trend in automation 13

In focus

“Everything under control”

Condition monitoring and

diagnostic systems for trouble-

free system operation

Handling and assembly

“Strong arm”

Spindle driven cantilever axis

EGSA for powerful applications


“Well armed”

Pneumatic and electric drives

and axes in action

Sensors

“Improving conditions”

Monitoring of flow rates and

air consumption using flow

sensors

www.festo.com

No. 13, 2008

tia13_EN_Druck7:tia13_EN_Druck.qxd 29.04.2008 08:08 Seite 1

Sunshine, sandy beaches and far-

off countries. Every year millions

of people fly to their holiday desti-

nations. They place their faith in

the experience and skills of the

pilots controlling the complex air-

craft. Despite the effortlessness

of flying it has lost nothing of its

fascination since the days of the

aviation pioneers at the beginning

of last century – neither for the

passengers nor for the pilots.

The seemingly easy journey

through the clouds is made possi-

ble by intelligent technical solu-

tions. Onboard electronics enable

the pilot to monitor all the relevant

data in the cockpit at a glance,

and inform him immediately of any

changes. He can then implement

corrective measures promptly in

the event of a critical situation.

Festo’s diagnostic and condition

monitoring systems provide you

with the same effortlessness in

the field of automation. Our objec-

tive is to increase system avail-

ability for system operators and

at the same time reduce total cost

of ownership. We support you, as

machine or equipment manufac-

turer, with innovative solutions

which will provide your customers

with added value.

Automation cockpit

Festo creates transparency in

automation regardless of whether

the topic is compressed air con-

sumption, cylinder positioning

time, deviation from reference val-

ues for working pressure, counting

cylinder strokes or valve switching

cycles. The diagnostic and condi-

tion monitoring systems presented

in this issue of trends in automa-

tion will help you to implement

preventive measures, accurately

pinpoint problem areas and react

quickly to deviations and errors.

And thus you will always know

that “Everything’s under control.”

Enjoy your reading!

Markus Ott

Head of Sales Communication


In focus

Everything under control

Increased system availability, lower life-cycle costs:

condition monitoring and diagnostic systems for

trouble-free system operation. 4

Newsticker

At a glance

New products, events and news in brief. 8


Well armed

Leading by seconds: pneumatic and electric

drives and axes in action during machine tool

changeovers. 11

Strong arm

Powerful, dynamic and accurate: the spindle driven

cantilever axis EGSA is easily integrated into

machines and systems. 14

Who’s the winner?

Lightweight, small, low-maintenance: single stage

vacuum generators score more points in comparison

with their multi-stage counterparts. 16

Sensors

Improving conditions

Reduce air consumption by continuously monitoring

flow rate and consumption with MS6-SFE and SFE1

sensors. 19

Pure function integration

CMPX, CMAX and CMXX servo-pneumatic and elec-

trical axis interfaces expand the CPX terminal. 22

Industry specific solutions

Active ingredient: automation

Laboratory automation: automated patch clamping

machines equipped with piezo valves control the

movement of fluid into ducts on test panels. 26

No risk, but fun!

Virtual driving license: combining the SPC200 axis

controller with the DNCI standard cylinder makes

this possible. 28

Automation worldwide

From the USA to Vietnam

Applications from all over the world. 30

Infoservice 34


4

Condition monitoring for industrial applications

Key features

Monitoring of actual values and comparison

with setpoints

Benefits

• Increased system availability

• Lower life-cycle costs

In focus

Everything under control

Where system downtime once resulted in costs of up to 10,000 euros per minute, condition monitoring and diagnostic sys-

tems are now ensuring almost trouble-free system operation. Using sensors and electrical units in valve terminals from

Festo for diagnosing components and systems, OEMs and system operators are able to concentrate on their specialised

areas of core competence. Examples are provided from the packaging industry, pharmaceuticals manufacturing, the optics

industry and the production of pre-cast concrete blocks.

trends in automation No. 13, 2008


5


More and more machinery

and equipment manufacturers are

recognising how important it is to

pay close attention to more than

just procurement costs, and to

carefully consider the system’s

overall life-cycle costs. After all,

procurement costs frequently

amount to only a small portion

of the costs of operating a system

over its entire life-cycle. Total cost

of ownership and life-cycle man-

agement are the “magic words”

in this respect.

Maintenance and repair

A study conducted by Rockwell

Automation revealed astonishing

figures: Between 15 and 40% of

the indirect costs incurred by man-

ufacturing operations result from

maintenance and repair. However,

roughly half of these costs can be

avoided – if strategically oriented

diagnostic and condition monitor-

ing systems are utilised.

