Servopneumatics

Mechatronic Motion Solutions

2

Mechatronic Motion Solutions

from Festo is a worldwide

unique system which comprises

components, modules and soft-

ware. It combines all types of

pneumatic, servopneumatic and

(electro)mechanical motion,

geared to your task. Irrespective

of the control system you use,

Mechatronic Motion Solutions

provides the appropriate inter-

faces.

Mechatronic

Guarantees mechanical and elec-

trical compatibility at all levels.

All pneumatic and electric drives

are equipped with suitable inter-

faces for mechanical, data and

energy transmission, thus ensur-

ing that different technologies

can be combined in one system.

It also enables complex handling

and positioning systems to be

set up easily and safely.

Motion

Stands for the comprehensive,

multi-dimensional portfolio of

linear and rotary drives as well

as a large variety of mechanical

and vacuum grippers. They pro-

vide a host of benefits, such as

high speed, precision, etc.

Solutions

Represents the decades of expe-

rience Festo has in the field of

handling technology, across all

industries and continents, as

well as its expertise in the devel-

opment of components and

sophisticated systems. They

range from pre-designed and

calculated components to sub-

systems and complete systems,

making them the logical answer

to the demand for pre-installed

and customised systems and

solutions.

Products for servopneumatic systems

3

Note:

For additional information

on our products, visit our

website at

www.festo.com

The Festo product range, from

controllers to drives, makes it

extremely easy to implement

servopneumatic systems. It is

also perfect for integration into

the CPX environment with uni-

versal fieldbus connection.

One of the latest intelligent CPX terminal modules:

the positioning module CMAX. With this module,

you can use a wide range of drives such as DGCI,

DNCI and DSMI, as well as control their position

and force.

More information on page 9

Application examples on pages 16–19

Brings drives to the right position gently and quickly

and then accelerates even more quickly: the elec-

tronic end-position controller CMPX. It is also new

in the CPX terminal and protects the drive and han-

dling unit through gentle pneumatic braking.

More information on page 10

Application examples on pages 16–19

The proportional directional control valve VPWP

with integrated pressure sensors doesn’t just give

you the best control results; in addition to the sen-

sor data, it also sends diagnostic data to the CMAX

and CMPX.

More information on page 11

Drives with displacement encoder DGCI, DNCI or

DSMI: drives with linear or rotary motion that also

give you the advantages of pneumatics. They offer

dynamic response, force and versatility – all with

a positioning accuracy of ± 0.2 mm!

More information on pages 12–15

4

Good reasons to choose servopneumatics

As the global market leader for

servopneumatic systems, Festo

now presents the third genera-

tion of servopneumatic drive sys-

tems. This includes groundbreak-

ing innovations such as the pro-

portional directional control valve

VPWP, which will open up new

fields of application and make

familiar solutions even simpler

and more stylish.

Perfectly matched

It goes without saying that the

individual Festo servopneumatic

components are perfectly

matched to each other, whether

they are used as stand-alone

units or together with pneumatic

or electric components. This

makes Festo servopneumatics

an important part of the mecha-

tronics kit.

Versatile positioning of

large loads

• Maximum power density in

automation – dynamic

response, force and versatility

are guaranteed with servop-

neumatics based on controlled

pneumatics.

• Position control or force cont -

rol? Why not both? Also with

positioning accuracy of up to ±

0.2 mm or 5% of the force set-

point value for a wide range

of drives.

Commissioning at the push of

a button

• The integration of the position

controller CMAX and the elec-

tronic end-position controller

Soft Stop CMPX into the modu-

lar electrical terminal CPX

reduces the time and effort

you spend on installation, con-

figuration and commissioning.

Electrical terminal CPX

with positioning module CMAX

Proportional valve

VPWP

Pneumatic linear drive

with integrated displacement

encoder DGCI

This means that you can always

be sure that you’re using the best

possible technology.

Servopneumatics is recommend-

ed whenever the following crite-

ria and advantages are important

to you:

When is it right to use servop-

neumatics? Your application

decides!

Pneumatic, servopneumatic,

electrical or in combination? The

decision is yours. Our expert con-

sultants give you the freedom of

choice, as Festo can provide you

with all three technologies.

If you ...

• ... prefer sturdy, compact,

low-cost solutions

• … want a repetition accuracy in

the tenth-of-a-millimetre range

• … want to reduce air consump-

tion by up to 30% in compari-

son to standard pneumatics

• … do not require maximum

precision and speeds as priori-

ties but are looking for cost

advantages of up to 50% com-

pared to electrical solutions

and for combining positioning

and force control to enable

new approaches to problem

solving.

