trend in automation 12

Trends in Automation Nr. 11, 2007

In focus“Safety first”Minimising risk with safety-related pneumatics

Valves and valve terminals“3x the choice with ASi”Creating decentralised solutions with the new valve terminals

Control systems“On the safe side”Checking fuel injection sleeves with compact vision systems

Handling and assembly“Discover the possibilities”Positioning Drives software for electrical drive systems

www.festo.com

No. 12, 2008

Safety rules

By the way, the two exceptionalathletes Alexander and ThomasHuber completed their speedyascent in 2:48.35 hours – 15 sec-onds faster than the previousrecord that had not been brokensince 2002.

The “trends in automation”Editorial team

Yosemite National Park, October2007: Two extreme climbers standat the foot of the 1000-metre gran-ite monolith El Capitan, one of theworld’s most famous challengesfor rock climbers. Their goal: toreach the top in record time. Eachgrip and step must be preciselyexecuted and teamwork is key. An attempt such as this requiresmaximum safety – even the slight-est lapse of attention or failure toconsider a risk can quickly lead todangerous situations.

It’s the same in automation. Thehigh dynamics that are ofteninvolved require coordinated sys-tem components. The interactionbetween man and machine mustbe harmonious, possible risksshould be identified in advanceand the pneumatic systemdesigned in such a way that risksdo not occur or are systematicallyavoided. Safety for man andmachine is the top priority.

Minimising risks with safety-ori-ented pneumatics means ensuringthe safe operation of machinesand systems at all times. “trendsin automation” addresses thistopic in the cover story “Safetyfirst”. Festo covers the key rele-vant safety functions, whether thesafe pressurising and exhaustingof system components, manipula-tion protection or the stopping andblocking of movements, with pneu-matic as well as servo-pneumaticproducts and solutions. Read moreon page 4.

In focus

Safety firstSafety-related pneumatics: minimising risk with the valve MS6-SV and clamping units DNCKE-S. 4

Newsticker

New products, events and newsflashes. 8

Handling and assembly

Ideal gripper typeThe servopneumatic proportional gripper HGPPI in theassembly of A/C system controllers. 10

Discover the possibilitiesFast and reliable: Positioning Drives software calcu-lates electrical drive systems for every application. 12

On the sunny sideSolar modules: spindle axis DGE-SP and servo driveMTR-DCI position the dispenser heads. 14

Valves and valve terminals

3x the choice with ASiRealising decentralised solutions with the valve termi-nals MPA, VTSA and CPV for AS-interface. 17

When space is tightThe valve series VOVG is available as an individualvalve, valve manifold and directly integrated. 20

Industry specific solutions

Divine purityClean water: decentrally installed CPX/FECs control28 filtration tanks with shut-off valves. 22

On the safe sideCompact vision system SBOI-Q check sleeves for vehicle fuel injection systems. 24

Reliable welding connectionsPneumatics, logistics services and training coursesare on board for the construction of ship blocks. 26

Services and products

ATEX – now ready to install!Systems in areas of explosion risk: assembled andtested complete systems with full documentation. 28

Automation worldwide

Applications – from Argentina to Indonesia. 30

Infoservice, Editorial 34

4

Greater safety: avoiding accidents with state-of-the-art safety technology

In useSoft-start and exhaust valve MS6-SV, clampingunits KEC-…-S and DNCKE-S

Benefits• Reliable pressurising and exhausting with

the MS6-SV• Braking with KEC-…-S and DNCKE-S

In focus

trends in automation No. 12, 2008

Safety standards are becoming more and more important. The requirements span the entire control

sequence – from compressed air preparation through drives and valves to controllers. Consequently,

the industry’s declared objective is to make processes and systems as safe as possible.

Safety first

3 Reducing pressure and force

5 Exhaustingsystem parts

8 Reversing movements

1 Force-freeswitching

10 Pausing and blocking movements

9 Reducing speed

4 Pressurisingsystem parts

10 Safety measures for 4 operating states

6 Maintainingpressure

7 Manipulationprotection

2 Two-hand control

Setting and service operation

Emergency operation

Initial position, standstill

Normal operation

5


Increased safety standardsand the new machine directivecoming into effect at the end of2009 make safety technology amuch discussed topic. Safety is a hot topic for Festo too, both inthe process industry and in indus-trial automation and is relevant for all automation levels and prod-ucts. Machines have to be con-structed in such a way as to avoidphysical damage. Certain safetymeasures can prevent hazards inall operating states of a machine.At the same time, the use of safetytechnology minimises the risk ofliability.

Forewarned is forearmedThe machine directive prescribesrisk assessment and possibly riskreduction for machines. The riskassessment then serves as a basisfor deriving and defining safetymeasures. The primary goal whendesigning a new system is to iden-tify risks in advance and, if possi-ble, to eliminate them throughappropriate planning. Since riskcan never be eliminated fully, thisresidual risk must be minimised or eliminated by means of techni-cal safety measures, for exampleusing safety-related pneumatics.These safety goals are achieved

using various safety functions. In this context, reliable operationof the machine in all modes andphases of the machine’s servicelife must be taken into considera-tion. For this reason, safety-relatedpneumatics offer solutions forcommissioning through automaticand manual operation to emer-gency functions such as reliablestopping or exhausting.

The three steps of risk analysisAccording to EN ISO 12100, a riskanalysis essentially comprisesthree steps: first the machine’slimits are determined, next the

risk situations are identified andfinally the risk assessment is car-ried out. Depending on the out-come of the risk assessment,either design-based safety meas-ures or technical safety measuresmust be defined. This process isrepeated over and over until theresidual risk is reduced to anacceptable level.

As a general rule, the simpler thesafety technology used in theapplication, the more efficient it is. The complexity of the safetytechnology is typically determinedby the range of risk possibilities

Mechanical:• Forced control (contours, cams)• Pneumatics• Hydraulics

old: EN 954

new: EN ISO 13849-1

DIN EN IEC 61508 seriesMechanical engineering DIN EN IEC 62061, process industry DIN EN IEC 61511

Electrical, electronic:• Sensors• Relays• Controllers (hard-wired logic)

Programmable, electronic:• Programmable mini control systems• Reliable bus systems• PLC safety

Klaus Gabriel, safety technology expert at Festo: “The safety functions for pneumatics can be sum-marised in approximately 10 functions. For thesesafety functions, we offer either individual productsor complete solutions for realising safety functionsin a system. Safety measures that can be integratedin a product offer our customers many advantages.

As a result, elaborate calculations and certification of conformity withstandards are no longer required, saving a lot of time and expert knowledge.”

Key safety related standards at a glance

6 In focus ... Safety first


Clamping unit KEC-…-S• Sizes: 16, 20, 25 mm• Static holding forces: 1,300; 3,200; 8,000 N• Assembly: Wide selection of mounting options

Cylinder with clamping unit DNCKE-S• Function: Double-acting• Sensing• Dimensions: ISO 15552 and VDMA (apart from the length)• Piston diameter: 40, 63, 100 mm• Stroke length: 10 ... 2,000 mm• Static holding forces: 1,300; 3,200; 8,000 N• Cushioning: Adjustable pneumatic end-position cushioning• Assembly: Wide selection of mounting options

Soft-start and exhaust valve MS6-SV• Safety measure: Gradual pressurisation, adjustable (soft start),

fast reliable exhausting• Size: MS6• With/without safety silencer• With/without pressure gauge• With/without pressure sensor SDE1• With indicator output (floating)• With LED status display

Both the clamping unit DNCKE-Sand the clamping unit KEC-…-S areapproved as holding devices andas brakes for use in safety-relevantcontrol systems. With appropriateadditional measures, however,they can also be used for accidentprevention in control systems of ahigher category. The componentsare certified by the BGIA (Occupa-tional Safety and Health Institute),affirming their particular suitabilityfor safety requirements.

