Production managers are faced with a dual task: they want to set up their plants flexibly and save energy at the same time. To achieve this, they are planning modular production cells, relying on autonomous mobile robots (AMR) and examining concepts for low-pressure areas. At the same time, they are coming up against an established infrastructure. Compressed air lines run through the hall. Every new system requires connections, every layout change causes effort.

Vacuum technology plays a central role in this environment. It grips, holds and moves workpieces in electronics production, logistics processes and the automotive industry. Traditionally, ejectors generate the vacuum with compressed air. This technology is well established and continues to form the backbone of many systems. However, new production concepts require additional systems.

This is exactly where electric vacuum generators come in. They work without central compressed air, a power connection is sufficient. An integrated electric motor drives a pump or blower. The system builds up the required vacuum directly at the point of use. The energy comes from the power grid or from the robot's vehicle battery. The vacuum is created directly at the end-of-arm tooling. This turns the gripping unit into a self-sufficient system and functions independently of stationary connection points.

This opens up new scope for AMR and AGV applications. The robots move through production without hose connections and do not require a fixed media supply. This approach also has an impact on cobots. As they often work in changing environments, every interface saved counts. Electric vacuum generators do not require external air preparation and therefore simplify integration and commissioning.

Factory planning without compressed air network

More and more companies are asking a fundamental question: where is compressed air no longer absolutely necessary? In individual production areas, and sometimes even in the entire plant, they are examining concepts that deliberately manage without this medium in order to use energy even more efficiently, reduce costs and achieve sustainability goals. Electric vacuum generators play a key role in such scenarios. They generate the required negative pressure directly at the place of use and do not require a central compressed air infrastructure. "Handling remains powerful and reliable, even if there is no pipe network," says Michael Pojtinger. There are also advantages in terms of factory planning, as production cells can be easily relocated if compressed air lines do not have to be re-routed. Electricity is generally available throughout the factory. This reduces planning costs and downtimes during conversions.

Michael Pojtinger, Head of Business Development Process Vacuum Automation (Components) at Schmalz. © Lard

"Depending on the application and load, electric vacuum generators save up to 95% energy compared to compressed air-powered ejectors," emphasizes Michael Pojtinger. "The actual savings depend on the number of cycles, load profile and operating time." The technical background: compressed air is generated centrally, processed and distributed via pipes. Each of these steps causes losses. Electrical systems efficiently convert electricity into negative pressure directly at the point of use. This allows users to reduce their operating costs and relieve the strain on the central infrastructure at the same time. Electric vacuum generators reduceCO2 emissions and thus the product carbon footprint (PCF), provided the electricity mix permits this.

Digital integration as part of the system architecture

Schmalz develops electric vacuum generators as part of a modular system architecture. The portfolio ranges from compact vacuum pumps for cobots and end-of-arm applications to high-performance electric pumps and vacuum blowers for stationary processes. The company thus covers different performance ranges and also offers components for the entire vacuum chain, from suction pads to sensors.

The electric vacuum generators record process statuses and make them available digitally. They can be integrated into networked production environments via IO-Link. This allows users to monitor the process and easily adjust parameters. "The vacuum component becomes a data-supplying field device. This creates the prerequisites for condition monitoring and condition-based maintenance," says Michael Pojtinger.

Vacuum generation in transition

Automation relies on dynamic, networked and modular structures. Electric vacuum generation fits into this picture. Schmalz has established corresponding solutions on the market and is constantly developing its portfolio in line with growing requirements.

Infrastructure-independent vacuum components do not replace existing pneumatic systems across the board. They expand the spectrum. Where compressed air becomes a limitation, they open up new degrees of freedom. "Production managers can use this additional option to consistently align automation with mobility, flexibility and digital transparency," explains Michael Pojtinger.