• … place great value on the use

of diagnostics to optimise

machine availability and

reduce downtime. Each device

in the control circuit supplies

differentiated diagnostic data.

• … already have compressed air

available.

5

Coordinating level

Control level

Field level

Se

rvo

pn

eu

ma

tic

Ele

ctri

c

Control system

Controller

Actuation

Drives

Coordinating system

Proportionalvalve VPWP

DNCI DGCI

End-position controller CMPX

Linear drives with displacement encoder

Sensor interfaceCASM

Position controller CMAX

Front unit Grippers Vacuum

IntegratedcontrollerFED-CEC

Integrated controller CECX

PLC (ABB, Allen-Bradley,Rockwell, Siemensetc.)

Pn

eu

ma

tic

6

The entire world of servopneumatics at a glance The range of servopneumatic

products in the modular mecha-

tronic system leaves nothing to

be desired.

End-positioncontroller SPC11

Axis controllerSPC200

Axis interfaceSPC-AIF

Proportional valvesMPYE

DSMI-B

Swivel modules withdisplacement encoder

Eth

ern

et

Fie

ldb

us

AS

-in

terf

ace

Rotary drives Vision systems

FHPP

Festo Handling and

Positioning Profile

CoDeSys

provided by Festo

FST 4

Festo Software Tool

FCT

Festo

Configuration

Tool

PositioningDrives

Design and calcula-

tion software for

electric drives

Axis interfaceCPX-CMMX

RoboticcontrollerCMXR

CPX-CEC

7

Ethernet

(Profinet

Ethernet/IP

EtherCat

TCP)

Fieldbus

(Profibus,

Interbus,

DeviceNet,

CANopen,

CC-Link)

8

Excellence in servopneumatics through innovative products

Maximum power density with

innovative servopneumatics

As the leading provider of

automation technology, Festo

sets high standards for itself,

especially when it comes to the

product portfolio. That’s why our

research and development

experts have been able to con-

sistently expand our range of

servopneumatic components

over the past few years. Three

factors in particular are evidence

of this:

• The most powerful, reliable

and energy-efficient servo-

pneumatics on the market

• Complete range of servopneu-

matic products: turning, grip-

ping, linear motion, control –

all from a single source

• Reasonable prices not just for

the products themselves, but

also when the overall life cycle

costs are taken into account

The following pages contain

more details about our range

of servopneumatic products.

9

Servopneumatic positioning module CPX-CMAX-C1-1

One of a kind: The new position-

ing module CMAX is one of a

kind. It is designed for simple

servopneumatic control of vari-

ous pneumatic drive families,

linear or rotational.The CMAX is

a positioning and force control

module of the electrical

terminal CPX.

Multi-purpose

Positioning technology using

servopneumatics is particularly

useful when compact, low-cost

solutions are required for mov-

ing loads typically in excess of

5 kg and accuracy within a few

tenths of a millimetre is suffi-

cient.

Benefits

• Positioning and force control in

one work step

• Compact, low-cost positioning

system for sturdy applications

• Fast processes/high productiv-

ity thanks to the FCT software

tool for simple commissioning

with auto-identification and

comprehensive diagnostics

Activation via control block CPX-

CEC-C1 and all fieldbuses avail-

able in CPX.

Technical data

Moving loads horizontal [kg] 1-300

vertical [kg] 1-100

Regulated force at 6 bar [N] 30-2700

Positioning accuracy [mm] ≥ ±0.2

Travel speed [m/s] Max. 3

Acceleration [m/s2] Max. 30

Modbus TCP

With CMPX, the unique Smart

Soft Stop principle is finding its

own way into the world of the

modular electrical terminal CPX.

The electronic end-position con-

trol enables a cycle time reduc-

tion of about 30%, with virtually

vibration-free travel to the

mechanical end positions.

Smart Soft Stop enables highly

dynamic movement of loads up

to 300 kg.

