Manufacturing automation helps improve speed, efficiency, and safety across assembly, sorting, material handling, and packaging. The use of pneumatic vacuum systems for automation provides a secure, damage-free way to safely move porous and non-porous materials at high speeds.
When designing and maintaining an automated pneumatic system, there is always the question of whether to use one larger vacuum generator for multiple cups (centralized) or a smaller generator for each cup (decentralized). In this blog, we break down centralized vs. decentralized vacuum systems and the considerations for selecting the best option for your material-handling application.
Centralized Vacuum Systems
Centralized vacuum systems feature a single pump or generator that powers multiple cups. Typically, the pump or generator remains stationary. The cups are grouped in clusters, which are connected to the pump using a network of tubes. The purpose of a centralized vacuum system for material handling is to perform a single action, such as lifting several products at once to place them in a bin.
Benefits:
- Typically easier and more cost-effective to install
- Less complicated operation and maintenance
- Requires less space and plumbing
- Can be used to lift large or heavy objects, like an automotive windshield
Considerations:
- More limited design flexibility
- If the pump or generator goes down, all of the cups stop working
Decentralized Vacuum Systems
In a decentralized vacuum system, one pump or generator operates each cup. This design allows the cups to act independently of one another. The biggest benefit of a decentralized system for manufacturing automation processes is that if one pump or cup fails to function, it does not affect the other pumps.
Benefits:
- Offers more flexibility as operational needs change
- Can be more complex to operate and maintain
- Requires additional plumbing and takes up more space
Considerations:
- Heavier design due to needing a pump or generator for each cup
- Not ideal for high-speed applications or systems that require end-of-arm tooling
Weigh the Material Handling Pros and Cons
Which option is “better” depends on your available space, the material weight, and budget. A centralized generator may cost less, but there’s a risk of the part dropping if one or more cups lose grip. Undersized vacuum tubing can also cause restriction, reducing your holding strength. A decentralized system will independently provide consistent vacuum levels at each cup.
Material characteristics, along with the transfer rate, conveying distance, and other system calculations must also be considered. A pneumatics expert can help you determine the best option and work with you to size vacuum components to your specifications.
If you have questions about pneumatic system design, our engineers are here to help! We have over 40 years of expertise helping customers discover innovative manufacturing automation solutions that increase production efficiency. Give our team a call to learn more!