2. Reliable pressurising andexhausting using MS6-SVThe BGIA-certified soft-start andexhaust valve MS6-SV serves as a decentralised/centralised unitfor supplying machines and sys-tems with compressed air. It is aself-testing redundant mechatron-

ic system according to the require-ments of ISO 13849-1. This meansthat the pneumatic safety measureof reliable exhausting is ensuredeven if defects occur within thevalve. But that’s not all – the safetycheck of the piston rod position isperformed directly by the valveduring the self test. This meansless complicated wiring, whichsimplifies installation.

that require individual attention.Standardised implementation ofsafety technology is therefore verydifficult.

Two examples for greater safety:1. Braking with KEC-…-S andDNCKE-SWhether in response to power failure, a requirement of the safetyfunction, intermediate stops forservice units, pressure failure ordrop, the clamping unit KEC-…-Sprovides braking action within precisely defined tolerances bymeans of a clamping componentacting on a rod by spring force. Itprovides this action over sustainedperiods, in applications involvingvarying loads, irrespective of fluc-tuations in the operating pressureand unaffected by system leaks.

is 1201Safety technology – pneumatic positioning

Infoservice 7


Attention: New machine directive!

The new machine directive comes into force on 29.12.2009. There will be notransition period. EU countries are required to incorporate the machine directiveinto national law by the end of 2009. Among other things, it contains safety andhealth protection requirements for the design and construction of machines. Themanufacturer is furthermore required to carry out a risk assessment. To this end,the manufacturer is required to determine the limits of the machine, to identifyhazardous situations and to estimate and evaluate risks. The system manufac-turer is obliged to implement suitable safety measures to reduce the risk to anacceptable level.

Euro

peG

erm

any

February 2007DIN ratification

October 2, 2006EN ratification

February 2007withdrawn by DIN

DIN EN ISO 13849-1

DIN EN 954-1

November 30, 2009

May 8, 2007Listing in the EU official journal

EN ISO 13849-1

EN 954-1

December 29, 2009

May 2006EN ratification

Incorporation into national law new machine directive

old machine directive

20072006 2008 2009 2010 2011

EN 954-1 initiates assumption of conformity with the machine directive 98/37/EC

EN ISO 13849-1 initiates assumption of conformity with the machine directive 2006/42/EC and 98/37/EC


Pure integration

Three valve sizes without adapters on onevalve terminal – for up to 32 standardvalves of widths of 18, 26 and 42 mm.These are not the only strengths of thevalve terminal VTSA. Also worth mentioningis its standardisation and flexibility: 100%ISO 15407-2 and ISO 5599-2 meet individ-ual configuration options through to com-prehensive function and system integrationwith up to 512 I/Os. But that’s not all: inte-gration of all common fieldbus systems andEthernet both in CPX-AIDA in metal designor CPX in standard design. Also included iserror detection by means of the integrateddiagnostic concept.

Sensors

Short ...

... and sweet: this is precisely the advantage of the proximity sensor SMT-8G/10G. With itsextremely short overall length in the direction ofthe slot length, it is the optimum sensing solutionfor grippers and all compact drives. Housing partsor cable outlets projecting beyond the slot lengthin the direction of the gripper jaws are thus a thingof the past. The sensor is equipped with a sturdyrobot quality sensor cable and two LEDs. It ismounted quickly and easily using a standard 1.5mm allen key.

Vacuum technology

Secure gripping

The vacuum security valve ISV not only ensuresabsolutely secure gripping, it also prevents loss of vacuum if a suction cup has not gripped the work-piece. The ISV closes the vacuum line or supply in thecase of a parallel arrangement of several suction cupsif there is a leak or if the workpiece accidentally dropsoff at one or more suction cups. The integrated filterprevents dirt attracted by the vacuum suction cupfrom getting into the vacuum circuit. The vacuumsecurity valve is harmonised with the comprehensivesuction gripper range ESG. This facilitates selection of the perfect connection size – for cost-effective use.

Compressed air preparation

A wealth of booster variants

Pneumatic pressure booster DPA: thebroad range comprising three differentdiameters and two pressure ranges foreach gets a boost.

DPA-…-D: The control-free price-optimisedvariant of the DPA range ensures twice theoperating pressure in all sizes.

DPA-…-A: Thanks to the integration of amagnet on the new piston system, thisbooster offers sensing options for cyclesor response times and thus informationabout the service life as well as oversizingand undersizing.

DPA-…-CRVZS2: Pre-assembled and easyto order with reservoir, pressure regulatorand all accessory parts such as pressuregauges and tubing.

8


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

www.festo.com/en/esg

www.festo.com/en/smt-8g-10g www.festo.com/en/vtsa

9


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


Impressive!

The maximum expandability of the valve terminal CPX/MPA surely sets a new world record: its internal serial communication and specific ASICsfor valve actuation mean that up to 512 I/Os per fieldbus node are possi-ble. 128 solenoid coils (e.g. for 3/2-way valves) and up to 8 additionalpower supply modules for pressure and voltage zones can be included.With the latest function integration, comprehensive diagnostics and inte-grated IT services. A true marvel for greater productivity and economy –in lengths of up to three metres!

Valves

Three new additions

These additions to the one-way flow control valvesseries are causing a sensation: the small, lightweightone-way flow control valve VFOC is the first choicewhen either money or space are tight. The optionaltamper-proof cap ensures that the set flow rate canbe securely maintained.

The second new addition is the new VFOC series withpush-in sleeve. Installation takes just seconds: insertin the cylinder via the integrated push-in sleeve, alignand you’re ready to go.

Completing the new trio is the valve GRSLA. Theincorporated scale clearly shows the set flow rate andenables this to be reproduced at any time.

VFOV

VFOC

GRSLA

is 1202 Handing system overview

Compressed air preparation

Filters at the start

Whether in terms of product range, functionality of components or services, the MS series fromFesto offers a fully integrated concept. In additionto the sizes MS4, MS6 and MS9, the MS9 is nowalso available in a metal bowl design. Also includ-ed from the outset are fine (LFM-B), micro (LFM-A)and active carbon (LFX) filters. The size and rota-tional adapters AMV and RMV for adapting to thenext size range up or down make compressed air preparation more efficient – thanks to mixedsizing.

Brochures

Handing system overview

The 100 or so pages in this brochure are devotedentirely to the topic of automation using multi-axisand positioning systems such as pneumatic andelectric handling modules, pick and place units,linear and three-dimensional gantries. A clearmatrix offers the perfect decision-making aid. Alsoincluded is a CD-ROM with full system description in pdf format and numerous animations.

10

Automotive supplier industry: Assembly of A/C system controllers

In useServop-neumatic proportional gripper HGPPI

Benefits• High flexibility within a single system• Independent gripper jaw control, therefore

no need to change grippers• No retooling times



Ideal gripper type

For some time now the design and look of car models have

been about more than just the body; even the controls inside

the vehicle express the driver’s individuality and aspirations.

