trend in automation 14

Trends in Automation Nr. 11, 2007

No. 14 2008

Vacuum technology

“Preventive monitoring in

vacuum systems”

Vacuum generator OVEM with

condition monitoring

page 12

Control Systems

“Intelligent control of systems”

Modular controller CECX

for multi-axis motions

page 14

Industry specific solutions

“Precision in the assembly

of vehicle lights”

Pneumatic mini slide DGSL

in operation on a rotary

indexing table

page 16

www.festo.com

Limitless partnershipsJointly-developed special products bring robotic ladies to life, page 4

Why have we dedicated our cover

story to the subject of “Limitless

partnerships”? The reason is sim-

ple: Long-term partnership-based

relationships with our customers

are the foundation of our success.

Across all the continents of the

world.

In addition to the fundamental

attributes of efficient partnerships,

such as reliability, communication

and the ability to develop, there is

also a particular emphasis on their

unique qualities, since individual

partnerships are as varied as the

people who enter into them.

From America to Russia, over

1,200 Festo sales engineers and

a similar number of project engi-

neers are at your disposal. The

personalised services we provide

range from planning to the com-

missioning of automation solu-

tions. You, the customer, can

define the framework and the

scope of the advice and services

which you wish Festo to provide.

The Japanese service robots fea-

tured in this magazine were able

to come to life only thanks to close

cooperation between Kokoro and

Festo. Joint development work led

to the production of the customer-

specific servopneumatic valves

which make the human-like move-

ment of the robots’ limbs possible.

For Festo, adaptable services are

an integral part of a partnership.

These services comprise every-

thing from free engineering soft-

ware to individual services relating

Unique partnerships,unique solutions

to logistics and system operation.

These can be tailored to your spe-

cific needs as desired.

Almost every automation solution

takes a unique form. This demands

a scalable product range. No mat-

ter whether as catalogue products

or customer-specific solutions,

pneumatic and/or electrical, Festo

offers the necessary wide choice

of automation solutions. These

define the depth of the value

which Festo can generate, able

as we are to provide a full band-

width with everything from com-

ponents to ready-to-install posi-

tioning systems.

With this edition of “trends in

automation”, we in Sales Commu-

nication would like to make our

contribution towards a unique

partnership. I hope that you enjoy

reading it!

Markus Ott

Head of Sales Communication

In focus

Limitless partnerships

Life-like robot: customer-specific proportional

valves ensure smooth movement. 4

Newsticker

New products, events and news in brief. 8

Bionic Learning Network

Seen in nature today – and in technology tomorrow

Learning from nature: artificial autonomous jellyfish

“AquaJelly” as a self-controlling system. 10

Vacuum technology

Preventive monitoring in vacuum technology

Versatile: the vacuum generator OVEM with condition

monitoring and process reliability. 12

Control Systems

Intelligent control of systems

Powerful: the modular controller CECX with the

CoDeSys software platform. 14


Precision in the assembly of vehicle lights

Automotive industry: the pneumatic mini slide DGSL

is used for the assembly of vehicle lights. 16

Wood joints

Woodworking: VUVB valves, standard cylinders and

pressure regulators form a powerful solution. 19

An extra helping of oxygen

Medical technology: miniature valves MH1 control

the output of mobile oxygen units. 22

Automation for medical progress

Pharmaceutical industry: ready-to-install control

cabinet solutions with a CPX/MPA valve terminal. 24

Bavarian biogases

Wastewater treatment: Linear and swivel actuators

control the butterfly and process valves. 26

Automation worldwide

From Korea to the Czech Republic

Applications from all over the world. 29

Infoservice 34

4

Customised Solutions

In use

• Special products and joint developments

• Components, systems and services precisely

matched to customers’ needs

• Ready-to-install systems

Benefits

• Saving time and money

• Enabling customers to concentrate on their

core competencies

• Supporting customers during the design, pro-

curement, installation and operational phases

In focus

Limitless partnerships

A sympathetic smile, a friendly wave, a charming conversation – jointly-

developed proportional valves breathe life into Japanese lady robots.

Special products such as these are only one aspect of a partnership that

spans the entire value creation chain.

Developing joint projects and finding solutions – our cooperation is worldwide and along the entire value

creation chain.

Human characteristics: Japanese lady robots make a natural

impression thanks to proportional pneumatics.

trends in automation No. 14, 2008

5


From design to procurement

and from assembly to operation,

Festo precisely matches compo-

nents, systems and services for

customer installations to the

needs of users along the entire

value creation chain.

Special applications

These go well beyond the possible

variants of catalogue products. A

project team carefully considers

the customer’s specifications and

then develops solutions with

application-optimised characteris-

tics in terms of functionality and

size. Sometimes a slight modifi-

cation of a standard product is

all that is needed to enable its use

in an application-specific context,

while at other times completely

new developments are needed.

Whatever the situation, customers

who buy special application prod-

ucts can then concentrate on their

core competencies. Frequently,

customised solutions would be

impossible without these prod-

ucts; for example, for applications

in extreme cold or in dusty, humid

or dirty environments. Or applica-

tions involving the control of the

expression of a Japanese lady

robot.

Individual wishes

In order to ensure that the Japan-

ese lady robot with its human

characteristics can genuinely move

like a real human being, the manu-

facturer Kokoro approached Festo.

Kokoro’s wishes were highly spe-

cific. In order to meet these, 50

proportional directional control

valves type MPYE from Festo were

used to control the small actuators

that control the robot’s limbs

under her smooth silicon skin.

No other automation supplier was

able to offer proportional valves

of the kind developed by Festo

exclusively for Kokoro in accor-

dance with the company’s specific

requirements. The project team,

consisting of engineers from Festo

Japan and Festo headquarters in

Esslingen, Germany, translated

Kokoro’s wishes into reality. The

valves were fitted with special

exhaust air flow controls in order

to provide even more precise con-

trol. This was necessary in part

because the limbs of the robot are

equipped with miniature cylinders

and very long tubing lengths. To

meet this challenge, standard pro-

portional direction control valves

MPYE from the Festo catalogue

were modified and adapted to

meet the robot’s specific needs.

Fast reaction time

“We also tested valves from other

manufacturers,” explained Koko-

ro’s Head of Development Takeshi

Kira, “but there was nothing else

on the market that was compara-

ble to the Festo proportional

valves.” Takeshi Kira also went on

to explain enthusiastically that the

MPYE has a fast reaction time, is

very durable and easy to use and

is relatively inexpensive.

A true partnership

Festo’s partnerships with cus-

tomers are not confined to indi-

vidual, specially made products.

There is a spirit of partnership

right along the value creation

chain, from design to procurement,

logistics and assembly to system

operation. Even at the design

stage, at the start of the value

Fast, durable and inexpensive. Each

robot has 50 specially designed MPYE

proportional directional control valves

that control the actuators, which in turn

power the limbs of the robotic woman

beneath her smooth silicone skin.

Günter Gebauer,

Head of Project Management

Customized Solutions:

“No matter whether for short or

long production runs, we have

the production technology and

know-how to deliver customised

solutions in the quantity required by the customer.

Festo’s support throughout the life cycle of cus-

tomers’ production systems ensures smooth opera-

tion and the availability of an agreed range of spare

parts. And on a worldwide basis.”

Individual and efficient: rodless drive with integrated valve as a “mini” customised

solution enabling a spinning machine to produce 1200 m of yarn a minute.

6 In focus ... Limitless partnerships


Individual and situation-specific: partnerships for every link of the value creation chain.

Individual and safe: pharmacy robot as a ready-to-install solution with a 3-axis loading

gantry, a front-end manipulator and a vision system ensures 100% safety during the dis-

pensing of medication.