Amounting to roughly 70% of

these expenses, repairs make up

the largest part of indirect costs -

as unplanned consequential costs

they even constitute between 10

and 28% of a system’s total life-

cycle costs. And according to infor-

mation published by an economics

journal, these consequential costs

have to be multiplied by a factor

of between 4 and 5! Why? Because

machine downtime may also result

in quality defects or inability to

deliver on time, and may even

impair the company’s corporate

image. Commissioning costs are

also high for product and lot

changeovers.

Germany:

Packaging industry

Machine downtime in the packag-

ing industry may thwart the high

demands placed on short cycle

times and high productivity. For

this reason the VPP 250 tubular

bag packaging machine from Wolf

Verpackungsmaschinen GmbH

with a cycle time of 100 bags per

minute is equipped with a diag-

nostic system for its pneumatic

components. The MS6-SFE flow

sensor and the SDE1 pressure sen-

sor monitor deviations from a ref-

erence value. Measured data and

available valve control and limit

switch signals are read into the

CPX electrical terminal and

processed by the FEC controller

module.

Process parameters such as sheet-

material dependent contact pres-

sure and belt wear are monitored

by means of position measure-

ments executed by the SMAT ana-

logue sensor included in the pneu-

matic feed cylinder. Coolant air

volume and pressure are also

monitored as process and sheet-

material dependent quantities in

order to avoid unnecessary use of

compressed air. Transverse sealing

knife wear is monitored by meas-

uring cylinder positioning time,

and monitoring for premature

wear during longitudinal sealing

is accomplished by measuring

cylinder travel time. Operation

hours and time-to-replace are

indicated by means of a cylinder

Diagnostics system included: The

MS6-SFE flow sensor and the SDE1 pres-

sure sensor monitor deviations from a

reference value for the VPP 250 tubular

bag packaging machine from Wolf Ver-

packungsmaschinen GmbH.

stroke counter and a switching

cycle counter for valves. The CPX’s

electrical peripherals monitor

events such as short-circuits, bro-

ken wires, overvoltage and valve

jamming.

Global access

Characteristic diagnostic values

include, for example, air consump-

tion and operating pressure for

the detection of leaks, as well as

positioning times. The diagnostics

Indirect costs for

manufacturing operations

Indirect costs

Costs for maintenance/repair

Potential savings through the use of diagnostics and condition monitoring

Maintenance/repair

Potential savings

15 to 40 % ca. 50 %


Short cycle times and good machine

availability at Davis Vision: Pressure

(SDE1) and flow rate (SFE1) sensors

monitor the pneumatic gripping mecha-

nism of a spindle, by means of which

optometric lenses are milled into the

desired shape.

6 In focus ... Everything under control


function detects malfunctions

and pinpoints their locations.

Functions such as counting the

number of valve switching cycles

and cylinder strokes support pre-

ventive maintenance. The FED

touch-panel displays the results,

which are also made available to

the machine’s controller via field-

bus. The diagnostic solutions can

be easily integrated into existing

control concepts. The machine

manufacturer’s servicing person-

nel, the machine operator’s main-

tenance personnel and external

service providers are thus able to

increase system availability and

optimise maintenance processes.

USA: diagnostics package

Remote monitoring of systems

via a PC and the elimination of

malfunctions without protracted

investigation is in great demand

in the USA. Diagnostics package

solutions available from Festo

enable Roman Stone, a manufac-

turer of pre-cast concrete products

in Long Island, New York, to keep

an eye on what’s going on in the

dusty production environment.

Roman Stone manufactures spe-

cially shaped blocks used to

enclose electrical cables. “Many

miles of electrical cable under

the streets of Manhattan are laid

in our pre-cast concrete blocks”,

reports directing manager Thomas

Montalbine, not without a hint of

pride.

The systems used to produce the

pre-cast concrete blocks are pneu-

matically controlled, but they

began to fail frequently due to

age and adverse conditions of use.

“We decided in favour of a com-

plete package from Festo for mod-

ernisation – a system that encom-

passes diagnostic services in addi-

tion to fully equipped control cabi-

nets, as well as sturdy and highly

resistant DNC cylinders”, explains

Montalbine.