So, for example, the controller for the A/C system in a sports

car is different to the controller for the A/C system in a peo-

ple carrier. Without flexible handling concepts, however,

assembly systems are severely restricted. This makes the

servo-pneumatic proportional gripper HGPPI with its inde-

pendent gripper jaw movements the ideal type for custom

solutions.

The custom engineering com-pany axelius automation GmbHdeveloped for Behr Hella Thermo-control GmbH a flexible assemblysystem for electronic componentsfor different variants of A/C systemcontrollers. In this system, plugsare inserted into panels. In thenext step, the panels are separat-ed into individual circuit boards,tested on the ICT tester and pack-aged for final assembly of an A/Csystem controller.

The servo-pneumatic proportionalgripper HGPPI positions the plugover the circuit board; during theplugging operation it holds theplugs which are inserted into thepanels with a force of 100 N perpin. “The proportional gripper canbe adapted to different plug sizesflexibly and without costly conver-sion”, explains Bernd Büsser, proj-ect manager for systems engineer-ing at axelius. “One signal from thesystem PLC via Profibus is all that’s

needed for adaptation to differentplug dimensions.”

Highly flexibleThe assembly step described isrequired since the plugs cannot be inserted in the reflow oven dur-ing manufacturing of the panels.This is where the HGPPI comesinto its own as a flexible means of rationalisation. “Whereasbefore we could only insert a spe-cific plug type on a specific paneltype on a single assembly line,now we can produce a large num-ber of variants with greater speedand flexibility”, says Peter Stillers,head of planning services at Behr-Hella Thermocontrol, delightedwith the productivity growth gen-erated by the new system.

Independently adjustable jawsThe servo-pneumatic gripperHGPPI combines mechatronics andmicrosystems technology in a sin-gle component, as it integrates

www.festo.com/en/hgppi

is 1203Proportional gripper HGPPI

Infoservice 11


to ensure controlled sequencesthanks to the integrated electron-ics. The gripper fingers with theirfree and independent position-ing offer maximum freedom ofmovement with an accuracy of ±0.1 mm. Changing grippers orelectric grippers calls for space,making the compact HGPPI theideal type for assembly tasks ofthe future.

gripper technology, electronics, adisplacement encoder and valves.This mechatronic intelligenceenables the small and lightweightgripper to move its jaws independ-ently of one another and thus togrip a wide range of shapes,weights and workpiece surfaces.Without this, complicated gripperchanges would be required.

The gripper jaws are actuated viasix piezo proportional valves inwidths of 5 mm. The innovativepiezo technology saves space andenergy since energy is only sup-plied during the switching move-ment. Piezo ceramic bending actu-ators with propor-tional switchingcharacteristics guarantee lowenergy consumption and fast cycletimes.

In the case of the servo-pneumaticproportional gripper, informationabout the displacement signal and the force is always available

Behr Hella Thermocontrol GmbH

Products A/C system control panels, A/Csystem controllers, controllers for electric heaters, fan con-trollers, A/C system sensors

Employees 1,000Contact D-59557 Lippstadt

www.bhtc.com

axelius automation GmbH

Products Assembly systems, testing technology, system construction

Employees 120Contact D-59555 Lippstadt

www.axelius.de

Producing large numbers of variants with greater speed and flexibility: with the servo-pneumatic proportional gripper HGPPI, costly conversion is no longer required.

Station upstream of the ICT test: a robot transports the finishedpanels to the panel separator with the help of a gripper unit. Theseparator cuts the panels into the individual circuit boards that arelater installed in the A/C system controllers. The gripper unit com-prises a number of grippers of the type HGPT and uses grippingforce retention to reduce the pressure. This enables the grippers to be set to an extremely gentle setting so as not to damage the circuit boards. The compact size of these T-slot grippers makes them almost customised for handling both delicate and small com-ponents.

12

Positioning Drives: software tool for calculating electric drive systems

Key features• Fast, reliable and convenient• Just a few application data need to be entered• Simple selection of the best possible solution



Discover the possibilities

Toothed belt drives, spindledrives or direct drives, servomotors, stepper motors or DCmotors, ball bearing guides orplain-bearing guides – the abun-dance of alternatives poses aproblem for the user: the correctdrive must be calculated. To makethe selection of the best possiblesolution as well as the associatedcomponents easier, there is nowsoftware to perform this calcula-tion. Selecting the ideal combina-tion from the wide and harmonisedrange of electric linear axes,motors, gearing, controllers andsoftware becomes clear after a few application data have beenentered. The tool can also calcu-

“Which is the right drive for my system? Is the selected drive accurately

sized? Will the required speed be reached?” The “Positioning Drives”

software provides the answer. It calculates the optimum electric drive

system for each application quickly, reliably and conveniently.

13


Festo Configuration Tool FCTSimple commissioning of an electromechanicalautomation unit with just a few clicks of the mouse.

The Festo Configuration Tool not only configures indi-vidual electromechanical drive systems, it also man-ages all electric drives within a system using one over-all software project.

The FCT is prepared for additions to the device family:each device type is supported by a separate softwarecomponent or plug-in.

Further advantages:• Clear division of the screen into the navigator

bar, workspace and online window for operatingthe drive

• Guided sequences• The software rejects impermissible combinations• Directly supports selection of the mechanical drive• Sizing possible online and offline

late the characteristic load valuesfor the selected drive quickly andreliably through the specificationof various project parameters.

Switch on and goFrom start to finish, a calculationproject involves a maximum of four steps.

Step 1: Enter application parame-ters such as installation position,mass, stroke and precision. Thereis also an option for specifying therequired travel time and of prese-lecting the drive technology.

Step 2: Select the required solu-tion package. These are sorted bymotor and axis technology, compo-nent utilisation, cycle time or priceto make selection easier.

Step 3: The program then outputsdetailed results such as motorcharacteristic, dynamic character-istic values, system data, productdata and parts list; these arestored as a file and can be reusedfor ordering and preparation ofmachine documentation.

Looking for that little bit extra?As a supplier of complete solu-tions Festo has the ideal answerfor every application, regardless ofthe requirements. The mechanicalinterfaces between pneumatic andelectrical components are mostlyidentical, which enables a hugenumber of combinations. Plug andwork makes commissioning easier,even without any specific previousknowledge. The components allcome from a single source, withknow-how and consulting included.

“Positioning Drives” is not an off-the-shelf solution; it is preciselytailored to the customer’s task.Once the possibilities have beendiscovered, the customer makesthe decision.

You can find the latest version atwww.festo.com/download.

14

Bonding of solar cells

In useSpindle axes DGE-SP with servo drive MTR-DCIfor positioning adhesive dispenser heads

Benefits• Accurate positioning of dispenser heads

along the X-axis• Feed function along the Z-axis• Stop function for substrate plates



ules. In principle, the system con-cept consists of a module forapplying the conductive adhesiveand modules for bonding in longi-tudinal and cross direction usingtin-coated copper bands. Pneu-matic and electrical componentsfrom Festo perform key functionsin the individual modules.

Precisely applied conductiveadhesiveApplication of the bead of adhe-sive to the substrate plates is per-formed using CNC control in theconductive adhesive applicationmodule. This requires precisionsince applying too little conductiveadhesive would not produceenough of a bond and too muchconductive adhesive could resultin short circuits. The two dispenserheads apply the adhesive atspeeds of 70 to 100 millimetresper second. They are carried on

separate X-axes that work inde-pendently of each other. Integrat-ed in the drive of the two electro-mechanical linear axes of the DGEare a motor, gearing and controllerfrom Festo as well as power elec-tronics with positioning control.This reduces the space required inthe control cabinet and the needfor extensive cabling.