• Consultancy

• Design aids

• Electronic catalogue

Engineering Procurement/logistics

• Festo Online Shop

• 24-hour delivery service

• Logistic Optimisation Service

• PrePack

Installation andcommissioning

• Ready-to-install solutions

• Commissioning of axis

systems

• Air Consumption Analysis

Operation

• Energy Saving Service

• Modular service contracts

• Air Quality Analysis

• Spare parts catalogue/

repair service

Reduce costs

Save time

Process reliability

is 1401Customised Solutions

is 1402Proportional Pressure Regulators

and Directional Control Valves

Infoservice 7


creation chain, customers can

benefit from their partnership with

Festo by using numerous software

tools for selection, simulation, siz-

ing and configuration. 20000 CAD

files and FluidDRAW and sizing

software are also available on-line

and can significantly reduce plan-

ning time.

Individual orders

Partnership is about respect at

every stage, including procure-

ment. Customers choose Festo

as a supplier on the basis of cost-

efficiency, speed and efficiency;

they can place orders via an indi-

vidual e-commerce link, the Festo

Online Shop or the Festo Hotline.

Respect also applies to delivery

times. The Festo Customer Service

Centre in St. Ingbert/Rohrbach,

for example, supplies customers

throughout Europe and Festo com-

panies worldwide on time; delivery

of special customer requests with-

in 24 hours to the 20 European

countries is also possible.

Ready-to-install systems

Customer-specific pneumatic solu-

tions, such as ready-to-install han-

dling or control cabinet units, are

the result of partnerships during

the assembly phase. Ready-to-

install systems are pre-tested and

supplied in accordance with the

customer’s design data and circuit

diagrams. They shorten the time

from the original idea to its imple-

mentation and cut down the num-

ber of interfaces which customers

have to deal with. In addition,

they come with a comprehensive

functional and fixed-price guaran-

tee. Ready-to-install systems are

delivered as complete solutions,

ready for immediate installation

in the machine, thus reducing sys-

tem design costs and the demands

placed on the customer’s technical

staff. These systems simplify the

procurement process and reduce

process costs thanks to the single-

sourcing principle and order pro-

cessing with a single part or proj-

ect number.

Partnership-based solutions also

benefit the operational phase,

the last link in the value creation

chain. This phase includes mainte-

nance contracts, help lines and hot

lines or advice on Total Productive

Maintenance. It can also comprise

services such as the Festo Air

Quality Analysis or the Festo Ener-

gy Saving Service, which enables

customers to save up to 60% of

their compressed air costs.

A lifetime

We should not forget the new

Festo Energy Monitoring System

GFDM. Or the diagnostic features

and condition monitoring systems

offered by Festo as part of its inno-

vative products based on the CPX

environment. This keeps partner-

ships dynamic throughout their

lifespan – and not just in the case

of seductive lady robots from the

Land of Smiles ...

Individual and space saving. The integrated controller which Festo supplied as a ready-

to-install solution for a pad printing machine enabled Teca-Print to save 75% of the

space which would be required by a conventional solution in a control cabinet.

Alfred Weibel, engineer at

Teca-Print:

“At the heart of the machine is

Festo’s integrated pneumatic

controller based on a PU duct

block. This technology enables

us to achieve the very high

functional we require with great efficiency. The

pneumatic components are made for the machine

and can thus easy to integrate.”

Valves and valve terminals

Performance-optimised: Valve series VB12

From individual valves to a multi-pin terminal –

the valve series VB12 stands for individual config-

uration and complements Festo’s existing polymer

valve series VB (VUVB, VTUB). Flexible, universal,

easy to use and with an outstanding price/per-

formance ratio; these are just some of the distin-

guishing features of this valve series. What is

more, the valves’ polymer bodies and weight-

optimised metal manifolds are very advantageous.

Sensors

Ready to install: fork light barrier

Reliability, efficiency and secure detection – this

is what the fork light barrier SOOF stands for.

There is a choice of two robust housings: metal

(SOOF-M) or reinforced polycarbonate (SOOF-P).

The U-shape of the robust housings, with a trans-

mitter and receiver on opposite sides, enable

them to be installed particularly quickly and easily.

Set-up using a potentiometer or the teach-in

method is simple. And there’s more. With its high

switching frequency and resolution it can detect

very small workpieces at a very high speed.

For installation in places that are not easily acces-

sible, the first choice is the SOOF-P: Thanks to its

LEDs, which are visible from all sides, the switch-

ing status of the light barrier can be seen from any

angle. In addition to a standard mounting, the fork

light barrier has a dovetail fitting on its plug sides

and undersides. This provides a further degree of

freedom during installation.

is 1404 Valve series VB

is 1405 Fork light barrier SOOF

8


+ + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + +

Electric Drives

Linear axes for heavy loads

Maximum dynamics and speed with excellent torsional rigidity.

These are the features of the electric linear axes EGC with recir-

culating ball bearing guides which come in numerous variants

and sizes, from mini to maxi. No matter whether they are used as

stand-alone components or complete system solutions, these elec-

tric axes have a more rigid aluminium profile, thus withstanding

higher loads and torques. The axes are an integral part of Festo’s

modular multi-axis and positioning system and offer standard

interfaces to other drives and motor packages. And that is not all:

the use of “Positioning Drives” software for sizing simplifies sys-

tem design work and helps to avoid costly oversizing.

Drives

Twice the gripping force, half the stroke

A powerful newcomer to the gripper series HGDT: the 3-jaw T-slot

gripper HGDT-F with a gripping force of up to 4000 N. In any given

size, it offers twice the gripping force of a conventional gripper and

half the stroke. The result is more secure gripping with heavier

loads and increased productivity.

It is ideal for use in harsh ambient conditions. The heavy-duty

T-slot plain-bearing guide and the gripper jaws that are precisely

matched to the gripper body ensure high rigidity and precision.

Internal purging air provides a seal to prevent the ingress of dust

and drilling coolant, while the integrated gripping force backup

function prevents the gripper fingers from opening and thus los-

ing the gripped workpiece as a result of a compressed air supply

failure.

is 1403 Three-point gripper HGDT

9


Germany, Energy Efficiency Award

1st place for Festo

Around 90 companies with exemplary projects for

increasing energy efficiency entered the Energy

Efficiency Award 2008 competition. Festo won over

the jury with the way energy is generated at its St.

Ingbert/Rohrbach site and took 1st prize. This

project resulted in an energy saving of 38% in

comparison with a new building with conventional

technology, corresponding to 366,000 euros per

year. The use of innovative components such as a

fuel cell, a cogeneration plant and a photovoltaic

installation also have an ecological benefit: 3,750

tonnes of CO2 a year less are released into environ-

ment.

+ + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + +


Safety@Festo: CPX/VTSA

Safety technology as an integrated function on a VTSA valve termi-

nal. Festo offers pneumatics, electrics and networking with inte-

grated diagnostic functions as a solution package from a single

source.

Integrated safety functions

1. Slow pressurisation after switch-on with integrated safety start-

up and quick exhaust valves. Enables the safe start-up of installa-

tions or sections of installations via an individual parameterisation

function. An integrated sensor monitors the piston position.

2. Valves with integrated switching position sensing, optionally

linked via one or two channels, for higher-order control systems,

e.g. press control systems.

3. Special valves with integrated safety functions for lifting and

rotary cylinders or manual workstations with manually operated

pneumatic clamps.


Ethernet node for EtherCat

CPX-FB38 EtherCAT fieldbus node – this is the key to the

easy integration of four valve terminal families, a CPX

terminal and the CPI installation system into a Beckhoff

automation environment.