Remote monitoring in the USA

Short cycle times and good

machine availability are also suc-

cess factors for Davis Vision, a

manufacturer of lenses for glasses,

and a supplier of optical systems

for roughly 35 million people in

North America. The use of remote

monitoring and diagnostic systems

for the production of optometric

lenses by means of CNC machines

with milling and polishing tech-

nologies ensure reliable processes

for the company. Sensors for

detecting pressure (SDE1) and

flow (SFE1) monitor the pneumatic

gripping mechanism for a spindle,

by means of which the lenses are

milled into the desired shape.

Based on a pressure profile, test-

ing is conducted daily on a PC and

via the FED 100 front-end display

in order to determine whether

there are any leaks in the com-

pressed air system. The flow sen-

sor transmits analogue or digital

signals to a standard controller.

Thanks to the condition-oriented

maintenance program, the compa-

ny is capable of detecting irregular

increases in compressed air vol-

ume – genuine condition monitor-

ing. “We’re thus able to replace

defective components within the

compressed air system between

shifts before it’s too late”, explains

William Barbaro, maintenance

manager at Davis Vision in Plain-

view, New York. And the real show-

stopper: Festo USA provides Davis

Vision with a service which is

unavailable anywhere else to date,

namely continuous fault monitor-

ing for the company’s pneumatic

processes conducted by Festo’s

experts in New York.

Roman Stone: specially shaped blocks

used to enclose electrical cables.

The CPX unit with a VTSA valve ter -

minal replaced Roman Stone’s old pneu-

matic control systems. Moreover, with

compressed air preparation from the

MS series, the MS6-SFE flow sensor, the

SDE1 pressure sensor and the FED front

end display, the diagnostic system was

up and ready to go.


is 1301Partner to the food and

packaging industries

is 1302Partner to the biotechnology

and pharmaceuticals industry

is 1303CPX electrical terminal

is 1304MS series service units

is 1305Sensors, image processing

systems, controllers

Infoservice 7


Saving money with flow sensors

The use of flow sensors can

achieve enormous savings. Overall

costs of more than 2685 euros can

be incurred as a result of undetect-

ed leaks during non-stop opera-

tion of a system over a period of

50 weeks per year. With costs of

this magnitude, the use of sensors

is amortised after just a few

weeks.

Finland: pharmaceuticals industry

What’s good for machines and

systems in discrete manufacturing

can only be right for process

automation in continuous opera-

tion. A consistent diagnostics con-

cept reduces the cost of goods in

the biotechnology and pharma-

ceuticals industry. Without a func-

tioning concept of this sort, it’s

almost impossible to meet current

requirements specified by the

United States Food and Drug

Administration (FDA) for process

analytical technology (PAT). For

this reason, for example, multiple

effect water distillation systems

supplied by Steris Finn-Aqua for

the production of ultra-pure water

for producing medications are

already integrating diagnostic sys-

tems with the CPX/MPA valve ter-

minal. “In addition to extensive

diagnostic options, we also save

30% of our installation costs using

the CPX/MPA”, explains Veli-Jukka

Parkkamäki, engineering manager

at Steris Finn-Aqua.

Remote I/O valve terminal node

The CPX/MPA modular valve con-

cept referred to by Parkkamäki –

a combination of a CPX remote I/O

terminal and an MPA solenoid

valve terminal - indicates the fault

source and location, as well as

corrective measures. This includes

error detection and pinpointing

in the form of module or channel-

oriented I/O diagnosis, valve diag-

nosis per channel, on-site display

in plain-text, data processing and

transmission via fieldbus. Also

included are expansion options

via Ethernet interface, integrated

IT solutions such as remote main-

tenance, e-mail or SMS alarm, and

diagnosis tracking with error mem-

ory. And thus everything is kept

under control.

www.wolf-pack.de

www.romanstoneco.com

www.davisvision.com

www.steris.com

Dr. Christian Boehm,

manager of the Technical Engineering Center for

Diagnostics at Festo Corporation in New York:

“Customer service is not limited to just delivering

replacement parts very quickly. Error diagnosis

and condition monitoring systems create true

added value that customers greatly appreciate,

especially in the USA: In addition to the latest automation compo-

nents, users who decide to take advantage of diagnostic solutions

can monitor their systems and eliminate errors without protracted

investigation. Festo USA offers a complete package including remote

monitoring of a system and valuable assistance in fault diagnostics.”

Reducing the cost of goods in the

biotechnology and pharmaceuticals in-

dustry: multiple effect water distillation

systems supplied by Steris Finn-Aqua for

the production of ultra-pure water for pro-

ducing medications integrate diagnostic

systems via the CPX/MPA valve terminal.