All that is needed to install themotor MTR-DCI is a cable for thepower supply and a Profibus cable.The commissioning process can be performed directly on the MTR-DCI via the LCD display or usingthe FCT (Festo Configuration Tool)on a PC. The two DGE linear axesalong the Y-axes use toothed belts.They are connected using a cardanshaft and therefore require onlyone drive. Precision actuation ofthe axes enables the dispenserheads to apply adhesive beads

On the sunny side

The client list of ACI-ecotec, based in the Black Forest, reads like a who’s

who of the solar energy industry. The company is achieving considerable

market success with systems for the production of thin-layer solar modules.

Electric linear drives, pneumatics and other automation components play

central roles here.

Silicon, the most importantconstituent in solar cells, is thesecond most frequently occurringelement on earth. However, turn-ing it into the crystalline cell formpreviously required for photo-voltaics takes a lot of work. Thin-layer solar modules are producedby applying photoactive semicon-ductors in thin layers to a low-costsubstrate, usually glass. The lowermaterial and energy consumptionand the possibility of a high levelof automation during productionoffer a considerable savingspotential in comparison with crys-talline silicon technology.

The ecoContact system conceptdeveloped by ACI-ecotec for theproduction of thin-layer solar mod-ules enables the construction ofcompact and customer-specificstandardised production struc-tures from 4x4 metre system mod-

15


with an accuracy of 0.2 millime-tres. The bead length, distancebetween beads, recipes, etc. canbe freely programmed. All workprograms can be stored and calledup at any time.

Speed and precision during bondingOnce the adhesive has beenapplied, longitudinal bonding andcross bonding are carried out inadjoining modules using contactbands and bus bars respectively,made from tin-coated copperbands. These bonding modulesuse Festo toothed belt axes of thetype DGE with recirculating ballbearing guides.

Throughout the bonding process,each processing step requirestransportation of the workpieceswithin the system as well as exactpositioning. So, for example, the

The application of the adhesive trail to the substrate plates calls for precision; this is achieved by means of CNC control in the conductive adhesive application module.

Two dispenser heads apply the adhe-sive at speeds of 70 to 100 millimetres per second.

In principle, the system concept by ACI-ecotect for bonding ofthin-layer solar cells consists of a module for applying the con-ductive adhesive and modules for bonding in longitudinal andcross direction using tin-coated copper bands. The picture showstwo modules for bonding the thin-layer solar cells in longitudinaland cross direction using tin-coated copper bands. The work-pieces coming from the conductive adhesive application moduleare assigned to the two modules by the module in the centre. The ecoContact system concept enables the construction of acustomer-specific standardised production structure from vari-able system modules.

Dipl.-Ing. Karl-Heinz Menauer,Managing Director of ACI-ecotec GmbH & Co. KG: “Staff and management areequally enthusiastic about the principle of photovoltaics.Since we founded the company

in 2004, our enthusiasm for innovation has beencomplemented by a strategy of driving new devel-opment, a strategy that has already been reward-ed with some excellent results on the market.Among these successes are systems for the pro-duction of thin-layer solar modules, with compo-nents from Festo playing a central role. We attachgreat value to close and open partnerships withsuppliers, such as we enjoy with Festo. It is veryimportant for us to accept the challenges in thismarket of the future, for which Festo will becomeincreasingly significant for us as a strategic partner.”

support bridge for program-controlled transport and position-ing of the substrate plate is drivenby two axes from Festo. They movealong their four-metre path withprogrammable acceleration and deceleration ramps and speed profiles. The positions can beapproached at up to 18 metres per minute and are programmed by means of teach-in.

Within the movement system ofthe bonding module, cylindersensure speed and precision duringthe feed movement, centring, swiv-elling and gentle stopping of thetable. They operate scissors forcutting contact bands and insulat-ing strips and also carry out arange of other functions. They areactuated by means of speciallydesigned valve terminals. Compactservice units prepare the com-pressed air from the network to

16 Handling and assembly ... On the sunny side


Festo components

at ACI-ecotec

Spindle axis DGE-SP-KF

Servo motor MTR-DCI

Compact cylinderADVUL

Compact cylinderADN

Proportional pressure regulatorVPPM

Valve terminal CPV

supply the systems. The controlcharacteristics of pressure profilescan be programmed using the inte-grated proportional pressure regu-lator VPPM. The user can alsochoose between three specific pro-files by pressing a button. Thepressure regulator can be actuatedvia fieldbus thanks to the connec-tion to the CPX terminal. Closecooperation between specialistshas resulted in an extremely pro-gressive system concept.

ACI-ecotec GmbH & Co. KG

Products Automation technology for assembly of small and micro products; process techniques such as selective soldering tech-nique, CO2 snow jet cleaning and dispensing, customer-specific production systems

Contact D-78112 St. Georgenwww.aci-ecotec.de

A standard cylinder ADN acts as a stop for the substrate plates.

The two adhesive dispenser heads are carried on separate Xaxes that work independently of each other and consist of a spin-dle axis DGE-SP and a motor unit MTR-DCI with integrated gearunit and positioning controller.

17

AS-interface

Field of application• Upstream machine and system functions

as in feeding units for material, in conveyorsections or for opening/closing magazines

• Downstream handling and packaging stations• Process industry

Key features• Increased productivity combined with

reduced costs for installation and power consumption

• High flexibility• Simple structure



3x the choice with ASi

Decentralised solutions are becoming increasingly popular –

and with them actuator sensor interface (AS-i) technology.

Fast, cost-effective and robust, AS-interface is suitable for

binary and analogue actuators and sensors along with small

valve terminals. Even though it will soon be 15 years on the

market, AS-interface is far from obsolete. The latest area

of application: the valve terminals MPA, VTSA and CPV

(Spec. 3.0) for AS-interface.

The market for AS-interface is booming. In 1997, there were100,000 slave applications world-wide; since then, this number hasincreased to over 10 million. Whenit comes to wiring at the lowestfield level, the fast and cost-effec-tive AS-interface always comesthird worldwide after Profibus DPand DeviceNet. In order to meetthe increasing requirements, moreup-to-date ASi specifications with

enhanced functionality and per-formance are constantly beingdeveloped (these new specifica-tions are always downwards com-patible with earlier ASi versions).

Fast, easy, cost-effectiveAn AS-i slave is the ideal way ofcontrolling a pneumatic controlloop system made up of limitswitches, valves and cylinders. If it is well designed, it will result in

Typical applications for AS-interface include conveyor sections,sorting systems with branches covering an extensive area andupstream machine functions.

18 Valves and valve terminals ... ASI to the power of 3


low energy consumption and opti-mum pneumatic sequences.Decentralised AS-interface instal-lations with short tubing lengthsand an optimised pairing of valvesand drives offer a straightforwardway of completing a network and a robust method of data transmis-sion. In addition, they also reducecycle times in a system by up to30% and air consumption by up toas much as 50%. The switchablepower supply (yellow/black cable)ensures flexibility and reduceslogistics. The open system to ENand IEC standards reduces con-ventional installation costs by upto 40%. A further advantage forthe user: AS-interface networkscan be seamlessly integrated intoall common Fieldbus and Ethernetenvironments.

