Supplement: Power
More electric drives, less pneumatics: What does this mean for the power supply?
By Maximilian Hülsebusch, global product marketing & communications manager, PULS GmbH T
he shift from pneumatic to electric drives is a well-known development in the industry. However, in recent years, this topic has gained significant
momentum. This is due to the continuously increasing cost pressure and the ever- stricter requirements for CO2 reductions. In both areas, the advantages of electric solutions prevail. This article illustrates, using the example of OEMs in the automotive industry, how smart industrial power supplies support the transition from pneumatic to electric drives.
Electric and pneumatic drives each have their advantages and disadvantages. Pneumatic drives are inexpensive to purchase, easy to operate, offer high overload resistance, and are robust against environmental conditions such as temperature fluctuations and increased dust exposure. However, pneumatic drives require a central, continuous compressed air generation, which involves significant effort. It is necessary to distribute and maintain a consistent pressure throughout the entire factory. If there is a loss of compressed air due to a leak in the system, it must be quickly identified and repaired, which entails high maintenance efforts. Especially in applications with many switching cycles, the high energy losses due to poor efficiency are significant during operation. Even in modern compressed air systems, the majority of energy is lost as waste heat. Additionally, the compressed air system must always be ready for use and therefore in operation, which results in high energy consumption. This leads to generally high operating costs and CO2 emissions.
28 May 2025
Electric drives combined with servo motors offer better energy efficiency and enable high speed and precision. Thanks to integrated microprocessors, most electric components have a bigger range of functions and allow access to application data in connection with a central monitoring system. Operating costs are generally lower, and the CO2 footprint can be sustainably reduced. Additionally, electricity can be easily distributed in the factory – almost without losses. The ability to convert and store electricity is another advantage. New technologies, such as wireless energy transmission, also come into play. Electric solutions are also significantly quieter, which reduces noise
Components in Electronics
pollution for the workforce. However, electric drives are more expensive to purchase. Additionally, the systems are more complex compared to pneumatic solutions and may require retrofitting existing equipment. OEMs are generally cautious about changes to proven systems. But the economic, political, and social pressure regarding energy efficiency is prompting more and more manufacturers to opt for the purely electric route. Therefore, new industrial plants often omit the installation of a pneumatic system right from the start. As is often the case, the automotive industry and its suppliers are taking a pioneering role in this regard.
The numerous projects to switch from pneumatics to electricity that PULS has accompanied in this segment had one thing in common: the right power supply system is crucial for success.
Decentralised power supply of conveyor systems
In the automotive industry, everything from large body parts and heavy engines to components from the small parts warehouse is transported via kilometre- long conveyor belts and driverless transport systems. In the BMW plant in Regensburg, Germany the assembly lines alone have a total length of 5.5 km. When the stoppers, diverters, as well
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