Flexible workhorse

Complex transfer and pick-and-place applications for workpieces with different surfaces are an industry-wide challenge. Controlling the tools used requires valves and vacuum ejectors. SMC has developed a flexible, energy-efficient, and process-reliable solution with the ZKJ series, which has now been further expanded to include a variety of communication protocols.

The fieldbus-compatible vacuum unit combines up to 16 ejectors and 5-way solenoid valves in a single manifold, creating an integrated system for simplified machine design and control. The series also boasts IP65 protection, an energy-saving function combined with high performance, a pressure- and de-energized open supply valve for high process reliability, and is compatible with various fieldbus protocols for comprehensive (remote) control and diagnostics.

From transfer and conveyor systems to automatic assembly machines and packaging and unpacking: Applications requiring both overpressure and vacuum units lead to complex designs when controlled separately. As a result, operating, energy, and maintenance costs also increase. With the ZKJ series, SMC offers an established vacuum unit for fieldbus systems, which has now been further developed and improved. Among other things, communication is possible via the fieldbus protocols Profinet, EtherCAT, EtherNet/IPÔ, and IO-Link, and the vacuum unit's air consumption is reduced by up to 92 percent thanks to the energy-saving ejector. Users continue to benefit from the modular design, which allows them to not only supply up to 16 ejectors with power and compressed air centrally, but also to create different vacuum circuits. High process reliability is ensured by the IP65 protection rating, an easily replaceable filter element, and a normally open supply valve that maintains the vacuum level and thus protects workpieces from falling. Compact, versatile, and economical

Instead of controlling multiple individual valves and ejectors, the ZKJ series accommodates 4, 8, 12, or up to 16 stations on a single unit, depending on requirements, and can be centrally connected to create different vacuum circuits. This significantly reduces the amount of cabling and piping required, while also reducing space and weight. While the overpressure units, consisting of 5/2-way solenoid valves, supply compressed air at up to 415 l/min, the fieldbus module with built-in pressure sensor provides vacuum and, thanks to its energy-saving function, reduces air consumption by up to 92%. This is achieved by a built-in check valve that maintains the vacuum pressure for workpieces with minimal air consumption. The fieldbus module automatically shuts off the supply valve as soon as the vacuum reaches the setpoint – and switches it back on when needed to maintain the absorption state. This significantly reduces air consumption.

Because the vacuum port is located above the exhaust port, filter element replacement is also easier and maintenance-related downtime is reduced. Overall, users benefit from significant savings combined with high performance and extensive flexibility.

First-class communication for complete control and transparency

Thanks to compatibility with the Profinet, EtherCAT, EtherNet/IP, and IO-Link fieldbus protocols, advanced communication for comprehensive (remote) control and diagnostics in the Industry 4.0 environment is possible – without the need for separate input and output units. This allows vacuum pressure, pressure values ​​of individual ejectors, suction power, and energy-saving functions to be monitored remotely, improving and accelerating the control and monitoring of applications.

A single M12 connector for wiring reduces the connection effort. At the same time, the ZKJ series also meets IP65 protection class, allowing use in environments exposed to dust and jet water. Additional process reliability is provided by the pressure-free supply valve, which maintains the vacuum even when the power supply is interrupted, thus preventing workpieces from falling out.
Industry-wide strong position and excellent networking

Flexible communication via four different fieldbus protocols, the modular design, a maximum vacuum of -89 kPa, flow rates of up to 415 l/min for the solenoid valves, various nozzle diameters of 0.7 / 1.0 / 1.2 / 1.5 mm, and the IP65 protection rating make the ZKJ series the ideal partner in numerous industries: from automotive and general mechanical engineering to the packaging, beverage and food industries, as well as the pharmaceutical and medical sectors.