3x the choice with ASiNew additions to Festo’s productrange: the new generation of valveterminals CPV, MPA and VTSA isnow on the market – with integrat-

ed AS-interface connections. Theyoffer three additional options pro-viding ASi with a wide range of dif-ferent applications.

The latest version of the valve ter-minal CPV uses the 7.A.7 profile of the ASI Spec. 3.0, making it the first of its type. It enables A/Boperation with 4 inputs and 4 out-puts per slave and opens the wayfor many new functions, solutionsand potential savings with AS-interface. Flow rates from 400 or800 l/min as well as double slaveswith 8I/Os are available for selec-tion. Up to 62 slaves per mastersignificantly reduce system costs.Cylinders and sensors are connect-ed to just one slave, reducing theinstallation complexity. The cycletime per CPV slave is a few hun-dred µs. The maximum bus cycle of 20 ms is reached once the net-work is fully expanded with 7.A.7profile slaves. Neither additionalconfiguration nor specialised pro-gramming knowledge is needed to

Decentralised, compact and modular machine structure - economically and flexiblynetworked using AS-interface.

* Example: Tubing length reduced from 3 m to 0.3 m thanks to decentralised installation at the AS-interface

** In comparison with conventional wiring

-30 %

-40 %

-50 %

reduction incycle times *

reduction ininstallationcosts **

reduction in air con-sumption *

ASi specification2.0 2.1 3.0

Inputs 4 4 4/8

Outputs 4 3 4/8

Max. bus cycle (ms) 5 10 20*

Number of digital slaves 31 62 62

Number of analogue slaves 31 31 62

Total I/O 248 434 992

Peripheral faults – • •

* All slaves to Spec. 3.0, profile 7.A.7

is 1204AS-interface

is 1206Valve terminal MPA

is 1205Standard valve terminal VTSA

is 1207Valve terminal CPV

Infoservice 19


use ASI Spec. 3.0. All the slavesneed is an ASi master also runningon Spec. 3.0 – everything elselooks after itself.

MPA and VTSA for AS-interface Modular sub-bases, compactsizes, integrated inputs and selec-table electrical connection technol-ogy (M8, M12, CageClamp, Harax,Sub-D) make the valve terminalMPA-ASi extremly flexible. With the 4I/O slave, the power can besupplied by either the yellow orthe black AS-i cable, halving thecosts of logistics. Both 4I/Os assingle slaves and 8I/Os as doubleslaves are available; the flow ratesizes MPA1 and MPA2 can bemixed. Flow rates of up to 700 l arepossible on the 2…8 modular valvepositions that can be equippedwith pressure regulators, gaugesand several pressure zones. Thesturdy metal design of the sub-base and valve also makes theMPA-ASI durable. The technicaldata:

• ASi Spec. 2.1• 31 slaves• 4I/Os per master• Fault bit and fault LED for each

slave• Bus and auxiliary power supply

looped through via 2x M12• Diagnostics of each slave• Watchdog

The powerful VTSA valve terminalwill be available with AS-interfacefrom autumn 2007. It has a flowrate of up to 1800 l/min and mod-ularity from 1 ... 8 valves – stan-dardised to ISO 15407-2 and5599-2. Its electrical data are thesame as that of the MPA-ASI, how-ever it also offers a shut-off platefor the hot-swap function thatenables valves to be replacedunder pressure. This makes it par-ticularly well suited to controllingcontinuous processes wheredowntimes must be avoided.

With over 30 products that supportAS-interface and over 1 million

product variants within the valveterminal range, Festo offers usersa range of economical and techni-cally harmonised automation solu-tions. The ever increasing demandin the market proves it – the poten-tial for AS-interface is nowherenear exhausted.

AS-interface – a growth market

Festo valve terminals

with AS-interface

Valve terminalVTSA, Spec. 2.1

Valve terminalMPA, Spec. 2.1

Valve terminal CPV,Spec. 3.0

450.000

400.000

350.000

300.000

250.000

200.000

150.000

100.000

50.000

0

20071998 1999 2000 2001 2002 2003 2004 2005 2006

20

Valve series VOVG

Field of applicationStandard pneumatics, handling systems,electronics/light assembly industry, processautomation

Key features• High flow rate with compact dimensions• Individual valve, valve manifold, direct

integration



When space is tight

What do you do if a shoe pinches when you try it on? The

general advice is to go up a size. If, however, a mechanical

engineer were to follow this advice, it might not go down

so well with the customer. The rule here is the smaller, the

better – and the more suitable! The new valve series VOVG

is the ideal solution for the narrowest of spaces. Compact

with an extremely high flow rate, the VOVG helps to keep

machine dimensions compact.

... on a PRS manifold ... as a customer-specific direct integration solution

VOVG as an individual valve ...

Where is the VOVG used?Wherever compact assembly isrequired, for example in compacthandling systems in the field ofstandard pneumatics or in theelectronics or light assemblyindustry. It can also be used in theprocess industry as a pilot valvefor valves and drives coming intocontact with other media.

What are the advantages for theuser?The narrow width of 10 mm ormore does not mean having to sacrifice flow rate – using either an individual valve or a valve mani-fold. A flow rate of 200 l/min, forexample, with the 10 mm width

results in correspondingly highcylinder speeds. Furthermore, theVOVG can be mounted on-site. Theresponse characteristics are nowbetter at reduced minimum oper-ating pressure. Higher perform-ance, however, does not meanshorter service life. Quite the con-trary; the durability has beenproven at over 50 million switchingcycles. Furthermore, the VOVGexhibits minimum leakage thanksto the reliable cartridge sealingsystem with piston spool, which in turn facilitates cost-effectiveoperation. And on the subject ofcost-effectiveness, the price/per-formance ratio is also impressive.

Technical data

• Flow rate: 200 l/min (100, 400 l/min)• Width: 10 or 12 mm (depending on the design)• Operating pressure range: -0.9 … 8 bar• Temperature range: -5 … 50 °C• Operating voltage: 5 V DC, 12 V DC, 24 V DC• Switching times (on/off ): 12/10 ms• Manual override: Pushing, pushing/detenting• Protection class: IP40

www.festo.com/en/vg

is 1208Valve series VOVG

Infoservice 21


How is the immense performancedensity achieved?Manifold rails can be used wherean individual valve is not suffi-cient. For example, 8-fold valvemanifolds with 200 l/min per valveand QS fitting. The next stepstowards even greater individuali-sation is customer-specific valvemanifolds. In this case, the keyterm for even greater performancedensity is direct integration. This is an extremely easy way of realis-ing customer-specific interfacesand installation requirements. Thisincreases the component densityeven further and simplifies han-dling.

VOVG supports process automationTwo typical applications in process automationunderscore the versatility of the new solenoidvalves VOVG.

Example: Valve control actuatorValve control actuators are used in processautomation for actuating disk or double poppetvalves. They comprise a displacement encoder, afieldbus interface and up to 4 control valves VOVG.

Example: Controlled linear drive unit with slideDemanding environmental influences togetherwith increased mechanical stress prompted cus-tomers to ask for a compact, sturdy and intelligentlinear valve actuator. Festo responded to theserequests with the type DLP-I that is used on slid-ing and gate valves. It comprises a displacementencoder, closed-loop control and four controlvalves VOVG and the proven linear actuator DLP –all hermetically protected. The required opening of the process valve is controlled through continu-ous comparison of setpoint and actual values.