Benefits

• Approx. 30% shorter travel

times and 30% less air con-

sumption than equivalent

standard pneumatic solutions

• Increased cylinder service life

• No vibrations when returning

to the end positions

• Suitable for use with all field-

buses/Ethernet and CEC avail-

able in CPX

• Easy commissioning, Festo

plug and work®

New functions

• Digital data handling

• Pressure sensors provide

reliable downtime control

• Two mid-positions can be

flexibly adjusted using the

fieldbus

• Brake output on proportional

valve VPWP

10

Electronic end-position controller Soft Stop CPX-CMPX-C-1-H1

Key features

Moving loads 1 ... 300 kg horizontal

1 ... 100 kg vertical

Actuation Via all fieldbuses available in CPX

Front End Controller FEC and CEC-C1

Mid-positions Up to two freely programmable mid-positions,

also via the fieldbus

Accuracy ± 0.25 % of the displacement encoder

length, and no less than ± 2 mm

Downtime monitoring via pressure sensors

in the valve

Reliable in combination with the “brake”

function

Max. line length between the controller and the drive: 30 m

Fast, vibration-free travel between two fixed stops

Teamwork for maximum servop-

neumatic productivity: the pro-

portional directional control

valve VPWP with integrated, dig-

ital, serial interface for the ser-

vopneumatic positioning system

CPX-CMAX and end-position

controller CPX-CPMX Soft Stop.

With the proportional directional

control valve, the force control

function is now also available for

the position controller CMAX.

Integrated pressure sensors con-

stantly monitor the pressure in

the chambers of the con nected

drive and give you an edge in

diagnostics and condition moni-

toring, as the fully

digitised valves supply the con-

troller not only with the sensor

data, but also with valuable

diagnostic values regarding their

own operating status. Total

process reliability!

Multi-sensor control

Integrated pressure sensors and

cascade control for optimum,

high-precision control results

and sturdy characteristics. Opti-

mum positioning characteristics

with speed and acceleration

ramps.

Additional function

Digital switching output for

controlling

• A shut-off valve or

• A switching valve for a clamp-

ing unit

Further advantages

• Durable: adaptive “self-

tuning” control algorithm

• Quicker to install: plug and

work with auto-identification

• More productive: comprehen-

sive diagnostic capabilities

11

Proportional directional control valve VPWP for servopneumatics

The design of the displacement

encoder differs depending on

its function, use and location.

Measuring absolute values,

incremental and contactless or

potentiometric (e.g. for retro-

fitting) – each option has its

own strengths.

Linear motion

Rodless drive DGCI with recircu-

lating ball bearing guide and

contactless displacement

encoder for measuring absolute

values.

Advantage: the drive can be

directly connected to CMAX or

CPX without an extra interface,

providing plug and work with

auto-identification.

12

Design options

Compressed air

VPWP

DGCI

CPX terminal

CPX terminalLinear motion

Standard cylinder DNCI to ISO

15552 with contactless dis-

placement encoder and addi-

tional sensor interface CASM.

As a signal converter, the sensor

interface CASM establishes the

connection between the incre-

mental displace ment encoder

with potentiometer and

the proportional valve VPWP.

This digitised bus transmission

is very secure.

Compressed air

VPWP

CASM

CMAX or CMPX

CMAX or CMPX

DNCI

Linear motion

Standard cylinder DNC to ISO

15552 with external displace -

ment encoder/potentiometer.

One design for all standard

cylinders.

13

CPX terminal

e.g. MLO-POT-...-LWG

Compressed air

CASM

CASM

DSMI

Rotary motion

Semi-rotary drive DSMI and sen-

sor interface CASM.

VPWP

Compressed air

CPX terminal

CMAX or CMPX

CMAX or CMPX

VPWP

e.g. DNC

With the combination of high-

power drives and an integrated

displacement encoder, it is pos-

sible to use the dynamic

response, force and flexibility of

pneumatics for many positioning

tasks with a positioning accura-

cy of up to 0.2 mm. Linear and

rotary motion is possible – ser-

vopneumatics can be used to

actuate a great variety of pneu-

matic drives.

Advantages built in:

integrated displacement

encoder

• Compact and flexible, with no

inconvenient external attach-

ments

• Long service life thanks to the

wear-resistant contactless dis-

placement encoder

• Simple installation and assem-

bly thanks to mounting acces-

sories from the corresponding

cylinder module.

