In an industrial process plant, a compact and clearly structured pneumatic solution was required to control multiple actuators. The goal was a robust, maintenance-friendly, and clearly documented installation in the control cabinet. The implementation was carried out using modular valve manifolds and centralized compressed air preparation.
At a glance
- Industry: Plant engineering
- Application: Pneumatic control of a process plant
- Medium / Process: Compressed air, control and switching processes
- Challenge: Structured integration of many valve functions within limited installation space
- STASTO solution: Modular valve islands with central air preparation and clear hose routing
- Result: High operational reliability and a clear, maintenance-friendly design
The challenge
In the system under consideration, numerous pneumatic functions had to be consolidated within a control cabinet. The control system comprised several actuators with different switching requirements that must be controlled reliably and reproducibly.
In addition to functional integration, the mechanical and organizational structure played a central role. The challenge was to achieve a high packing density without restricting accessibility for maintenance and commissioning. At the same time, clean hose routing, unambiguous labeling, and a clear separation of power and control lines had to be ensured.
Standard solutions with decentralized individual valves would have resulted in increased wiring and installation effort as well as a confusing installation.
The STASTO solution
Compact valve manifolds with electrically actuated individual valves were used; they feature a modular design and were integrated directly onto mounting rails in the control cabinet. The valve technology enables centralized bundling of all switching functions while simultaneously reducing installation effort.
The compressed air preparation was implemented using a combined service unit with filter, pressure regulator and pressure gauge. This ensures a stable and defined supply for the entire valve structure.
The hose routing was implemented with a consistently structured approach and a clear separation of the individual functional groups. Manifold strips enable clean distribution of compressed air to the respective outlets. Electrical connections were implemented in a compact design using plug-in systems, which facilitates commissioning and simplifies troubleshooting.
The solution was implemented in close coordination with the plant engineering company, particularly with regard to installation space, accessibility, and interfaces to higher-level control systems.
The result
The implemented pneumatic solution is characterized by high operational reliability and a clear structure in the control cabinet. The centralized valve technology reduces complexity and significantly improves clarity.
Thanks to its modular design, the system is easy to maintain and can be easily expanded or adapted as needed. The defined compressed air preparation contributes to stable continuous operation and minimizes disruptions.
There is also an organizational advantage: clear labeling and a structured arrangement make service, documentation, and later modifications easier.
Added value for machine builders
- Reduced installation and wiring effort
- Compact integration of many functions in a confined space
- Clear structuring in the control cabinet
- Simplified commissioning and troubleshooting
- Excellent expandability thanks to the modular design
- High process reliability thanks to a stable compressed air supply
This solution is particularly suitable for
- Process plants with numerous pneumatic switching functions
- Machines with centralized control cabinet pneumatics
- Systems with limited installation space
- Applications with high requirements for ease of maintenance
- Automated systems with structured media distribution
Contact
We develop technical solutions for structured pneumatic systems in plant engineering together with you, based on your requirements.
Talk to our experts – we will be happy to advise you.