The benefits at a glance

• Optimised pneumatics, electrics and networks

• Comprehensive diagnostics and function integration

• Digital and analogue I/Os, valves, sensors, proportion-

al pneumatics and axis interfaces for electric drives in

IP65/67

• 4 centralised pneumatic platforms on CPX

• 3 decentralised pneumatic platforms on CPI

• 3 installation concepts

(centralised, decentralised, hybrid)


Valve terminals for ex zones 2, 22

Nearly 4,000 Festo products have already been

certified for explosion protection categories. It is

now also possible to install the high performance

combination of electrical terminal CPX and valve

terminal MPA in areas with a potentially explosive

atmosphere (zones 2 and 22). For the first time,

all the required modules can be individually evalu-

ated and selected in a configurator in accordance

with explosion protection requirements. Thanks

to the new certification, it is possible to select and

install pneumatic components and subsystems

which are matched even more closely to the

requirements of individual stations.

is 1407 Safety Technology Guide

is 1406 Energy efficiency

10


AquaJelly

An artificial autonomous jellyfish with electric

drive and intelligent, adaptable mechanical

components.

Bionic Learning Network

Seen in nature today – and in technology tomorrow

Learning from nature and gaining access to new realms of automation tech-

nology – this is the objective of the Festo Bionic Learning Network. An excel-

lent example of this concept is the jellyfish, which uses the recoil principle

to generate a floating motion. This bionic imitation – the Festo “AquaJelly” –

uses a mechatronic system consisting of an electric drive, sensors and an

intelligent controller.

“Bringing together nature and

technology” – this is the motto of

the Festo Bionic Learning Network.

Working together with students,

well-known technical universities,

institutes and research and devel-

opment companies, Festo sup-

ports projects and experimental

and technological ideas which may

well be interesting areas of appli-

cation in tomorrow’s world. The

aim is to use bionics to make auto-

mated motion sequences even

more efficient and productive.

Moreover, “the Bionic Learning

Network is part of our commitment

to basic and vocational technical

training,” says Dr. Eberhard Veit,

Chairman of the Board of Directors

at Festo.

Autonomous control: AquaJelly

This artificial, autonomously con-

trolled jellyfish is a self-controlling

system in water which emulates

schooling behaviour. It consists

of a translucent hemisphere and

eight tentacles for propulsion.

At the centre of the AquaJelly is

a watertight laser-sintered body

which houses a central electric

motor, the two lithium-ion polymer

11

Lights on for communication

Eleven so-called environmental

sensors in the form of infrared

LEDs on the dome of the creature

provide intelligent schooling

behaviour, permitting, among

other things, evasive manoeuvres

and the establishment of a hierar-

chy for charging their batteries.

Internal sensors direct the peri-

staltic drive in four possible direc-

tions. A pressure sensor not only

determines AquaJelly’s depth and

position in the pool but is also

used to pick up energy. When an

AquaJelly is charging its batteries

at the charging station, it sends an

“Occupied” signal to its shoal.

Each AquaJelly decides for itself

what to do based on its state,

which in turn depends on its

charge, the position of its drive

and also its closeness to other

AquaJelly creatures. The resulting

schooling behaviour occurs with-

out any pre-assigned control of the

overall system.

In terms of future automation, it is

very probable that major tasks can

be carried out independently and

autonomously using autonomous

or semi-autonomous systems that

act separately but communicate

with one another.

Floating on air: AirJelly

This type of drive was hitherto

completely unknown in the history

of aviation. AirJelly is the first fly-

ing machine ever to “swim” in air

like its water-borne cousin via an

intelligent and adaptive use of

peristaltic motion. The lightness

of the AirJelly is thanks to the heli-

um-filled ballonet.

AirJelly’s sole source of power is

two lithium-ion-polymer recharge-

able batteries connected to a cen-

tral electric drive. It transmits

power via a bevel gear to a succes-

sion of eight spur gears, which

move the eight tentacles of the jel-

lyfish via cranks. Each tentacle is

designed as a structure with Fin

Ray Effect®. This, in combination

with an intelligent mechanism, cre-

ates fascinating prospects for elec-

tric drives in lighter-than-air pow-

ered flight.

Prospects for the future

The prospects for future applica-

tions are not yet clear. However,

with these and other exhibits Festo

is showing a workable vision for

automation technology and is

playing a pioneering role by asking

questions regarding the future.

This underlines its high level of

innovation both in automation and

in the didactic field. AquaJelly and

AirJelly are excellent examples of

how the Bionic Learning Network

helps Festo to achieve this aim.

batteries, the recharging control

unit and the servo motors for the

swash plate. The AquaJelly’s con-

trol in a three-dimensional space is

by shifting weight.

Attractions at the Hanover Fair: AquaJelly in an aquarium

Elegance under water: the structure

of each tentacle is based on the Fin Ray

Effect®.

... and AirJelly in the air.


12

Vacuum generator OVEM

Field of application

All applications that require not only specific

functionality but also condition monitoring and

process reliability

Key features

Vacuum sensor with LCD display and air-saving

function

Handling and vacuum technology


Preventive monitoringin vacuum systems

The monitoring of operating parameters in vacuum handling systems means

that it is at last possible to monitor and thus optimise cycle times directly.

This is made feasible by the condition monitoring capability of the vacuum

generators used.

Reliability through condition

monitoring. This is future-oriented

monitoring, with measurements

against a setpoint entered by the

user. What does this mean in prac-

tice? It means that the vacuum

generator itself can detect a slow

or sudden leak or any deteriora-

tion in the evacuation time for the

build-up of vacuum. The master

value is the cycle time, which rep-

resents the speed of a handling

operation and thus the productiv-

ity of an installation. The purpose

of the vacuum generator OVEM

with condition monitoring facilities

is to prevent machine failures and

downtime by taking action before

they occur, such as through pre-

ventive maintenance. For specific

applications the diagnostic criteria

can be set to more or less strin-

gent values.

OVEM has it all

OVEM is a new modular vacuum

generator series which can be con-

figured as needed. It expands

Festo’s modular vacuum system

with the availability of nozzle

diameters of 05, 07 and 10. Since

May 2008, 24 models have been

available; by the end of the year,

all variants and sizes will be avail-

able.

Process reliability is an important

factor with the OVEM. For exam-

ple, the easy-to-read LCD display

with additional barograph (with

With the vacuum generator OVEM,

users have a choice of three performance

classes and numerous models with differ-

ent functionalities. All models have an

integrated air-saving function.

is 1408Vacuum generator OVEM

is 1409“Vacuum Technology” poster

Infoservice 13


choice of modes) enables continu-

ous status monitoring of a com-

plete vacuum system. For this pur-

pose, the integrated solenoid

valve is used to control the com-

pressed air supply. This valve can

be operated in 2 modes: NC (nor-

mally closed, no vacuum genera-

tion) or NO (normally open, as a

safety function with vacuum gener-

ation). An integrated non-return

valve prevents the vacuum from

collapsing.

OVEM helps to save time

The vacuum generator and ejector

pulse are controlled by two inte-

grated solenoid valves. Short tub-

ing lengths ensure fast switching

times, which in turn mean that

workpieces are set down quickly

and reliably; there is even a regu-

lating screw to adjust the ejector

pulse. All operator controls and

display components are located

on the front of the generator. The

OVEM is also extremely easy to

maintain. An integrated filter

means clean process air, which can

be checked through an inspection

window, also located on the front.

The vacuum generator is thus vir-

tually maintenance-free.

Mounting options for the OVEM: on an

H-rail, from the front, the side or the rear.

Wolfgang Hanold,

Product Manager Vacuum

Technology at Festo:

“Our new vacuum generator

series OVEM reflects our cus-

tomer’s demand for high relia-

bility and safety, simple instal-

lation and energy-efficient

vacuum generation. Festo’s modular handling and

assembly technology system now offers a full range

of options, from basic, low-cost functions to intelli-

gent solutions.”OVEM makes it possible: condition monitoring functionality for the most important

operating parameters.