14

Drives and displacement encoders

Standard cylinder DNCI

Technical data

• Diameter: 32, 40, 50 and 63 mm

• Stroke length: 10 ... 750 ... 2000 mm

• Max. force: 430 ... 1680 N

• Suitable for CMAX, CMPX and as a measurement

cylinder

Key features

• With contactless displacement encoder for

incremental measurement

• Wide range of piston rod variants

• Standard cylinder to ISO 15552

• Optimum performance with guide and

clamping unit

Linear drive DGCI

Technical data

• Diameter: 18 … 63 mm

• Stroke length: 100 … 2000 mm

• Max. force: 120 ... 1680 N

• Suitable for CMAX and CMPX

Key features

• With guide

• With contactless displacement encoder for

absolute measurement

• Based on linear drive DGC

• Supply ports optionally on end face or front

• Wide range of options for mounting on

drive units

• System product for handling and assembly

technology

15

Semi-rotary drive DSMI

Technical data

• Diameter: 25, 40 and 63 mm

• Swivel angle: 0 ... 270° swivel angle

• Mass moment of inertia up to 6000 kg/cm²

• Suitable for CMAX and CMPX

Key features

• Based on swivel module DSM

• Built-in rotary encoder

• Compact design

• Wide choice of mounting options

Displacement encoder MLO

Technical data

• Stroke: profile 225 ... 2,000 mm,

connecting rod 100 ... 750 mm

• Measuring principle: potentiometric,

contacting and measuring absolute values

• Suitable for CMAX and CMPX

Key features

• Function: analogue

• System product for positioning applications

and Smart Soft Stop (SPC10/SPC11)

• Version: profile or connecting rod

• Low-cost

• Ideal for retrofitting

The task

Wooden planks of different

thicknesses are sawn into slats

of different widths using high-

speed saws. During the sawing

process, each plank is pressed

down by three rollers (m = 80 kg)

and moves at 3 m/s. The contact

pressure can be adjusted

according to the type of wood.

Once the plank has gone

through the machine, the con-

tact rollers must return to their

initial position without coming

into contact with the conveyor.

The data for the plank that is

being fed into the machine are

transmitted to the system by

the fieldbus.

The solution

A proportional directional con-

trol valve VPWP-6 on each stan-

dard cylinder DNCI-100-100 con-

trols the movement of the con-

tact rollers. The core of the con-

trol unit is made up of a CPX ter-

minal with a local CPX-FEC, a

Profibus interface, three CMAX

modules and an I/O module.

New for CMAX: the combinable

record switch unit. This ensures

reliable switching through differ-

ent operating statuses. The unit

switches between position con-

trol and force control on an

event-controlled basis.

The CPX-FEC controls the CMAX

modules via I/O and fieldbus.

The advantages

• The stand-alone solution

independently controls the

pressing process

• Fast and flexible

• A system for position and

force control, freely program-

mable

• Safety functions integrated

into the system: emergency

off and “Board fed in” signal

for locking the system

• Clear error diagnostics

16

Pressing unit for sawing wooden planks

17

Areas of application

The full potential of servo -

pneumatics comes to the fore

in the following fields:

• Production engineering,

e.g. flexible and controlled

pressing of workpieces with

a defined force

• Packaging technology, e.g.

repositioning goods from a

conveyor belt to a packag-

ing unit

• Conveying technology, e.g.

in pushing and sorting

functions

• Dosing technology, e.g. in

volume filler systems

• Test engineering, e.g. for

positioning the test

equipment

18

The task

The bags must be filled with 50

to 150 ml in just a few seconds.

The outlet port of the dosing

valve must be flexibly adjustable

between 0 and 100%. A preci-

sion of ±0.5 mm is sufficient for

this task. Another important

requirment is that the filling

liquid must not be heated up

by the drive.

The solution

Four standard cylinders, each

with a valve VPWP, control the

filling process. A CPX terminal

with a Profibus interface and

four CMAX modules controls the

four axes. The positioning stroke

of the cylinder is set via the

fieldbus, independently of the

volumes to be filled.

In order to protect the cylinders

against the cleaning agents,

each one is individually encap-

sulated. The valve terminals and

proportional valves are mounted

in areas of the machine that are

shielded from splash-water.

The advantages

• Flexible dosing of a wide range

of media

• High cycle rate

• Each filling cylinder can be

controlled individually

• Compact design

• Uses the existing CPX terminal

• Great value solution

• No temperature rise

• Can be controlled directly via

the PLC

• No programming required

Filling in a matter of seconds

19

Safety – Your requirements in focus

Note:

You can find more details in

our safety brochure, available

in PDF format from the down-

load area

www.festo.com

The aim of the risk assessment

is, amongst other things, to

determine the hazardous situa-

tion and then estimate the risks.

This applies to the entire life

cycle of a machine.

For operation, this is generally

split into four modes:

• Basic setting/rest

• Normal operation

• Set-up and service operation

• Emergency operation

The necessary safety functions

can be derived from these oper-

ating modes:

An example: Reversing at

reduced speed and with dual-

channel protection against

unexpected restarting.

