In the manufacturing industry, choosing the right equipment for your operations is crucial. When it comes to orbital forming equipment, one of the key decisions manufacturers face is whether to opt for pneumatic or servo assembly equipment. While both have their advantages, understanding the true cost implications, including initial investment, long-term maintenance, and operational efficiency, is essential.
Comparing Initial Costs: Pneumatic vs Servo Systems
One of the primary reasons many manufacturers prefer pneumatic systems is the lower initial cost. Servo-driven machines, on the other hand, can cost anywhere from 25-40% more than pneumatic ones, depending on machine options, joint functional requirements, and plant utility requirements. While the initial investment for servo systems is higher, they offer a range of benefits that can offset this higher upfront cost over time.
Operational Costs: Understanding Air Consumption in Pneumatic vs Servo Systems
The cost of operating pneumatic systems can be significant due to air consumption. To calculate this, you need to consider the number of rivets or workpieces being formed, the air needed for each machine cycle, and the cost of the air. The formula for calculating the annual cost of air consumption is:
Annual Cost of Air Consumption = EAV × Air Consumption per Cycle × Cost of Compressed Air per Cubic Foot
Where EAV stands for the estimated annual volume of rivets or workpieces to be formed.
Below is the air consumption rates for different sizes of our machines.
125 Series: 0.009236 cubic feet per machine cycle
240 Series: 0.026696 cubic feet per machine cycle
310 Series: 0.040849 cubic feet per machine cycle
500 Series: 0.120233 cubic feet per machine cycle
750 Series: 0.162858 cubic feet per machine cycle
840 Series: 0.278567 cubic feet per machine cycle
For example, let's consider our Standard B-500 Orbital Bench-Top Riveter. This machine has an air consumption rate of 0.120233 cubic feet per cycle. With a conservative estimate of running a part every 6 seconds or 10 parts per minute (assuming only one rivet per part), the machine could potentially run 1,080,000 parts per year.
To calculate the annual air consumption:
1,080,000 parts/year × 0.120233 cubic feet/part = 129,851.64 cubic feet/year
The cost of compressed air can vary based on your provider, but using an estimate of about $0.015 per cubic foot, the annual air consumption cost would be:
129,851.47 cubic feet/year × $0.015 per cubic foot = $1,947.77 per year
This calculation illustrates that while pneumatic systems may seem cost-effective initially, the ongoing costs of air consumption can add up significantly. Additionally, maintaining air compressors and ensuring consistent air quality adds to these operational expenses.
On the other hand, servo systems eliminate the need for compressed air, thereby reducing these ongoing costs. Servo systems are also quieter and not subject to fluctuations in air pressure that can impact the performance of pneumatic machines.
Maintenance Costs: Longevity of Pneumatic vs Servo Systems
While both pneumatic and servo systems are designed for durability, maintenance requirements differ. Pneumatic systems necessitate regular attention to air compressors, filters, and seals, which can be prone to wear and damage from moisture in the air. Servo systems, however, avoid these issues, offering robust performance without the need for air-related maintenance.
Both systems share common maintenance needs such as routine cleaning and lubrication, and occasional replacement of bearings and spindles. Our equipment is built to be exceptionally robust, ensuring long operational life for both pneumatic and servo systems.
Performance and Precision: How Servo Outpaces Pneumatic
Servo systems provide significant advantages in terms of control and precision. These include:
Increased control of the forming process
Variable advance/retract rates
Reduced cycle time by minimizing retraction from part to part
Higher forming force capabilities without the need for hydraulic systems, thus avoiding complexity, noise, and leaks
Multiple form heights without the need for a separate servo axis
Enhanced control for measure-then-form applications, such as height-sensing pressure pads and pre-form rivet length checks
While pneumatic systems are valued for their simplicity and ease of use, servo systems offer superior performance capabilities that can lead to improved productivity and product quality.
Training and Control: Mastering the Complexity of Servo Systems
One important consideration when opting for servo systems is the need for additional training. Due to the increased number of controls and variables that can be adjusted, operators may require more training to fully utilize the capabilities of servo systems. Although this training represents an added cost, it is a worthwhile investment that can significantly enhance the performance and efficiency of your operations in the long run.
Pneumatic vs Servo: Making the Best Choice for Your Operations
Ultimately, the decision between pneumatic and servo assembly equipment depends on your specific needs and operational priorities. Pneumatic systems may be more cost-effective initially and simpler to operate, but servo systems provide greater control, efficiency, and long-term savings by eliminating costly air consumption and minimizing maintenance.
When evaluating your options, consider the total cost of ownership, including initial investment, operational costs, and maintenance requirements. By doing so, you can make an informed decision that aligns with your business goals and enhances your manufacturing processes. Contact us today to discuss your needs and determine what equipment is best suited for your assembly needs.