Zeit [s]

Vacuum [%]

TE: Evacuation time

(200 ms)

T1: Transport time

(500 ms)

TA: Ejection time

(100 ms)

T2: Return time

(500 ms)

100

85

50

TE T1 T2TA0,2 0,7 0,8 1,3

Monitoring Monitoring Monit. Monitoring

Cycle time

iDo you have a concrete application for which you

would like help?

The fast way to help yourself: the free “Vacuum

Selection” software tool available in the Festo

digital catalogue on DVD or as a download from

www.festo.com/download

14

CECX modular controller with CoDeSys software

platform

Field of application

• Controlling machines and installations

• Motion control applications

Key features

• Fieldbus master functionality

• Programming in accordance with IEC 61131-3

(CoDeSys) with optional SoftMotion software

package

• Easy programming and commissioning

• Graphic editors for planning of motions

• Versatile communication interfaces

Control Systems


Intelligent control of systems

The modular controller CECX means that Festo’s range of products now

includes models with fieldbus master functionality and for motion-control

applications. The CECX is fully compatible with a wide spectrum of fieldbus

systems such as CAN-Bus and Profibus.

15


Machines and installations

fully under control. The modular

controller CECX is Festo’s new

fieldbus master controller. This

means that the Festo product

range has now gained a high per-

formance control unit which,

depending on the version, can pro-

vide both comprehensive PLC func-

tions as well as multi-axis motions.

Thanks to the wide choice of func-

tional modules available, for exam-

ple digital, analogue or counter

modules, the CEX is a universal

controller which covers a broad

range of applications in the gener-

al machine construction sector.

The controller is suitable for the

automation of both complete

machines and installations and

separate machine units which are

then integrated into a larger instal-

lation.

Adapting control systems to cus-

tomers’ needs

In addition to offering controller

functions, the CECX is also

designed for use in actuating elec-

tric drive systems. Says Achim

Kottmann, Product Manager Con-

trol Systems at Festo: “Wherever

PLC functions and motion control

meet, the CECX is an ideal choice,

since, when used together with

CoDeSys software, it offers a uni-

realisation of coordinated motions,

including interpolations. Users can

call on graphic editors to carry out

easy planning of motions. And

integrated visualisation is a useful

way of testing sequences before

commissioning. With these fea-

tures, the CECX is the ideal choice

when a combination of PLC and

motion control functions is

required.

Universal

As the CECX has to be as compati-

ble as possible with other control

system components, it is impor-

tant for it to offer a wide range of

communication interfaces to other

systems. It therefore offers the

interfaces CAN Bus, Profibus mas-

ter/slave and Ethernet (TCP/IP,

Easy IP). The controller is thus

fully compatible with a wide range

of control system architectures

and can be used virtually univer-

sally.

form programming interface for

control tasks and motion

sequences.” Thanks to these uni-

versal capabilities of the modular

controller CECX, its applications

are not limited to specific indus-

tries. Possibilities include the

packaging industry, assembly sys-

tems and handling. Moreover, it

can easily be combined with all

Festo components, thereby greatly

reducing the amount of program-

ming work to be done by cus-

tomers.

Multi-axis motions possible

The controller is available in two

variants: type CECX-X-C1 without

motion control functions and as

the motion controller type CECX-

X-M1. The major difference is that

type CECX-X-M1 can, thanks to the

additional “SoftMotion” software

package, carry out coordinated

multi-axis motions. Both variants

are equipped with the CoDeSys

software package, which defines

the controller functions. This soft-

ware platform, which conforms to

IEC 61131-3, enables fast and sim-

ple configuration of the CPU and

I/O modules, together with easy

programming and commissioning

of pneumatic and electrical

automation solutions. Comprehen-

sive module libraries facilitate the

Achim Kottmann,

Product Manager Control

Systems at Festo:

“Thanks to this controller’s high

performance, it is quite easy

for us to match the degree of

automation to customers’

requirements. This is an impor-

tant step which supports Festo’s offer of customised

solutions.”

Technical data

• Fieldbus master interfaces:

CAN-Bus on board, Profibus master DP V1, Profibus slave DP V1

• Optional modules with further interfaces: optional Ethernet module

RS422/RS485, optional CAN module (2nd CAN interface)

• Digital and analogue peripheral modules

• Modern programming system CoDeSys in accordance with IEC 61131-3

• Modular IP20 system

• Easy mounting of control system on an H-rail

• UL/CSA and C-Tick approval certificates

Electric drives, valve terminals to actuate pneumatic cylinders, sensors, vision systems

and operator panels can be found in large numbers in modular machine and assembly

systems, such as this one at MAT in Althütte. This is one of the many possible applica-

tions for the new modular controller CECX.

16

Automated assembly machines for vehicle

lights

In use

• Pneumatic mini slide type DGSL

Benefits

• Drive and guide in one unit

• High torsional rigidity and precision

• Transport and separation functions



The great strengths of the mini slide DGSL are brought to the fore in the fully automated assembly machine

for vehicle lights. Its rigidity is invaluable for all handling motions, while its precision deals efficiently with

the separation of all components involved.

The lights are given a brightness test

before final assembly.

Precision in the assembly ofvehicle lights

Technical data

• Sizes: 4 to 25 mm

• Cushioning: metal stop, P and polymer cushioning

• Workpiece mass: up to 6,139 grams (size 25)

• Repetition accuracy: linearity and parallelism in

the 1/100 mm range

• Safety functions: clamping cartridge or end posi-

tion locking

• Easy mounting thanks to precision interfaces

• Easy stroke adjustment and fitting of air connec-

tions, all from the same side

Mini slide type DGSL

17


Fichter Maschinen GmbH

specialises in the design and pro-

duction of assembly machines

for workpieces measuring 3 to

200 millimetres and with cycle

times of 2 to 15 seconds. To this

end, Fichter installed pneumatic

and electric actuators, sensors

and test equipment supplied by

leading manufacturers. Among

the customers who appreciate

the quality of Fichter’s products

is a major supplier to the automo-

tive industry, who relies on Fichter

for fully automated assembly

machines for light bulbs with cycle

times of less than 2 seconds. Each

machine assembles plastic bases,

metal contacts and pre-sealed

glass envelopes into finished

lights and all components are fed

in automatically. The overall

assembly process is split between

two motorised rotary indexing

tables. One table is used for func-

tion testing and separates out

incorrectly assembled or defective

light bulbs, while the other carries

out the actual final assembly and

checks the finished product. This

is where the mini slide DGSL

comes into play. It provides all the

vertical motions for the pick and

place handling units and separates

the components.

Assembly indexing table

The light sockets pass via a spiral

conveyor and a linear conveyor

to a transfer station. To ensure

smooth and trouble-free transfer,

the fittings are first separated by a

mini slide DGSL. A pick and place

handling unit then picks up each

fitting and turns it before placing it

in a workpiece carrier on the rotary

indexing table for processing.

The left and right-hand contacts

for the light fitting also pass via a

spiral conveyor and a linear con-

veyor to a second transfer station.

Dipl.-Ing. (FH) Jürgen Stiedl,

General Sales Manager at Fichter:

“It is vital for us as a machine builder to be able

to carry out planning work quickly and easily. We

use standardised system concepts and modules

to do that. This makes for a better overview, sim-

pler technical procedures, faster throughput and,

of course, ultimately leads to lower costs. We depend on close coop-

eration with our suppliers to achieve this level of standardisation in

our machines. In the field of pneumatics, our partnership with Festo

has proved valuable. Its innovative products, such as the new guide

unit DGSL, help us to achieve our objectives.”