Tamper-proof, preven tion

of unexpected start-up

Stopping, holding

or blocking a

movement

Reversing a

movement

Reducing speed Switching to unpowered

Exhausting Pressure and force

reduction

Maintaining pres-

sure

Pressurising

13

50

04

en

20

10

/04

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PhilippinesFesto Inc.KM 18, West Service RoadSouth Superhighway1700 Paranaque City, Metro ManilaTel. ++63 (0)2/776 68 88, Fax 823 42 19 E-mail: info_ph@festo.com

PolandFesto Sp. z o.o.Janki k/Warszawy, ul. Mszczonowska 705090 RaszynTel. ++48 (0)22/711 41 00, Fax 711 41 02 E-mail: info_pl@festo.com

RomaniaFesto S.R.L.St. Constantin 17010217 BucurestiTel. ++40 (0)21/310 29 83, Fax 310 24 09 E-mail: info_ro@festo.com

RussiaOOO Festo-RFMichurinskiy prosp., 49119607 MoskowTel. +7 495/737 34 00, Fax 737 34 01 E-mail: info_ru@festo.com

SingaporeFesto Pte. Ltd.6 Kian Teck WaySingapore 628754Tel. ++65/62 64 01 52, Fax 62 61 10 26 E-mail: info@sg.festo.com

SlovakiaFesto spol. s r.o.Gavlovicová ul. 183103 Bratislava 3Tel. ++421 (0)2/49 10 49 10, Fax 49 10 49 11 E-mail: info_sk@festo.com

SloveniaFesto d.o.o. Ljubljana

IC Trzin, Blatnica 8

1236 Trzin

Tel. ++386 (0)1/530 21 00, Fax 530 21 25

E-mail: info_si@festo.com

South AfricaFesto (Pty) Ltd.

22-26 Electron Avenue, P.O. Box 255

Isando 1600

Tel. ++27 (0)11/971 55 00, Fax 974 21 57

E-mail: info_za@festo.com

SpainFesto Pneumatic, S.A.U.

Avenida Granvia, 159

Distrito Económico Granvia L'H

08908 Hospitalet de Llobregat, Barcelona

Tel. 901243660, Fax 902243660

Tel. ++ 3493/261 64 00, Fax 261 64 20

E-mail: info_es@festo.com

SwedenFesto AB

Stillmansgatan 1, Box 21038

200 21 Malmö

Tel. ++46 (0)20/38 38 40, Fax 38 38 10

E-mail: order@festo.se

SwitzerlandFesto AG

Moosmattstrasse 24

8953 Dietikon ZH

Tel. ++41 (0)44/744 55 44, Fax 744 55 00

E-mail: info_ch@festo.com

TaiwanFesto Co., Ltd.

Head Office

24450, No. 9, Kung 8th Road,

Linkou 2nd Industrial Zone

Linkou Hsiang, Taipei Hsien,

Taiwan, R.O.C.

Tel. ++886 (0)2 26 01-92 81,

Fax ++886 (0)2 26 01 92 86-7

E-mail: festotw@festo.com

ThailandFesto Ltd.

67/1 Moo 6 Phaholyothin Road

Klong 1, Klong Luang,

Pathumthani 12120

Tel. ++66 29 01 88 00, Fax ++66 29 01 88 33

E-mail: info_th@festo.com

TurkeyFesto San. ve Tic. A.S.

Tuzla Mermerciler Organize

Sanayi Bölgesi 6/18

34956 Tuzla - Istanbul/TR

Tel. ++90 (0)216/585 00 85, Fax 585 00 50

E-mail: info_tr@festo.com

UkraineFesto Ukraina

DP Festo

ul. Borisoglebskaya, 11

Kiev, 04070, Ukrainia

Tel. +380 (0)44/239 24 33, Fax 463 70 96

E-mail: info_ua@festo.com

United KingdomFesto Limited

Applied Automation Centre, Caswell Road

Brackmills Trading Estate

Northampton NN4 7PY

Tel. ++44 (0)1604/66 70 00, Fax 66 70 01

E-mail: info_gb@festo.com

United StatesFesto Corporation (New York)

395 Moreland Road, P.O. Box 18023

Hauppauge, N.Y. 11788

Call Toll-free 800/993 3786

Fax Toll-free 800/963 3786

Tel. ++ 1(0)314/770 01 12, Fax 770 16 84

E-mail: customer.service@us.festo.com

VenezuelaFesto C.A.

Av. 23, Esquina calle 71, No. 22-62

Maracaibo, Edo. Zulia

Tel. ++58 (0)261/759 09 44, Fax 759 04 55

E-mail: festo@festo.com.ve

VietnamFesto Co., Ltd (Cong Ty Tnhh Festo)

No. 206 Tran Nao Street

Ward Binh An, District 2

Ho Chi Minh City, Vietnam

Tel. +84 (0)8/740 69 09, Fax 740 69 10

E-mail: info_vn@festo.com

Festo worldwide