressure regulation.
- Faster production changeovers by allowing pressure profiles to be selected automatically via the PLC.
- Increased equipment reliability through the use of a pre-engineered, factory-tested assembly.
- Reduced maintenance time by eliminating manual pressure adjustments and simplifying fault diagnosis.
The integrated control package also provided greater process visibility, enabling production engineers to monitor system performance and optimise operating parameters over time.
Conclusion
The bespoke SG Controls pneumatic pressure control assembly provided a reliable and highly accurate solution for automated manufacturing. By combining Proportion-Air's precision pressure regulation technology with SG Controls' system integration expertise, the customer achieved improved process consistency, enhanced production efficiency, and reduced operational downtime.
The modular design allows the assembly to be readily adapted for a wide range of industrial applications where accurate electronic pressure control and repeatable pneumatic performance are critical.
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