This paper presents results from the project "Planning the efficient use of compressed air in the body construction" of the "Green Carbody Technologies" innovation alliance (www.greencarbody.de). The overall objective of the alliance is to achieve energy savings of around 30% across the entire body manufacture value chain. With this overriding objective in mind, the pneumatics used in the body construction were analysed. The energy efficiency of compressed air in the body construction is currently a key topic of discussion. Until now, however, there has been a lack of transparent data/measurements for the compressed air consumption of production plants in the body construction. This means that measures such as the omission of high-pressure systems when planning new systems, the removal of pneumatic drives for welding or even completely compressed air-free production are being considered and discussed without access to reliable information. Advantages such as the high power density, long service life and robustness of pneumatic drive technology are underestimated. The results of this project show the cost-effectiveness and energy efficiency of the pneumatics in the body construction. The measurements from production plants produced some surprising results. During the course of the analyses, consumption turned out to be lower than first assumed. The reasons for this include the clamping, gripper and welding technology used, which is characterised by short strokes and fewer movement cycles. For the planners of new systems, there is now transparent data available at body construction, cell and component level. The numerical values and statements have been compared with the experiences of various car manufacturers and verified. A welding point of a servo pneumatically driven C gun thus costs approx. 0.013 ct (air consumption of 7 l). A complete system with a throughput of 80 components per hour consumes approx. 50 to 200 m3/h (70 ct/h to 300 ct/h), depending on the size. The costs for the compressed air share, which is required from an energy perspective during the production of a car body, are approx. 6 euros (all sections including paint shop). The share of the body construction with extensive drive technology is approx. 3 euros. Around half is attributed to the high-pressure system, which accounts for an investment of approx. 350,000 to 500,000 euros for a new factory. Total cost analyses therefore show that even high-pressure systems are efficient - provided they are also maintained and used only for welding gun technology and are not used for purposes other than those for which they were intended. The replacement of pneumatic welding gun drives is not to be recommended: Yes - compressed air is an expensive energy source, if energy-saving technologies and heat recovery are not used. However, the pneumatics used in the body construction are ideal for use as drive technology if configured correctly. Other areas such as the paint shop and the issue of process/auxiliary air should be examined in greater detail. Irrespective of this, energy savings of 30% can be achieved. This is possible through measures such as shut-off systems, leakage elimination and energy monitoring systems. Unused potential lies in the efficient design of the generation, in particular the use of heat recovery and the correct configuration of the pneumatic drive technology. Many systems and components in the body construction are oversized. It is therefore important that planners and decision-makers have access to easy-to-use software tools, with which they can quickly evaluate the entire value chain from compressed air generation to application for parameter variations and cost analyses. This paper demonstrates one possible approach. Detailed results will be published in "Efficient use of compressed air in the body construction" planning guidelines in 2014/10/.


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