Air motors: powerful, compact and robust
Air motors offer decisive advantages over many other drive solutions. They provide high power density in very compact dimensions, are robust and are suitable for a wide range of industrial applications. However, one typical characteristic of conventional air motors repeatedly presents designers and users with challenges:
The actual speed depends on the load.
At no load, the motor reaches high speeds. As the load increases, the speed decreases accordingly. This can become problematic, especially in automated systems, robotic applications or machining processes. If the actual motor speed is unknown, changes in the process may go unnoticed. The consequences can include fluctuations in quality, tool wear, process disruptions or, in the worst case, damage to the machine and workpiece.
The solution: giving the air motor a “view” of its own speed
This is where our EU-patented technology comes in. A non-contact speed sensor integrated directly into the air motor continuously measures the actual motor speed. The measurement is contactless and therefore wear-free, robust and reliable. For the first time, this makes exactly the information available that is crucial for intelligent monitoring and control:
How fast is the motor actually running?
Setpoint and actual speed can be compared continuously. If the motor load changes, the airflow can be adjusted accordingly. This transforms the air motor from a purely pneumatic drive into a controlled and monitored drive system.
Constant speed even under changing loads
The desired motor speed is specified as a setpoint. The integrated sensor continuously feeds back the actual speed. A controlled regulating valve then supplies exactly the amount of air the motor requires for the respective operating condition. If, for example, the required torque increases, the air supply can be adjusted accordingly. If the load decreases again, the control system responds to that as well. In this way, the motor can maintain its specified speed even under changing loads, within its technically available power and torque range. This creates reproducible conditions, particularly wherever a defined speed is crucial to the process.
No proprietary control system required
A particularly important advantage of our technology is its open control architecture. Users are not necessarily tied to a special control system from us. Speed control can also be implemented on the customer side using a suitable standard PLC and integrated directly into the existing machine control system. The basic principle is simple: Specify setpoint speed → measure actual speed → evaluate deviation → regulate airflow. This allows machine builders and plant operators to integrate the control strategy themselves into their existing automation architecture. Alternatively, we can of course provide a control solution tailored to the application.
this flexibility is particularly attractive for special-purpose machinery, automation systems and robotic applications: The existing control platform can remain in place.
The next step: torque becomes process information
However, controlled speed is only one part of what is possible. The technology becomes particularly interesting when the motor load or torque is also taken into account. Because the required torque often reveals what is happening in the process. A simple example is an agitator. If the viscosity of the medium changes, the load on the agitator changes as well. This change can be detected through the behavior of the drive and used for process monitoring. Another example is machining tools. As tool wear increases, the required machining forces can change. The resulting change in motor load can provide indications of the tool's condition. The air motor therefore no longer provides mechanical power alone. At the same time, it becomes a source of information about the process.
This is where Industry 4.0 begins
For us, Industry 4.0 does not mean making a proven drive unnecessarily complicated. It means using existing components more intelligently and capturing relevant process information where it is generated. Continuous measurement of speed and load can generate data that can be used, for example, for process monitoring, quality assurance, condition monitoring, tool monitoring or predictive maintenance. Using the customer's PLC, this information can be linked with additional machine and process data and, depending on the system concept, passed on to higher-level systems. In this way, our technology brings together two worlds:
the simplicity and power density of a pneumatic drive with the capabilities of modern, data-driven production.
Today, an air motor can do more than just turn With our patented technology, we are systematically advancing a proven drive concept. The conventional air motor becomes a drive whose actual speed is known, whose speed can be actively controlled and whose operating data can provide valuable information about the process. And crucially: The technology can also be integrated into existing PLC and automation concepts. This creates new possibilities for machine builders, plant operators and automation engineers, ranging from simple speed monitoring to intelligent process analysis.
Patented technology meets Industry 4.0
Compact. Powerful. Speed-controlled. Monitorable. PLC-integrable. Do you have an application in which speed, torque or process monitoring plays a decisive role? Talk to our specialists. Together with you, we will assess how our patented air motor technology can be integrated into your application and your existing control system.