22

Water treatment for 300,000 inhabitants in thegreater Paris area

In useDecentrally installed CPX/FECs control 28 filtra-tion tanks using Copac linear valve actuators for shut-off valves

BenefitsSturdy and reliable solution with IP67 protection



Divine purity

The river Seine was once protected by the Celtic goddess

Sequana, after whom it is named. Her protection, however,

did not extend to the industrial age, when cities such as

Paris began pumping their sewage straight into the river.

These days, however, the sewage treatment plant Les Gré-

sillons is once again making sure that the Seine is clean –

using automation technology from Festo.

Les Grésillons is presentlytreating 100,000 m³ of water fromthe Seine every day. This corre-sponds to a catchment area of300,000 inhabitants. This figurewill have tripled by the time expan-sion of the system is complete in2015; it will purify the sewage pro-duced by 1 million people in thegreater Paris area and return it toFrance’s third largest river.

Special filter technologyLes Grésillons differs from conven-tional sewage plants with biologi-cal purification stages in that ituses special filter technology, notbacterial activation tanks. After the

www.festo.com/processautomation

mechanical purification stageusing sand filters and screeningunits, the pre-treated sewagepasses through three levels con-taining biofilters, specifically so-called Biolest technologies, wherethe nitrogen is removed from thesewage.

The supply to the 28 biofilters aswell as the backwashing process is controlled by process gates such as shut-off or butterfly valvesusing automated pneumatic actua-tors. Festo developed a specialCopac linear actuator DLP withthrough piston rod for the 28Fontaine shut-off valves without

Infoservice 23


housing to facilitate the use of ahandwheel in emergencies. Eachshut-off valve is equipped with twoproximity sensors SME-8 for sens-ing the mechanical end stops andtransmitting them to the controller.

CPX for reliability28 decentrally installed electricalterminals in conjunction with thevalve terminal MPA actuate thedrives and record all data relatingto the 28 filtration tanks. Each tank has an interface with the cen-tralised Allen Bradley controller via a DeviceNet fieldbus that isconnected to the valve terminals.The CPX also integrates the FrontEnd Controller FEC for managingthe control circuits locally andensuring safety positions. Its diag-nostic functionality enable the CPX

to quickly detect any faults in theplant. IP67 protection permittedthe open installation of the elec-trical wiring and pneumatic tubingwithout a protective guard. TheCPX concept as well as the highprotection class reduced the elec-trical and pneumatic installationcosts to a minimum.

Apart from reliable automationtechnology, the plant operatorSIAAP, the supplier of the filtrationtanks Stereau as well as the manu-facturer of the shut-off valvesFontaine were also able to rely onFesto’s services for training andcommissioning, thus saving valu-able time. The inhabitants of theSeine valley no longer need to relyon the services of the Celtic god-dess Sequana; a further 70 filtersystems are to be installed in LesGrésillons by 2012.

w2.siaap.frwww.stereau.frwww.hfontaine.com

Clean water in the Seine: thanks tobiofilter systems in Les Grésillons.

Fast detection of malfunctions via thediagnostic functions of the CPX/MPA.

Specially designed Copac linear valveactuator DLP with through piston rod: reli-ability for the non-housed shut-off valvesof the filtration tanks.

is 1209Partner to the process industry

24 Industry specific solutions


On the safe side

Faulty components in the production process are every

industrial firm’s nightmare. Valuable time, tight budgets

and reputation are at stake. System manufacturers therefore

need to get to grips with their customers’ increasing quality

requirements. Inspection systems such as intelligent com-

pact vision systems or the Checkbox from Festo ensure these

nightmares never see materialise.

Quality assurance is a centralissue at Technik-Zentrum-Esslin-gen GmbH (TZE), particularly whenit comes to the production ofsleeves for fuel injection systems.With a part throughput rate ofapprox. 100 inspection parts per minute, the previous manualand visual final inspection was no longer adequate. A visualinspection system was needed.

A two-fold inspection systemThe problem called for a completepackage of feed and visual unit. Itwas expected to feed the drawingsleeves in the correct orientationand at the same time to check thecross-sectional diameter of thepart cross sections. Against thisbackground, TZE opted for thecom-pany ifc intelligent feedingcom-ponents in Oedheim.

As a supplier of flexible feed sys-tems for type and orientationchecking and quality inspection,ifc primarily uses vision systemsand components from Festo. In the case of the sleeves, a Check-box Compact PLC in com-binationwith the new surface-based visionsystem SBOI-Q was felt to be theideal solution.

100% quality processThe sleeves are inspected at twostations; the first one checks thecross section and the second thediameter. The “multifunctional”Checkbox Compact PLC is the firststation. It controls the flow of thesleeves and at the same timechecks their cross section as they

Complete solution comprising feed unit and visual unit: the Checkbox Compact PLCand compact vision system SBOI-Q inspect drawing sleeves for vehicle injection systems.

Inspection of sleeves for vehicle fuel injection systems

In useCheckbox Compact PLC and intelligent compactvision system SBOI-Q

Key features• 100 % quality inspection• Reliable detection and rejection of faulty parts• Smooth material feed

www.festo.com/en/sboc www.festo.com/en/chb

25


pass the optical duct. It performs a comparison against the dimen-sions of a good part learnedbeforehand and sends a signal tothe ejector in the case of a faultypart.

If the cross section of the inspect-ed part is acceptable, a message is forwarded to the downstreamintegrated compact vision systemSBOI-Q. As per the second station, it checks the part diameter andensures that only perfect partsreach the production process. The interaction of the two sys-tems guarantees 100% qualityinspection. Deformed or damagedparts are reliably detected andrejected.

Checkbox Compact PLC

User-friendlyThe Checkbox Compact features a teach-in functionthat enables it to learn inspection parts automaticallyand without the need for complicated programming.The CheckOpti software facilitates fine tuning duringthe recording and monitoring of the most minute contour deviations or quality-related measured vari-ables. Following the presentation of sample parts, the user defines various inspection characteristicswith the aid of the software, including length, height,surface, centre of gravity or angle, and loads theinspection program onto the Checkbox.

FlexibleIts compact design and clear interface definition meanthat the Checkbox Compact can be integrated eveninto existing systems with limited space. All of thecomponents required are incorporated into its hous-ing, including the entire imaging sensor system (lens,lighting, camera). The optical duct underneath theCheckbox Compact faces downwards and is thus easyto integrate in the material flow.

IntelligentThe multifunctionality of the Checkbox Compactmeans it can control the entire feed process. It fea-tures I/O for communicating with a master PLC as well as an option for encoder linking. An additionalPLC is therefore not necessary.

Intelligent compact vision system SBO..-Q

The intelligent camera delivers reliable inspectionresults for a broad range of applications. The systemcan be used to check regularly and irregularly movingor static parts. Left: SBOI-Q with integrated lens;right: SBOC-Q with threaded connection for differentlenses.

is 1210Checkbox Compact PLC

is 1211Compact vision system SBO..-Q

Infoservice

26

Automated welding systems in shipbuilding

In useValve terminals CPX/MPA, standard cylinderDNCB, MS series service units

Benefits• Reduced installation and wiring complexity

with CPX/MPA• Total solution package from products and

training courses to logistical services



Reliable welding connections

“With the installation of a PEMA flat panel line for the automated construc-

tion of ship blocks at Britoil Offshore Services Pte. Ltd. in Singapore, we’ve

taken a major step in expanding our Asian business”, says Pekka Heikonen,

President of the Finnish Pemamek Group. In this particular case, pneumatic

components ensure sturdy welded joints for connections in shipbuilding.

