Mar 10, 2025
With the widespread application of industrial automation, smart manufacturing, and micro pneumatic systems, the demand for small-scale air circuit integration and airflow control is growing. More and more companies are choosing to implement refined, modular, and automated control for their equipment.
One of our clients, aiming to simplify their equipment structure, facilitate control, and improve production efficiency, decided to have us develop a customized manifold that includes functions such as flow control, air circuit on/off, and pressure regulation.
After thoroughly communicating with the client and confirming their requirements, our technical team quickly began the design process based on the gathered information and finalized an initial plan.
This manifold was made from aluminum alloy, which is lightweight and durable. Its surface was anodized to enhance durability, corrosion resistance, and aesthetic appeal.
Internally, the manifold was designed with multiple air channels. These channels were arranged in a way that connected different inlets and outlets to the solenoid valves. The purpose of this design is to precisely control the on/off and flow direction of the air, allowing for efficient adjustment and control of the pneumatic system.
During the design process, our technical team continually updated the drawings based on client feedback, making modifications to parameters such as hole placement, air circuit configuration, installation methods, and thread specifications.
We then quickly produced two complete samples, each consisting of a manifold, three coils, and three pilot guides. After testing, we promptly sent the samples to the client.
Upon testing, the client confirmed that all components were functioning well but raised two new issues:
1.The client requested that the internal air holes be enlarged to accommodate a higher air flow rate.
2.Although our existing coils worked well, the client's existing coil could not be replaced due to the different manifold assembly interfaces. The client wanted the ability to freely choose which coil to use, while keeping the hole positions identical to the original sample.
Our technical team quickly revised the drawings based on the client's requirements and provided feedback.
We enlarged all the air holes to over 1/8 inch and removed any burrs from the holes to prevent clogging.
To address the coil compatibility issue, we developed a new adapter. Its internal thread fits with the pilot guide, and the external thread fits with the manifold. The adapter also includes the appropriate sealing rings. By installing this adapter on the manifold, it allows compatibility with coils of different interfaces.
The adapter has two small holes that can be installed or removed using a circlip plier. Additionally, we added two sealing rings at the connection between the adapter and the manifold to ensure airtightness.
Furthermore, we cut a groove at the top of the original pilot guide to facilitate easier installation in the working environment.
After further simplifying the structure, we sent the revised samples to the client. After testing, the client confirmed that all accessories were functioning well and happily signed the first batch order.
In the second batch of products, we made additional improvements. First, we modified and simplified the adapter structure and added a hex design to make installation more convenient.
Secondly, based on the client's request, we replaced the standard NBR sealing rings with EPDM material, which is more suitable for high-temperature and outdoor environments.
With years of experience in the pneumatic field, Fokca specializes in customizing pneumatic components for customers. Our technical team, through a deep understanding of customer requirements and extensive expertise in the pneumatic industry, provides creative solutions and is dedicated to offering tailored products and solutions.
You can explore more of our customer cases. If you need further assistance, please feel free to contact us.
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