How do integrated vacuum generators achieve on-demand vacuum supply?
Publish Time: 2025-10-15
In modern high-speed automated production, the pace of material handling is accelerating, placing higher demands on the response speed, energy consumption control, and spatial layout of gripping systems. Traditional centralized vacuum systems rely on long pipes and large vacuum pumps, resulting in slow response, high energy consumption, and numerous leak points. Integrated vacuum generators, particularly compact devices with integrated suction and shut-off functions, are becoming an ideal solution for high-speed handling applications. Not only are they responsive and compact, but their intelligent design enables on-demand vacuum supply, significantly improving system efficiency and energy savings.
1. On-demand Vacuum Supply: From "Continuous Pumping" to "Precise Control"
Traditional vacuum systems typically use a central pump that operates continuously, maintaining negative pressure regardless of whether the suction cup is in contact with the workpiece, resulting in significant energy waste. Integrated vacuum generators, however, utilize built-in solenoid valves and control logic to achieve on-demand vacuum generation and release. When the robotic arm approaches the workpiece, the system triggers a vacuum generation command, rapidly generating negative pressure to complete the suction process. Once the workpiece is in place, the vacuum is immediately disconnected and the air blow function is activated to quickly release the workpiece. The entire process is activated only when needed, avoiding idle operation and truly achieving an energy-saving "pump when needed, shut down when not in use" mode.
2. High-Speed Response: Vacuum Establishment Completed within 20ms
The integrated vacuum generator utilizes the Venturi effect, generating negative pressure through a nozzle using compressed air. Its core advantage lies in its extremely fast response speed. Thanks to its compact internal flow channel design and highly sensitive solenoid valve, vacuum response time is as short as 20ms, and operating frequency exceeds 20Hz, meaning it can complete more than 20 pick-and-place cycles per second. This performance is perfectly suited for high-speed, high-speed sorting, labeling, and case packing applications, ensuring stable pick-and-place cycles of 0.5 seconds or less, significantly improving production line efficiency.
3. Integrated Pick-Off Function: Integrated Design Improves Control Precision
The "Pick-Off" function is key to achieving on-demand vacuum supply. Traditional systems require multiple external valves to control suction and blow-off, resulting in complex piping and prone to leaks. The integrated vacuum generator integrates three functions: vacuum generation, suction control, and blow-off release, into a single, compact module. When the release command is issued, the system not only shuts off the vacuum but also immediately delivers positive airflow to actively "blow" the workpiece off the suction cup, preventing delays in dropping or misalignment caused by residual vacuum. This integrated "suction-and-break" control ensures precise and reliable operation, making it particularly suitable for handling easily sticky materials such as thin paper, plastic film, and glass.
4. Compact Design: Space Saving and Optimized Layout
The integrated vacuum generator utilizes a miniaturized, modular design, resulting in a compact and lightweight design that can be installed directly at the end of a robot arm or near the gripper, eliminating the need for bulky vacuum pumps and long piping external to the device. This "near-source air supply" approach not only reduces pressure loss but also significantly saves installation space, making it particularly suitable for deployment in confined workstations or high-density production lines. Furthermore, the compact design reduces system inertia, improving the robot's movement flexibility and positioning accuracy.
5. Reduced Piping and Wiring: Simplified System, Improved Reliability
Traditional vacuum systems require numerous pipes and cables connecting the central pump and actuators, making installation complex and prone to failure. Integrated vacuum generators integrate the air and electrical circuits, typically requiring only one compressed air line and one control signal line to operate all functions. This significantly reduces the number of pipes and wiring, lowering installation costs and maintenance effort. It also reduces the risk of leaks and poor connections, improving overall system stability and maintainability.
6. Intelligent Control: Supports Energy Saving and Status Monitoring
The integrated vacuum generator also features energy-saving mode and status feedback. Built-in sensors monitor vacuum levels, leaks, and operating cycles in real time, enabling fault warnings and preventive maintenance. Select models support IO-Link communication, enabling seamless integration with PLCs for remote monitoring and parameter adjustment, further enhancing its intelligent capabilities.
With its integrated suction-and-discharge function, high-speed response, compact design, and intelligent control, the integrated vacuum generator truly delivers "vacuum on demand." It not only improves the efficiency and precision of the handling system, but also provides an efficient, reliable and sustainable vacuum solution for high-speed automated production lines by saving energy and consumption, simplifying wiring and saving space.