Thus the delivery of the hugewelding systems to Britoil is partof a series of globally successful,turnkey and customer-specificsolutions from Pemamek. Theimpressive export figures account-ing for 80% of total sales speakvolumes. “Due to a lack of special-ists in this area, Asian shipyardscurrently have a huge need forautomated systems of this type”,explains Mr. Heikonen. “And theautomated welding systems resultin a 25-fold increase in productiv-ity”, adds Jyri Passila, engineeringmanager at Pemamek.

Huge systemsThe welding systems are simplyhuge, measuring 150 metres inlength and, depending on the sta-tion, 4 to 22 metres in width. Oncesheets measuring 12 metres by 12 metres have been clamped, arobotic welding station attachesreinforcing plates. The number of reinforcing plates welded for acruise liner, for example, can beanything up to 180,000, easilyusing 50,000 tons of steel.

Pemamek considers the vision systems used to program therobotic welding systems to be astrategic competitive advantage.Equipped with these systems, the

Welding on a huge scale: welding systems for shipbuilding are up to 150 metres in length.

Festo components

at Pemamek

Standard cylinderDNCB

MS series service units

Valve terminalCPX/MPA

27


customised welding systemsenable precision production ofindividual items. “Also associated with this, is our systems’ ability toconstruct different ship types onone and the same system”, stress-es Mr. Passila.

Minimum installation complexityPneumatic automation technologyis used above all for clamping andpressing as well as for small, pre-cise movements of the weldingtorch. “We rely on the sturdy andmodular valve terminals CPX/MPAwith Profibus connection as theyreduce installation and wiringcomplexity and are very cost effec-tive”, says Mr. Passila.

Apart from the valve terminals that are hidden away almost invis-ibly in recesses in the robot’sarms, the classic drives DNC andDNCB ensure reliable clampingand pressing of the panels whileservice units from the modularMS4 and MS6 series prepare thecompressed air. “But it’s not justthe pneumatic components that

help us in the automation of oursystems, even though they suit our needs perfectly”, explains Mr.Passila, “it’s the complete packageoffered by Festo: comprehensivetechnical support and training,logistical services as well as relia-bility of both the products and theservices.” This means that ship-builders worldwide can rely onsecure welding connections.

Clamping and pressing using pneumatics: in use in the welding torches.

Sturdy and modular: CPX/MPA with Profibus connection.

Pemamek OyAutomations-Systeme GmbH

Products Workpiece handling, welding sys-tems, automation for shipyards,wind systems or power plants

Contact FIN-32201 Loimaawww.pemamek.fi

28

ATEX in ready-to-install solutions

In useIn areas of explosion risk in accordance withdirective 94/9/EC

Benefits• Assembled and tested complete systems with

full documentation• Saves time and money during planning and

assembly• Universal explosion protection conformity

Services and products


a remote I/O system, is locatedcentrally among the valve termi-nals directly in the explosion area.This system converts the bus –often an intrinsically safe “ProfibusDP” – into output signals that arecarried to the individual assem-blies via fixed wiring. The feedbacksignals from the drives are alsodetected using this system, as areanalogue input and output signals.

An example of an ATEX-compliantcontrol system is the combinationof a valve terminal CPV10 EEx i anda remote I/O system from the com-panies R. Stahl and ABB for zone1/category 2G. Further remote I/Osystems are available.

What advantage does this solutionconcept offer for control cabinets?

ATEX – now ready toinstall!

At Festo, ready-to-install solutions are a central theme in all

areas. Whether as a pneumatic control system, solenoid

valve cabinet, cylinder/valve combination or control block.

Costs, time and safety are reasons that convince users and

increasingly enable them to follow a philosophy of a reduc-

ing total cost of ownership. Festo now also offers more than

just components in the ATEX world. The trend is moving

towards the ready-to-install solution.

To recap: since 2003, anyequipment and protective systemsfor use in areas of explosion riskmust be approved in accordancewith directive 94/9/EC. Over 3,700Festo products are already certi-fied in accordance with explosionprotection categories. This is theideal basis for applying the sav-ings produced by ready-to-installsolutions to the “ATEX world”.

A good example: ATEX-compliantcontrol system In the process industry, where thedistance between the controllerand system is frequently greaterthan with production, handlingand assembly machines, bus sys-tems are being used more andmore frequently instead of elec-trical multi-pin cables for signaltransmission. The coupling point,

www.festo.com/en/ex 29


is 1212Pneumatics and explosion protection

Infoservice

Explosion protection with ready-to-installsolutions: electropneumatic control system in the control cabinet, MS seriesservice units and ball valve drive units(zone 1/category 2GD).

Ready-to-install solutions: advantages in detail

Procurement• 1 contact partner = 1 supplier• 1 order number = delivery of one item• 1 date• Fixed price guarantee• Warranty for the entire module

Logistics• No warehousing costs for individual parts

and no combination thereof• Just one supplier means reduced costs

Design• Relieves pressure on deadlines• No design costs• Circuit diagram is created by Festo• Reduces the costs for documentation

Installation and commissioning• Combined assembly for direct installation• Reduces the assembly time• Tested complete module

Apart from valve terminals, otherpneumatic components can alsobe integrated into the control cabi-nets. For example the air distribu-tion system, the sensor for systempressure, further control elementsand large power valves.

Electropneumatic control system for the explosive area II 2G EExe ib IIC T4: valve terminals and pressure switches with ignition pro-tection type EEx ib, remote I/O system by Stahl with Profibus inter-face and input/output modules.

30


automation worldwide

ArgentinaPneumatic mix 30

South AfricaAbsolutely safe 31

TaiwanCost-effective capacitors 32

NetherlandsSystematic palletising 32

IndonesiaDosing made easy 33

automation worldwide Argentina

Systems for the manufacturing andpackaging of beverages are thespeciality of FRUSSO MáquinasEmbotelladoras, in particular com-plete solutions in the area of smalland medium-sized production sys-tems. Just one example: the pro-cessing and filling of transparentPET cans with flavoured tequilawith added carbon dioxide for aMexican company.

Pneumatic mix

Quarter turn actuator DRD

Once the system has beenloaded, standard cylinders DNClift the cans while compact cylinders ADVU fit the lids. Quar-ter turn actuators DRD then sealthe cans. Sensors also play asindispensable role in the system,whether inductive sensors of the type SIEN/SIEF, the pressuresensor SDE1 or the opto-elec-tronic sensor SOEG-RSG. The

programmable logic controllerFEC-FC600 and the multi-pinvalve terminal CPV-14 round offthe list of components. A strongmix!

www.frusso.com

31



South Africa

180 million preservatives are pro-duced each year in the condomfactory of Kohrs Medical Suppliesin South Africa – using machinerysupplied by Richter Hi-Tech ofHanover. A machine dips a glasstube into liquid latex, which is then vulcanised by heat, and theresult is a condom. Before pack-ing, these products are tested bybeing stretched over a metal tubecarrying high voltage. If the latexskin of the preservative is too thin,sparks will fly and the condom inquestion is rejected.