General view of the fully automated

assembly machines for vehicle lights

Mini slides type DGSL provide all the

vertical motions required for the pick and

place handling units on the machines.

18 Industry specific solutions ... Precision in the assembly of vehicle lights

is 1410Mini slide DGSL

Infoservice


Fichter Maschinen GmbH

Products Innovative system solutions rang-

ing from semi-automated assem-

bly machines through to complex

fully automated assembly lines

for suppliers to the automotive

and electrical industries

Contact D-79356 Eichstetten

www.kfm-fichter.de

Another pick and place handling

unit picks up one left-hand and

one right-hand contact and places

them in the appropriate positions

in the light socket.

Test indexing table

The next station checks the light

sockets to ensure that the contacts

are present and are inserted to the

correct depth. A handling unit sep-

arates out flawed workpieces.

At the same time, a pick and place

handling unit on the first indexing

table picks up a light bulb from the

separator and places this in a car-

rier. In a next step, the light bulb is

subjected to a brightness and dim-

ming test. Flawed workpieces are

immediately separated out. After

this, a pick and place handling unit

removes the tested light bulb from

the carrier on the test indexing

table, turns it and inserts it into a

socket. A final test is then carried

out to ensure that the finished

light works correctly. On the last

station a specific mark is imprinted

on the product for identification.

Two handling units, one for correct

workpieces and one for rejected

ones, pick up the finished prod-

ucts and put them in the appropri-

ate containers. All the pneumatic

actuators in the system are con-

trolled by valve terminals type

CPV 10.

After the functional testing is complete,

the light bulbs are fitted into sockets by a

handling unit.

Valve terminals type CPV 10 control the

pneumatic actuators in the installation.

19

Woodworking industry:

Edge banding machine and CNC machining

centre

In use

• VUVB valves on mounting plates

• Standard cylinders DSNU and DNC

• Pressure regulators DB

• Cylinders ADNP made of high performance

polymer

Benefits

• Complete system solutions save time and

money

• VB valve system is easy to retrofit

• Faster cycle times thanks to higher flow rate

• Attractively priced pneumatic components



Wood joints

Boards are fed in, the edges are glued and pressed, an edge

banding is applied, the projecting ends are trimmed and the

top and bottom edges are milled flush. The Contriga edge

banding machine operates quickly and precisely. To ensure

that the machine itself can be assembled equally quickly, its

manufacturer Reich Spezialmaschinen GmbH uses ready-to-

install pneumatics, developed by working hand in hand with

specialists from Festo.

Wood is a material which is

easy to work and is found almost

everywhere. Woodworking is as

old as the human race; woodwork-

ing tools such as drills, axes and

splitting wedges have been known

since the Stone Age. These simple

tools have now been developed

into highly technical and complex

machines in which the driving

force is no longer muscle power

but instead pneumatic and elec-

tric. The special machine builder

Reich Spezialmaschinen GmbH in

Germany produces woodworking

tools under the brand name Holz-

Her. Its products range from circu-

lar saws to CNC machining centres

for woodworking to meet the most

critical requirements and incorpo-

rate high performance pneumatic

components from Festo. The latest

result of the cooperation between

Reich and Festo is the Contriga

edge banding machine, which

applies edge trims to finished

wood workpieces.

Prize-winning design

The innovative design of the Con-

triga has won prizes; it received

the reddot design award 2007

and the iF-Design Prize 2008. The

pneumatically-controlled sliding

covers move up and down at the

touch of a button and uncover the

working units – thanks to Festo

standard cylinders type DSNU. The

Contriga thus not only requires

significantly less space than com-

Innovative design: the Contriga edge banding machine.

20 Industry specific solutions ... Wood joints


parable machines but also offers

users a facility for rapid tool

changing.

The objectives for the design of

this new machine were to increase

its speed and simplify its assembly

as much as possible. The develop-

ers, working with Festo specialists,

therefore chose Festo VUVB valves

with a high flow rate. These were

supplied ready assembled on

mounting plates and all set up

together with pressure regulators

type DB, tubing and labelling. The

valves control the cylinders which

clamp the workpieces during pro-

cessing.

Systems instead of components

The VB valve system was chosen

as it is easier to retrofit. Any spare

positions on the mounting plate

can be effortlessly fitted with addi-

tional valves and each valve can be

replaced individually, while instal-

lation is greatly simplified by the

pre-assembled systems. Installa-

tion technicians need only install

and connect the complete units

and need not worry about the

time-consuming task of fitting indi-

vidual tubes. The system solution

was specially developed for Reich.

The idea of using pre-assembled

systems has already gained

ground: “As a result of working

with Festo, Reich now makes sure

A spray unit applies a releasing agent

to the surfaces and edges of the panels.

The regulator controls the volume and

pressure of the spraying operation.

VUVB valves with high flow rates are supplied pre-assembled and pre-set on mounting

plates, together with DB pressure regulators, tubing and labelling.

Pneumatically-controlled sliding covers

move up and down at the touch of a but-

ton to allow access to the working units.

21


that designers think in terms not of

individual components but of com-

plete systems,” confirms Denis

Lorber, Head of Development at

Reich Spezialmaschinen GmbH.

Development through teamwork

During this project Festo develop-

ers worked closely together with

Reich, both on the development

at the company HQ in Nürtingen

and on the production of wood-

working machinery by the sub-

sidiary company Reich-Austria

Ges.m.b.H. in Austria. This enabled

Reich’s designers to contribute

their knowledge to Festo’s devel-

opment process. “In the course of

this joint project, we were particu-

larly impressed by the fact that,

although Festo is a large company,

we were always able to contact the

right people and obtain a solution

which was ideal for our needs,”

explains Denis Lorber.

Ready-to-install pneumatics

reduce system designers’ work-

load and ease the burden on budg-

ets. From procurement to logistics,

system design and documentation,

installation and commissioning,

Festo offers everything from a sin-

gle source with just one project or

order number. Complete solutions

make installation and commission-

ing easier and save time and

money. Components with standard

functions are more than adequate

for the requirements of the wood-

working industry where the main

emphasis is on an attractive

price/performance ratio.

The joint venture continues

The system concept developed

for the Contriga is now also being

used for the CNC machining centre

Easy Master 7018.This machine

processes wood workpieces fully

automatically into, for example,

doors, handrails for stair or

shelves. The machine, which was

launched by Reich in May 2008,

also features VUVB valves pre-

installed on mounting plates and

ADNP cylinders, attractively priced

components which are made from

high performance polymer and are

used as feed cylinders. The cylin-

ders advance plastic runners,

which transport the workpieces

from the vacuum holding devices

and through the machining centre.

In the development of Easy Master

7018, Reich was able to draw on

the experience gained with Contri-

ga; this resulted in another joint

project between Reich Spezial-

maschinen GmbH and Festo.

In the CNC machining centre Easy Master 7018, wood workpieces are shaped and

processed fully automatically, for example, for the production of the frame of a bay

window as shown here.

A wooden door with a different view. The CNC machining centre mills the shape and

then edge banding is applied by the Contriga.

Denis Lorber, Head of Development at Reich

Spezialmaschinen GmbH:

“Thanks to our close cooperation with Festo, our

work was significantly reduced. Ready-to-install

pneumatics save time and money. In future, I can

even imagine that Festo could produce system

solutions on demand at short notice.”

HOLZ-HER Reich

Spezialmaschinen GmbH

Products Woodworking machines

Contact D-72622 Nürtingen

www.holz-her.com

Medical technology: mobile oxygen kits for

patients with chronic obstructive pulmonary

disease

In use

Miniature valves MH1 with approval for use

with oxygen

Benefits

• Compact installation

• High flow rate

• Fast cycle times

An extra helping of oxygen

Millions of people suffer from shortage of breath due to ill-

ness. With the miniature valve MH1, which can be installed

in very confined spaces, Festo helps to provide a mobile

oxygen supply, enabling these patients to enjoy a signifi-

cantly better quality of life.

