Pneumatic drives remain widely used in industrial automation due to their simplicity and reliability, yet their overall energy efficiency is typically low. This study introduces an energy-efficient pneumatic drive concept that enhances braking control and enables compressed air recovery without modifying the actuator’s mechanical design. A transient one-dimensional mathematical model is developed to describe system dynamics and is combined with a particle swarm optimization (PSO) algorithm to determine optimal switching coordinates for the braking phase under constraints on piston motion and positioning accuracy. To assess the validity and limitations of simplified models, the optimized process is additionally investigated using a three-dimensional CFD model with moving mesh and valve control. The CFD model is validated experimentally using pressure measurements in the cylinder chambers. The results reveal that conventional isothermal 1D models underestimate transient pressure and energy parameters by up to 30–35% in systems with air recovery, highlighting the necessity of 3D analysis for accurate energy assessment. Optimization increases the duration of the recovery phase by a factor of 2.8 while maintaining cycle time and improving positioning accuracy. The resulting cycle energy efficiency reaches 53.4%, significantly exceeding typical industrial values. The proposed methodology provides a practical framework for designing energy-efficient pneumatic drives.
Rogovyi et al. (Fri,) studied this question.