Condoms which pass the test100 % are rolled up and passed to a packing machine. Here, twoCPV valve terminals control theactuators which pack the condoms

into foil two at a time. Throughputthe production process, it is essen-tial to maintain a hygienic environ-ment - which naturally includes the compressed air used in theprocess. An MS6 combination with a branching module, a lubri-cator and a filter regulator keepsany dirt at bay which could impairquality. This is how perfect con-doms are made – fully tested andabsolutely safe!

www.rrtmedcon.com www.richterhi-tech.com

Absolutely safe

Netherlands

Systematic palletising

32



Taiwan


Cost-effective capacitors

Electronic components have to bemanufactured as cost-effectivelyas possible, something that canonly be achieved with highly automated production machines.For RODER Electronics MachineryCo. Ltd., the largest supplier ofmachines for capacitor productionin Taiwan, Festo Taiwan has sig-nificantly increased the level ofautomation of the serial AC/DCcapacitor winding machines.

A combination of valve terminalsof the type VTUB, DB series com-pressed air preparation modules ,vacuum generators VN and tubingPUN-E optimises the productionspeed of the machines and at thesame time saves installationspace. The pre-fitted valve termi-nals VTUB in particular mean thesolution covers various pressurerequirements and depending onthe machine design, is compatiblewith internal and external pilotcontrols.

www.roderco.com

Valve terminal VTUB

Package and pallet conveying sys-tems, layer and robot palletisers,automatic truck loading, systemsfor layer-order picking – the product range at CSi industriesB.V. is immense. Many tasks – individual solutions: CSi devel-oped a compact and sturdy han-dling system for palletising canswith different dimensions and volumes.

The gripping system on the robotflange comprises sturdy guideddrives DFM that can be flexiblyadjusted to the can dimensions

thanks to the electric piston rodcylinder DNCE. This is driven andactuated by a servo motor MTR-DCI with integrated positioningcontroller. The servo motor is con-nected directly to the robot con-troller via the CANopen interface of the CPX platform.

www.csiweb.nl

33



Indonesia

Front End Display FED

Ball valve drive VZPR

Dosingmade easy

Festo has supplied a completesupport system for controlling achemical dosing and mixing sys-tem to PT Henkel in Bogor, WestJava. The system comprises fourmain process stations: rolling oildelivery, rolling oil process, sol-vent-based process and three mix-ing systems for the MPT process.

The system is controlled by an IPC PS1 controller with integratedProfibus/Ethernet as a master controller as well as five electricalterminals CPX-FEC with Profibusmodule as slaves. Dosing of theraw materials into the mixing tanksis performed based on weightspecifications. The mixing pro-cesses are executed according to a predefined sequence and sched-ule stored in the PLC. Processvalves and actuators from Festo,for example ball valve drive unitsof the type VZPR, play an impor-tant role in transporting the mate-rials. Parameters such as formu-lae, process sequences andprocess timings are input using a Festo text panel of the type FED-90.

Guided drive DFM-B

Electric piston rod cylinder DNCE with servo motor MTR-DCI

1201 Safety engineering – pneumatic positioning1202 Handing system overview1203 Proportional gripper HGPPI1204 AS-interface1205 Standard valve terminal VTSA1206 Valve terminal MPA1207 Valve terminal CPV1208 Valve series VOVG1209 Partner to the process industry1210 Checkbox Compact PLC1211 Compact vision system SBO..-Q1212 Pneumatics and explosion protection

infoservice „trends in automation“ 12

Take advantage of your personal info service!Convenient – fast – direct – free of charge – without obligation.

is 1200

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From

Editorialtrends in automation 12January 2008

Published by:Festo AG & Co. KGRuiter Straße 82D-73734 Esslingen

Chief editor:Ralf Sohn, Marketing [email protected] Ott, Sales [email protected]

Reproduction of excerpts is permissible,provided that the source is acknowledgedas “trends in automation 12, January 2008

Higher speeds and increased flexibility in a single pick and place module (HSP-AE)In a highly competitive market, time is of the essence. Whether it is the time to design,

select compatible components and assemble your own pick and place system or

the cycle time of the final solution. Why take a risk when guaranteed performance

is available off the shelf – with the flexibility to suit your applications at a highly

competitive price?

Pick and place modules: speed & accuracy!

Electric Drive Automation

Optics Miniature assembly High speed electronics Micro assembly

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25512227

IndonesiaHead OfficePT FestoJl. Sultan Iskandar Muda no.68Arteri Pondok IndahJakarta 12240, IndonesiaTel: +62-21-27 50 79 00Fax: +62-21-27 50 79 98

Branch OfficesBandung Tel: +62-22-732 1329, 732 1330,

732 0753

BatamTel: +62-0816 50 23 10

Cikarang Tel: +62-21-893 67 49

GlodokTel: + 62-21-659 97 69-70

Makassar Tel: +62-0813 42 05 52 00

Medan Tel: +62-61-453 89 35, 452 00 11

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

JapanHead Office1-26-10 HayabuchiTsuzuki-ku, Yokohama 224-0025Tel: +81-(0)45-593-56 10/-56 11Fax: +81-(0)45-593-56 78

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

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

MalaysiaHead OfficeFesto Sdn Berhad10 Persiaran IndustriBandar Sri Damansara52200 Kuala LumpurTel: +(60 3) 62 86 80 00Fax: +(60 3) 62 75 64 11

Branch OfficesPenangTel: +(60 4) 643 0918

IpohTel: +(60 5) 548 1002

Johor BahruTel: +(60 7) 352 3719

MalaccaTel: +(60 6) 335 1018

New ZealandHead OfficeFesto Limited20 Fisher CresMT. WELLINGTONAucklandTel: +64-(09)-574-10 94Fax: +64-(09)-574 10 99

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

Cagayan de OroTel/Fax: +63 (88) 857-4904

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

Bacolod CityMobile Phone: +63 (0917-8807050)

IliganTel/Fax: +63 (63) 221-1966

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 WaySGP - Singapore 628754Tel: +65-62640152Fax: +65-62611026/62659276

Head OfficeFesto Korea Co., Ltd.470-1 Gasan-dongGeumcheon-guSeoul #153-803Tel: +82-(0)2-850 7114Fax:+82-(0)2-864 7040

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

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

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

UlsanTel: +82-(0)52-292 4215

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

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

Branch OfficesHsinchuTel: +886-3-658-8318, 658-8307

KaohsiungTel: +886-7-384-2856

Taichung Tel: +886-4-2475-7278

TainanTel: +886-6-202-3083 to 4

ThailandHead OfficeFesto Ltd.67/1 Phaholyothin RoadKlong 1, Klong LuangPathumthani 12120Tel: +66 (0) 29 01 88 00Fax: +66 (0) 29 01 88 33

Branch OfficesSaraburiTel: +66 (0) 36 31 54 10

Laemchabang/ChonburiTel: +66 (0) 38 33 06 04

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

VietnamFesto Pte. LtdVietnam Rep. Office8th Floor, #801, Miss Ao Dai Building,21 Nguyen Trung Ngan St,Ben Nghe Ward, Dist. 1Ho Chi Minh CityTel: +84 8 910 12 13Fax: +84 8 910 12 93

HanoiTel: +84 4 974 68 33

Festo Asia Pacific

trend in automation 12

Documents

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valve manifold

requiresmaximum safety

safety rulesby

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valve terminals mpa

tightthe valve series

vehicle fuel injection