More freedom of movement for COPD

patients thanks to mobile oxygen supply.

22 Industry specific solutions


oxygen supply. Oxygen is fed over

the breathing apparatus and a

nasal cannula.

Breathe deeply with MH1 valves

This is where Festo gets involved,

because the very small and versa-

tile Festo miniature valve MH1 in

mobile oxygen systems regulates

oxygen delivery to precisely meet

requirements. The advantage lies

in the lower oxygen consumption

compared to standard systems.

Patients experience improved

mobility and quality of life as the

air supply is available for longer.

MH1 valves are extremely small

and are ideal for the tightest

installation spaces. The 2/2-way

version with oxygen approval sup-

plies 25 l/min. The LED display on

the MH1 valves enables visual

monitoring of the operating status

from all sides.

Studies reveal that more

people are suffering from Chronic

Obstructive Pulmonary Disease

(COPD) than had previously been

assumed. According to The Euro-

pean Lung Foundation approxi-

mately 44 million COPD patients

worldwide increasingly deal with

their illness using oxygen therapy.

Solutions for every situation

Different systems are available

for long-term oxygen therapy.

Patients whose general condition

only rarely allows them to leave

their bed receive the oxygen via

a concentrator that converts room

air into concentrated oxygen gas.

The inhaled air is enriched with

oxygen by a compressor that

presses the air into a molecular

filter that in turn filters out nitro-

gen N2. This increases the amount

of oxygen in the remaining gas

mixture.

Mobile patients satisfy their oxy-

gen requirement by mobile com-

pressed gas cylinders or standard

liquid oxygen systems. Mobile liq-

uid oxygen systems weigh 1.5 kg.

They comprise a portable unit with

a tank and a stationary reservoir.

It takes only 40 seconds to fill the

mobile unit, which then gives

patients up to 13 hours of full free-

dom of movement with a stable

is 1411Miniature valves MH1

Infoservice 23


Miniature valve MH1: extremely versatile,

approved for use with oxygen.

Technical data

• Nominal flow rate: 25 l/min.

• Switching times: 4/5 ms

• Overall width: 10 mm

• Maximum pressure: 1.8 bar

• Approved for use with oxygen

• Average temperature: -5 to +60 °C

• Max. permissible temperature: +100 °C

What is COPD?

COPD stands for “Chronic Obstructive Pulmonary

Disease”. It is a term for chronic bronchitis and

emphysema, i.e. when the airflow to the lungs is

constantly restricted. The most important symp-

toms of COPD are breathlessness and a severe

cough.

The main reason for the development of COPD is

smoking. Nine out of ten COPD patients smoke or

have previously smoked. Non-smokers can, how-

ever, also be affected, since prolonged exposure

to dust or hazardous gases in the workplace can

also cause this illness.

COPD is fundamentally incurable. Treatments simply

aim to ease symptoms, delay the spread of the dis-

ease and increase patients’ expectation and quality

of life. A distinction is made between three degrees

of severity. The first two degrees are treated by med-

ication, while for the third, long-term oxygen therapy

improves patients’ quality of life by ensuring a sta-

ble concentration of oxygen in the blood.

24

Pharmaceutical industry: production of injec-

tion media such as anti-infectives and cardiac

drugs

In use

Ready-to-install control cabinet solutions with

CPX/MPA to control diaphragm valves

Benefits

• Ready-to-install

• Fewer interfaces

• Simplified documentation



Automation for medicalprogress

“We had absolutely no time to think about details,” says Manfred Broustin, Head of PLT at

the Parenteral Medication Production Leverkusen facility of Bayer HealthCare, describing

the conversion of a production facility at the company’s Leverkusen site. “We reduced the

risks of this project by asking Festo to supply ready-to-install control cabinets.

In only four weeks, the proj-

ect team completed the conversion

of the plant for the production of

infusion and injection solutions

such as anti-infectives and cardiac

drugs. “We eventually needed to

start production again, longer

downtimes would not have been

acceptable,” explains the automa-

tion expert.

The parenteral medication

production facility ...

... in Leverkusen alone produced

over 18 million bottles and more

than 1.5 million freeze-dried vials

in 2007. These were used by Bayer

HealthCare to produce over 16 mil-

lion packing units. “Our markets

are characterised by continuous

growth,” says Broustin. In order

to increase production capacity

and cut costs, the company has

decided in favour of further

automation. Before conversion,

the automation in the plant was

only limited and it was thus more

costly to operate it and maintain

documentation.

“Automation has enabled us to

monitor and document the com-

plete production process fully

In 2007 18 million infusion and injec-

tion bottles were produced using ten

filtrate tanks and four mixing tanks for

anti-infectives and cardiac drugs.

is 1412Biotech/Pharmaceuticals

Products and Services

is 1413Ready-to-install Pneumatics

Infoservice 25


automatically, continuously and

without paper,” is how Broustin

explains the reason for the con-

version. A process control system

records measured values and

transfers these to a master EDP

system. Validation of processes

is vital if manufacturers wish to

maintain a leading position in

world markets and meet legal

requirements such as those of the

FDA.

Vertical production

Bayer HealthCare operates a so-

called vertical production process.

Following the procurement of raw

materials and packaging at the

right price, three steps are

required for the actual production

process:

1. Chemical or biotechnological

processing of active ingredients

2. Formulation of active ingredi-

ents to create finished medication

3. Packaging

The plant for the production of par-

enteral medication operates on the

same principle. On the upper level,

solutions are made up in mixing

tanks in accordance with recipes

and transferred to filtrating tanks

for filling. On the lower level, the

finished medication is filled into

bottles, bags or vials on five filling

lines.

An important factor at the planning

stage was to subdivide the plant

so that the plant sections could be

cleaned individually. With around

60 different recipes and over 20

plant sections, the plant needs to

be wet cleaned and sterilised at

least five times a day.

Ready-to-install control cabinet

systems

Modular Festo valve terminals type

CPX/MPA are used to control the

diaphragm valves in the plant,

while a CPX electrical terminal is

used to process the analogue val-

ues for the measuring systems

and control valves. The CPX/MPA

terminals accommodate control

valves and analogue and binary

I/Os in a single unit, which means

that only one bus node is required.

Field devices from the explosion

protected area of the plant are

also linked to the CPX via firewalls.

“Given the tight deadline for the

conversion work, having valve

terminals that were supplied fully

configured and protected in stain-

less steel control cabinets was

ideal; we only needed to integrate

them in our production plant,”

reports automation expert

Broustin enthusiastically.

Supplied fully tested, together

with all design data, circuit dia-

grams and a comprehensive func-

tional and fixed-price guarantee,

ready-to-install control cabinets

shortened the time from the initial

idea to a functional machine and

reduced the number of interfaces

required. Documentation for the

cabinets was generated using

EPLAN. It was therefore very sim-

ple to integrate it into Bayer’s

overall documentation. Automa-

tion technology has made a real

contribution towards medical

progress.

Continuous documentation: the automation of the parenteral medication production

plant has brought genuine progress in data management.

Reliable control: ready-to-install control cabinets shortened the time from the initial

idea to a functional installation.

Bayer HealthCare AG – a subsidiary of Bayer AG

Products: 1. Animal health: veterinary drugs and care prod-

ucts for farm and domestic animals

2. Bayer Schering Pharma: diagnostic imaging,

general medicine, specialised medicine, health

care for women

3. Consumer care: prescription-free medication,

food supplements

4. Diabetes care: glucose measuring devices, test

strips

No. of staff 51,500

Contact D-51368 Leverkusen

www.bayerhealthcare.com

26

Wastewater treatment:

Gut Großlappen sewage treatment plant in

Munich

In use

Linear and swivel actuators for process

automation

Benefits

• Opening and closing of butterfly and process

valves

• Cost advantage of more than 50%

• Robust and corrosion resistant



Bavarian biogases

Striking architecture: the digester tanks

of the Gut Großlappen sewage treatment

plant run by the local utility Münchner

Stadtentwässerung.

