For an automated assembly line, you need a screw compressor that holds a stable pressure all day, followed by dry, filtered air. For a line that uses 1 to 2 m³/min, a 4-in-1 compressor such as the K 110 (1.7 m³/min at 8 bar) or the K 150 (2.2 m³/min at 8 bar) supplies the air, the receiver, the dryer and the filtration in one machine.
Our page on compressors for industry and production describes the air installation of a whole site. Here we work out what an assembly line needs, station by station.
What uses air on a line
- Cylinders for transfer, clamping and pressing. Their consumption is worked out from bore, stroke and cycle rate: see how much air a pneumatic cylinder uses.
- Grippers, which are small cylinders.
- Vacuum generators for suction cups. They use air continuously for as long as they hold a part: this is often the item forgotten in the calculation.
- Air screwdrivers, which work in short cycles: see which compressor for 10 screwdriving stations.
- Blow-off for cleaning, ejection or drying, often open all the time: see the air consumption of a blow-off nozzle.
A worked example: an 8-station line
The values below are example assumptions. Replace them with those in your components' manuals or with a measurement on the line.
- Cylinders and grippers: 24 cylinders, 360 l/min in total at the line's cycle rate.
- Vacuum generators: 6 generators of 60 l/min, active for half the cycle: 6 × 60 × 0.5 = 180 l/min.
- Screwdrivers: 4 screwdrivers, 150 l/min in total given their screwing time.
- Blow-off: 2 nozzles open continuously, 100 l/min each: 200 l/min.
Total: 360 + 180 + 150 + 200 = 890 l/min.
A line runs without breaks: these figures are already averages over the cycle, so they are not reduced the way garage tools are. Then add the margins:
- Safety margin of 25%, which also covers small leaks: 890 × 1.25 = 1,112 l/min.
- Expansion margin of 20%, for one more station: 1,112 × 1.2 = about 1,335 l/min.
The K 110 delivers 1,700 l/min at 8 bar: it covers this need with headroom.
Which compressor for which line?
| Line | Recommended model |
|---|---|
| Need up to 1.7 m³/min, margins included | K 110, 11 kW 4-in-1 screw, 340 L receiver |
| Need up to 2.2 m³/min, margins included | K 150, 15 kW 4-in-1 screw, 2.2 m³/min at 8 bar |
| Dryer and receiver already on site | S 150, 15 kW standalone screw, 2.2 m³/min at 8 bar |
| Several lines | S 220 PM or a multi-machine installation, as an industrial project |
Our article 4-in-1 or standalone compressor helps you decide between the two.
Stable pressure rather than high pressure
On an automated line, a pressure that varies changes the speed of the cylinders, the force of the grippers and the hold of the suction cups. Cycle times drift, and faults appear with no visible cause.
- Set each machine with its own regulator, a little below the lowest pressure in the network. The machine then always sees the same pressure.
- Set the compressor just above, without excess. Every extra bar costs electricity: see how to calculate compressor pressure.
- Choose variable speed. The K and S series match their flow to demand and limit pressure swings.
Synchronised cycles and the buffer receiver
On a timed line, several stations can start their cycle at the same moment. Instant demand then exceeds the calculated average. A buffer receiver placed near the line absorbs these peaks and stops them dropping the pressure at the furthest station. The air receiver size calculator gives a starting volume.
Dry, filtered air
Water and particles wear cylinder seals, make valves stick and clog vacuum generators. A refrigerated dryer and filtration matched to the flow are the basis. The ISO 8573-1 air quality class is defined with our technicians, according to your components. For lubrication, follow each component maker's manual. If the air touches the product, the requirements of your sector apply: see also our article on fine filters.
List your stations in a quote request: we will check the line's flow and pressure with you.
For your trade: Compressor for industry and production.