Smart Pneumatics - Opportunities for industry through intelligent pneumatics

Added value to boost your success

Intelligent pneumatics from AVENTICS - Internet of Things
  • Predictive maintenance through integrated diagnostics
  • Energy efficiency through effective use of compressed air
  • Operating comfort thanks to simple plug-and-run Application

Smart Pneumatics - Opportunities for industry through intelligent pneumatics

AVENTICS offers direct added value for your IoT concept, with smart components that integrate seamlessly into a digital environment thanks to on-board intelligence and compliance with all relevant communication standards. Our solutions focus on the flexible further use of the generated information. Local evaluation and storage in the component, in a local database, in a private or public cloud – all options are covered.

AVENTICS' pathway to the Internet of Things

Want to check the state of wear? Need information on energy efficiency? The new Smart Pneumatics Monitor will provide you with reliable answers. It sends status messages to defined employees and parent IT systems without detouring to the machine controller. This minimizes the risk of machine downtime and substantially lowers operating costs.

Together with our AES fieldbus solution, the Smart Pneumatics Monitor (SPM) IoT gateway analyzes existing sensor signals and uses the result to generate status information. To monitor the wear of a shock absorber, for example, the SPM breaks down the end switch signals to evaluate the cushioning sequence. Algorithms written by AVENTICS based on the company’s application experience analyze this data internally and send the  information either to defined people or to the parent MES or ERP systems via the OPC UA interface.

The SPM makes it easy for AVENTICS customers who are already using AV valves and the AES fieldbus system to take a further step towards implementing IoT solutions. Programming of the SPM can even be edited while the application is running, without any impact on communication to the controller.



SMART PNEUMATICS MONITOR (SPM) – the intelligent solution from AVENTICS

SPM basic equipment and connections
  • Local data collection and analysis independent of the controller 
  • Pre-installed analysis modules for condition monitoring and energy efficiency analyses 
  • Simple creation of individual analyses 
  • Support of IoT-relevant communication interfaces 
  • Open platform for extensive customization 

SPM basic equipment and connections

  • eSOM/3517 with TI AM3517 32-bit ARM Corte @600 MHz
  • Linux OS with VPN and firewall
  • Graphical user interface for parameterization and programming
  • Optional LTE modem (GSM, UMTS, HSPA)
  • 10/100 Mbps Ethernet LAN, 10/100/1000 Mbps Ethernet LAN, USB 2.0 host, DVI/HDMI, RS232/RS485 bundled to RS422, real-time clock
  • 12–24 V/DC power supply
  • Communication protocols: OPC UA Server, OPC UA Client, Modbus Master, Modbus Slave, MQTT, S7 RFC1006, cloud connectors: SPA, Microsoft Azure IoT

Smart Pneumatics Analyzer – Turning Data Into Information

Everyone talks about the Industrial Internet of Things or IIoT – but there are often problems in implementation. Getting started has never been easier – IIoT can now come to you. You can reach your goal quickly and easily with the Smart Pneumatics Analyzer (SPA) mobile unit. By digitalizing the pneumatic environment, the SPA provides you with options to directly experience the benefits and potential of IIoT applications on your own machine. You can simply connect the SPA to an existing machine via the compressed air supply and have an instant analysis option for key machine characteristics, such as compressed air consumption and possible leakages. The SPA contains a Smart Pneumatics Monitor (SPM) connected with IO module (DI, DO and AI), SIM slot for mobile data, Wi-Fi router, AS series air prep with integrated pressure sensors, and a tablet to visualize data.

There is a case for two application environments with AS2 (flow 7…1583 NL/min) and AS3 (flow 10…2500 NL/min) series air prep units. Ask AVENTICS to demonstrate one at your location – or purchase one of your own.

Application examples – Internet of Things

Examples of SPM application

The four SPM applications listed below are characteristic examples that illustrate this innovative IoT gateway's simple operation, its great flexibility and outstanding efficiency.

EXAMPLE 1: Maintenance monitor – determining wear

The shock absorber in this configuration had been replaced in regular routine intervals determined on the basis of past experience with the individual application – purely as a precautionary measure and not based on actual facts. The SPM now uses the cylinder sensor data to analyze the cushioning's timing characteristics.

Because cushioning time decreases over the service life of the shock absorber, it provides direct proof of its state of wear. As soon as a critical value is reached, an error message can be output to exchange the shock absorber before it fails.


EXAMPLE 2: Data management – counting switching cycles

A valve's state of wear is very difficult to determine from the outside but additional internal sensors would increase its size and add to costs. In contrast, the SPM is able to provide information on the expected service life of the valves – without incurring additional costs and effort. By measuring the valve's exact switching cycles it is possible to extrapolate the end of its typical service life. Preventive maintenance can then be carried out to avoid downtimes in critical applications.

Example 3: Energy efficiency – detecting leakages

Energy efficiency is a key economic factor. The SPM gives a clear indication of where and how compressed air consumption changes – and allows users to determine the location of possible leakages. Predictive diagnostics is one of the main arguments for efficient use of the SPM.

In this example:
Increase in consumption only when valve is actuated -> Anomaly/leakage on or downstream of valve.
Overall increase in consumption -> Anomaly/leakage in supply or upstream of valve

EXAMPLE 4: Optimized consumption – creating optimal compressed air Balance

Whether during initial configuration or to improve ongoing operation: An optimum compressed air level saves money and prevents wear on the components. An SPM analysis helps you to determine the optimal operating point for a perfect balanceof the work to be carried out and the supplied energy.

In this example:

The preset pilot pressure is reduced gradually and the impact on compressed air consumption and cycle time is monitored to determine the operating point where the cycle time can be maintained with the least energy consumption.

Useful links

Additional information on the Internet of Things

The industrial revolution has just begun. Accordingly, it is important to understand current developments and know the course of politics and the economy will take for future success. Our collection of links connects you to topics and trends in official discussion and makes sure you can give your input whenever the Internet of Things is the subject of conversation.

Internet of Things platform

The official website on the topic with an abundance of helpful background information and an up-tp-date blog.

Internet of Things platform

Federal Ministry for Economic Affairs and Energy

Topic page on the strategy and challenges of the Internet of Things.

Federal Ministry for Economic Affairs and Energy


Industry association topic portal with publications and information on dates and committees on the Internet of Things.



Online forum from the VDMA industry association with a collection of topics and next step suggestions for aspects of the Internet of Things.

VDMA forum


The OPC Unified Architecture (UA), released in 2008, is a platform independent service-oriented architecture that integrates all the functionality of the individual OPC Classic specifications into one extensible framework.

The OPC Unified Architecture


Node-RED is a programming tool for the networking of hardware devices, APIs and online services in a new and interesting way.


Product examples – intelligent pneumatics

Proximity sensor, ST4-2P series

Proximity sensor, ST4-2P series

One sensor, one 4-mm cylinder slot, two switching points – the formula for the ST4-2P series’ success for precise solutions in the tightest of spaces. The sensors are simple to assemble, easy to program, and measure two switching points in a range of 50 mm.

Electronic pressure sensor, PE5 series

Electronic pressure sensor, PE5 series

Ultra-sensitive, reliable, simple handling thanks to intuitive menu navigation and a large display in red or green: PE5 series electronic pressure sensors can be used in a wide range of applications with their increased protection classes IP65 and IP67.

AV valve system with AES fieldbus system

AV valve system with AES fieldbus system

The AV system offers high performance through a wide range of electrical and pneumatic connection options. It can easily be adapted to the requirements of any safety-related pneumatic control. The long service life guarantees long operating times in safety-related controls without failures or the need for maintenance.

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