27


The city of Munich has set itself an ambitious project. The river Isar, which flows through this

Bavarian metropolis, is to be cleaned up so that people can once again swim in it. To achieve

this, the city operates a network of two sewage treatment plants to purify the wastewater

generated by 1.5 million people. Pneumatic automation technology ensures reliable opera-

tion of the new digester tanks in the Gut Großlappen sewage treatment plant.

The sewage treatment plants

operated by the utility Münchner

Stadtentwässerung purify

560,000 m3 of wastewater every

day. The Gut Großlappen sewage

treatment plant is one of the

largest plants in Germany. It com-

prises mechanical and biological

cleansing, a phosphate precipita-

tion plant, a sand filter, sludge

treatment in digester tanks, sludge

incineration, energy recovery and

gas collection. The biogas gener-

ated during the digestion process

in the tanks is used to meet the

energy needs of the sewage treat-

ment plant.

The four digester tanks are

31.5 m high and have a capacity

of 14,500 m3 each and cost the

Münchner Stadtentwässerung

63 million euros. The designers

chose striking architecture as

a counterbalance to the Allianz

Arena, the home stadium of the

football team FC Bayern München.

They also chose pneumatic

automation technology.

Why pneumatics in a sewage

treatment plant?

Pneumatic automation technology

reduces investment, installation

and operation costs in comparison

with conventional electrical instal-

lations. Cost advantages of more

than 50% can be realised. Many

system planners choose pneumat-

ic actuators to open and close but-

terfly and process valves because

of their continuous operation, long

service life and overload protec-

tion. Compressed air is intrinsically

safe, since it opens and closes

valves without the need for elec-

tricity. In practical terms, this

means that pneumatics are easy

to work with, robust and ensure

high plant availability.

Maintenance-free and overload

protected

Pneumatic actuators are mainte-

nance-free for their entire service

life, which, at more than a million

switching cycles, means that a

pneumatic actuator will outlast

any process valve. As the shut-off

valves in sewage treatment plants

are actuated only at irregular inter-

vals, the tolerance of pneumatic

actuators to overload should not

be forgotten. Deposits or caked-

on material on valves may lead

to considerably higher breakaway

torque values. Pneumatic actua-

tors are overload proof, while elec-

tric drives will reach their torque

limits in cases where greater than

normal torque or force is required.

With pneumatic actuators, it is

possible to increase the operating

pressure and thus the force and

torque output. As most valves in

sewage treatment plants are oper-

Maintenance-free and overload-proof: Copac linear actuators (DLP) open and close the

gate valves in the pig trap stations.

28 Industry specific solutions ... Bavarian biogases

is 1414Process Technology

is 1415Partner to the Process Industry

Infoservice


Safety devices to shut off digester gas lines: Copar semi-rotary actuators (DRD/DRE).

ated in open/close mode or as

manually operated valves, pneu-

matic technology opens up a con-

siderable potential for rationali-

sation.

Pneumatic cylinders provide reli-

able control

They are robust and corrosion

resistant and thus suitable for

harsh environments; they only

have a few moving parts and are

easy to operate. Pneumatic cylin-

ders involve no additional costs,

even for explosion protection

zone 1. Particularly in digestion

towers, in which the process of

digesting sludge at temperatures

of around 40° C produces gases

containing methane and carbon

dioxide, explosion protected actu-

ators to open and close the shut-

off valves are vital. Electric actua-

tors, on the other hand, require

monitoring for overtemperature,

torque, switching frequency and

servicing and maintenance inter-

vals, which means an enormous

number of I/Os to wire up.

In the digester tanks ...

... of the Gut Großlappen sewage

treatment plant, Festo pneumatic

actuators are installed for gate

valves (Copac actuators) and but-

terfly valves (Copar). Copac linear

actuators (DLP) open and close

the gate valves in the pig trap sta-

tions used to clean the sewage

sludge pipes. Further large size

linear actuators are installed at

the floating sludge drainage sta-

tions. Copac actuators are ideal

for controlling gate valves. They

act directly on the gate plate and

make it possible to approach vari-

ous different positions.

Copar semi-rotary actuators

(DRD/DRE) are fitted to butterfly

valves as safety devices to shut

off digester gas lines. Copar actua-

tors are used for open/close func-

tions; in conjunction with commer-

cially available electro-pneumatic

position controllers they ensure

accurate travel to various different

positions, particularly for ball

valves, stopcocks, shut-off valves

560,000 m3 of sewage per day: the city of Munich operates two sewage treatment

plants to purify the wastewater generated by 1.5 million people

and butterfly valves. Pneumatic

components keep the Bavarian

biogases firmly under control and

the water quality of the river flow-

ing through Munich is once again

good enough to swim in.

29

trends in automation No. 14, 2008trends in automation No. 14, 2008

automation worldwide 29

Korea

Reliable coatings 29

Germany

Hand in hand 30

Taiwan

Precision lens production 30

Germany

Magical water games 31

Italy

Firmly wrapped up 32

Czech Republic

More energy with Festo 33

automation worldwide Korea

Rotary machines for tablet produc-

tion, capsule filling machines and

high speed mixers are just a few

examples of the output of the

Korean manufacturer Pharm Tech

Korea. No matter whether for the

pharmaceutical, medical or pack-

aging industry, more than 70% of

the machines which this company

produces are exported. And they

feature Festo components, as in

this example of a tablet coating

machine.

A pressure regulator type

MS4-LR and a valve terminal

type MPA are installed in a

separate control cabinet. The

pressure regulator provides

precisely the right pressure

required for the operation of

the machine, while the valve

terminal actuates and deactu-

ates the nozzles on the coating

machine. The semi-rotary actu-

ator DSM is used to switch the

feed of coating material on and

off.

For Pharm Tech Korea as a

strongly export-oriented com-

pany, it is not only high quality

components that are important.

Consistent quality, worldwide

delivery and a spare parts serv-

ice are also decisive factors.

Also much appreciated by

Pharm Tech Korea’s customers

is the detailed product docu-

mentation that Festo provides.

Reliable coatings

30 automation worldwide

Germany

automation worldwide

Integration into the world of work.

At Nordbahn gGmbH, handicapped

people carry out all kinds of tasks,

from simple assembly to working

on complex machine tooling sta-

tions. In order to be able to offer

a wide range of employment, the

company also accepts orders from

industry, including the biochemi-

cal and automotive industry. One

example is the test machine for

plastic tubes for blood plasma,

which Nordbahn designed itself,

working hand in hand with ifc

intelligent feeding components

GmbH, which integrated a com-

plete vision system into the

machine.

The handicapped workers lay the

tubes on a conveyor belt that

feeds the tubes to workpiece car-

riers, each holding ten tubes. In

the test chamber vacuum grippers

type ESS-10-BS pick up the tubes

and turn them 360°. While the

tubes are being turned, a compact

vision system SBOC-Q-R2B from

Festo records up to 12 images of

the tubes and detects scratches,

cracks and splits. The vision sys-

tem software transmits the result

to the master controller, which

separates out any defective tubes.

Once they have passed this

inspection stage, the tubes are

packed by hand ready for trans-

portation.

www.ifc-online.com

GLA-2AS is an assembly machine

for optical lenses made by the

Taiwanese manufacturer Guann

Way Technologies Co, which spe-

cialises primarily in programming

for automated installations and

also in improving and maximising

the output of production lines and

processes.

When linked to a bonding machine

or a loading/unloading system,

the GLA-2AS can form a complete

production line for the manufac-

ture of optical lenses. This features

a highly efficient lens changer,

equipped with a HGP gripper. Its

strengths are the versatility and

extremely adaptability of the grip-

per fingers. With its slim design,

the pneumatic mini slide DGSL

from Festo also proved ideal for

the customer’s requirements and

has been extremely reliable. The

combination of a mini slide and

the swivel/linear unit HGDS also

saved installation time.

www.guannyinn.com.tw


Hand in hand Precision lens

production

31



Germany

Fast-switching valve MHE4

Magical water games

Taiwan

Rapture among the audience.

Logos and figures slide down a

wall of water of up to 10 metres

high, while dynamic lighting cre-

ates graphics and scripts in all

kinds of colours and shapes. The

Magic Waterfall is truly eye-catch-

ing. It is constructed like a print

head 1 to 10 metres long, with

100 MHE4 valves per metre. The

individual water streams are creat-

ed by several nozzles, resulting in

an opaque water curtain that is

highly suitable for use as a projec-

tor screen. The valves’ switching

times are faster than the human

eye can follow, creating messages

for the viewer that float down the

waterfall and disappear in a basin.

The water wall is an invitation not

only to viewers but also to those

wishing to play. Speed is the key

when it comes to reaching through

a programmed hole in the waterfall

and wet shirtsleeves are the result

of being too slow. The closed water

loop not only offers magic and fun

but also has a practical side. The

Magic Waterfall acts as a high-tech

air humidifier to improve the

atmosphere in enclosed rooms.

Parallel gripper HGP

Swivel/gripper unit HGDS

32



Italy

Firmly wrapped up

The manual preparation of plastic

pipe and tubing for transport is

a tedious job, and extremely inef-

ficient. Automatic wrapping

machines supplied by Italian man-

ufacturer Campetella provided the

solution by utilising pneumatic

automation technology.

The system wraps polypropylene

straps around pipe or tubing at

a speed of 80 metres per minute,

binding it firmly together. The flexi-

ble machines are capable of auto-

matically controlling tubing length,

diameter, the thickness of the rolls

and the strapping, and counting

the number of rolls. “Our goal was

a compact, clear-cut design, and

Festo’s reliable standard drives,

MS series modular service units,

flexible MPA terminal with multi-

pin connection and above all the

CPV-SC miniature valve terminal

were just what we needed”,

explains managing shareholder

Carlo Campetella.

www.campetella.it

33



More energy with Festo

Czech Republic

xxxxxxxxxxxxxxx

Sewage sludge is full of energy

and the operator of the city

sewage treatment plant in Karls-

bad, Czech Republic, is well aware

of this fact. Working together

with KV engineering Karlovy Vary,

Skanska CT and K&H Kinetic, the

operator developed a two-stage

system for the processing of pri-

mary and excess sludge which

involves anaerobic stabilisation

in a digester tank. The aim was

to improve the sludge treatment

process and make effective use

of biogas. The valves in the gas

flow control system, which were

mainly electrically controlled,

were replaced with pneumatic

valves. Installed products at pres-

ent include the heavy-duty semi-

rotary actuators DRD to operate

the butterfly valves in the pipeline

through which biogas is fed to the

boiler system. Their strength is

their precision, which enables trav-

el to a number of different posi-

tions, particularly for the butterfly

shut-off valves and gate valves.

Once the installation had been

upgraded, there was not only an

improvement in the mechanical

dewatering of the digested sludge

but the production of biogas also

increased – and was exploited

efficiently as electrical and heat

energy.

1401 Customised Solutions

1402 Proportional Pressure Regulators

and Directional Control Valves

1403 Three-point gripper HGDT

1404 Valve series VB

1405 Fork light barrier SOOF

1406 Energy Efficiency

1407 Safety Technology Guide

1408 Vacuum generator OVEM

1409 “Vacuum Technology” poster

1410 Mini slide DGSL

1411 Miniature valves MH1

1412 Biotech/Pharmaceuticals:

Products and Services

1413 Ready-to-install Pneumatics

1414 Process Technology

1415 Partner to the Process Industry

infoservice “trends in automation” 14

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From

Impressum

trends in automation 14

September, 2008

Published by:

Festo AG & Co. KG

Ruiter Straße 82

D-73734 Esslingen

Chief editor:

Markus Ott, Sales Communication

[email protected]

Reproduction of excerpts is permissible,

provided that the source is acknowledged

as “trends in automation 14, 2008

As unique ...... as your fingerprint: Customised solutions,

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and know-how from Festo.

www.festo.com

AustraliaHead OfficeFesto Pty. Ltd.Melbourne179-187 Browns RoadNoble Park Nth VIC 3174Tel: +61(0)3/97 95 95 55Fax: +61(0)3/97 95 97 87Call Toll Free: 1300 88 96 96Fax Toll Free: 1300 88 95 95

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27833362

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26313924/26316838

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25512227

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732 0753

BatamTel: +62-816 50 23 10

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Makassar Tel: +62-813 42 05 52 00

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Semarang Tel: +62-24-355 66 53, 355 48 24

SurabayaTel: +62-31-849 10 44, 841 05 12

IranFesto Pneumatic S.K.Kh. Ramsar, Ko. Behbahan No.1P.O. Box 15815/148515 TeheranTel: +98-(0)21-8882 9225Fax: +98-(0)21-8882 2162

Branch OfficeTabrizTel: +98-(0)41-1524 1809

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Branch OfficesNagoyaTel: +81-(0)52-937-39 10

OsakaTel: +81-(0)6-6320-34 27

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Branch OfficesBusanTel: +82-(0)51-205 4921

DaeguTel: +82-(0)53-604 4365

SuwonTel: +82-(0)31-217 5163

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DaejeonTel: +82-(0)42-861 7797

GwangiuTel: +82-(0)62-955 4168

ChangwonTel: +82-(0)55-288 7797

CheonanTel: +82-(0)41-533 4871

GumiTel: +82-(0) 54-458 2235

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Branch OfficesPenangTel: +(60 4) 643 0918

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Branch OfficesChristchurchTel: +64-(03)-348 87 96

WellingtonTel: 0800 433 78

HamiltonTel: 64-(07)-846 60 80

PhilippinesHead OfficeFesto IncFesto BuildingKM 18, West Service RoadSouth Super Highway1700 Paranaque CityMetro ManilaTel: +63 (2) 77 66 888Fax: +63 (2) 82 34 219

Branch OfficesCebuTel: +63 (32) 345-1120

BaguioTel: +63 (74) 447-0394

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DavaoTel/Fax: +63 (82) 299-4275

Bacolod CityMobile Phone: +63 (0917-8807050)

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General Santos CityTel: + 63 (83) 382-0005

Zamboanga CityTel: +63 (62) 991-0489

Tarlac/PampangaMobile Phone: +63 (0928-5028288)

SingaporeFesto Pte Ltd.6 Kian Teck WaySingapore 628754Tel: +65-62640152Fax: +65-62611026/62659276

TaiwanHead OfficeFesto Co.Ltd9 Kung 8th RoadLinkou 2nd Industrial zone24450 Taipei Hsien Taiwan, R.O.C.Tel: +886-2-2601-92 81Fax: +886-2-2601-92 87

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Taichung Tel: +886-4-2475-7278

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Northern Branch/LamphunTel: +66 (0) 53 58 13 37-9

VietnamFesto Pte Ltd.Vietnam Rep. Office206, Tran Nao Street, Binh An WardDistrict 2Ho Chi Minh CityVietnamTel: +84 (8) 7406909Fax: +84 (8) 7406910DID:+84 (8) 7406908

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