+ 8


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

Sensors

Compact, versatile, inexpensive

Low cost reliable functioning.With its versatile con-

figuration and connection options, and thanks to its

minimal size of just 30 x 30 mm, the SPAB pressure

sensor can be used worldwide in all industry sectors.

Switching point settings are highlighted by means of

a switching status indicator, as well as by identifying

the display value via a specific colour. Practical: After

one device has been programmed, settings can be

transferred to all other SPAB pressure sensors.

Electrical drives

Logical supplement

After integrating the MTR-DCI motor unit into the HSP

handling module, the HSW high-speed handling mod-

ule is now joining forces with electric drives under its

new designation: HSW-AE. The electrical variant for

repositioning workpieces at a 90° angle is available

in 10, 12 and 16 mm sizes. As is also the case with

the HSP-AE, the module is programmed at the control

panel of the MTR-DCI-..-HM, or by means of FCT soft-

ware.

Advantages of the HSW-AE at a glance:

• Freely selectable positioning

• Freely selectable speed

• Smooth motion sequences

Ideal for use in insertion processes at various speeds,

and for stacking thin workpieces that require different

handling sequences.

Position transmitter

Small but impressive

It’s the first position transmitter the size of a cylinder

sensor – the SMAT-8M. Depending on the drive, the

sensing range is a large as 40 mm; an analogue volt-

age signal is used for a feedback signal. It’s used

directly on standard drives from Festo – without

accessories – in particular on short-stroke cylinders

and grippers. Ideal for all applications with space

restrictions.


9


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

Vision system

Parts in view

Detection of position and rotational position

sensing of parts, precision positioning of axes,

2D quality testing and type identification – tasks

which are easily executed by the SBOx-Q compact

vision system. Recently added to the family of

intelligent surface based cameras: the price-opti-

mised SBOx-Q-R3x-WB compact vision system

with wide VGA sensor (resolution:750 x 480). For

applications with minimal requirements for dura-

tion of analysis (in comparison with VGA variants),

and for which CAN bus (intended for integration

into a CPI network) is not necessary.

Online replacement parts catalogue

Quick assistance

The new online replacement parts catalogue is now even

more user friendly - with numerous improvements and new

features. Just enter the part number and place your order

online – direct from the bill of materials (furnished with

installation instructions), or from the PDF file into the shop-

ping basket. Replacement part drawings can be zoomed

via mouse click, and can also be saved and printed out as

PDF files. The extended search function indicates which com-

ponents the part still applies to, and also the possibility of

searching for certain types. It doesn’t get any more conven-

ient than that.

Sensors

Simply accurate!

Highly accurate and simple to use: the new SOE4

fibre-optic units. Super fast operation with switch-

ing frequencies of up to 8000 Hz. Furthermore

they can be quickly installed thanks to top-hat rail

mounting. Ideal for detecting small parts, and

available in three different variants: for teach-in,

with display or with analogue output. The perfect

system expansion for Festo’s range of sensors.

www.festo.com/spareparts

Valves and valve terminals

Analogue I/O module for thermocouples

Mixing various electronic modules within a single system,

for example digital and analogue I/Os, technology modules

and pneumatics, make the CPX terminal highly modular and

extremely flexible. Thanks to the CPX-4AE-TC, the CPX I/O

range will now be expanded to include a 4-channel, analogue

input module for temperature measurement via thermocou-

pler. The advantages: minimised installation width for the

valve terminal, reduced per channel and system costs, and

less downtime thanks to diagnostics – including individuality

thanks to selectable connection technology depending on

the operating environment.

Temperature measurement

from -270 to 1820° C


10


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

Brochures

Safety at a glance

Maximum safety at the workplace: The new “Safety

technology guideline” offers competent answers

to important questions regarding safety-oriented

pneumatics – from risk analysis, sample circuit dia-

grams and protective measures, through to Festo’s

entire product portfolio.

Didactic

39th WorldSkills in Japan

1000 apprentices from 50 countries representing 48 compet-

ing professions in front of 300,000 visitors – these are the

figures which distinguished the 39th WorldSkills vocational

world championships that took place at the end of 2007 in

the Japanese city of Shizuoka at the foot of Mount Fuji.

In the mobile robotics competition, the trainees had to pre-

pare and program the mobile Festo robot Robotinoμ in such

a way that it was able to carry out various tasks autonomous-

ly. With the help of control software, the Robotinosμ are

transformed into an attractive experimental learning platform

that covers the basics of sensor technology, electrically

operated motor controls, image processing and, mobile

robotics.

The participants in the mechatronics competition were

required to assemble industrial automation systems. Festo

Modular Production Systems MPSμ were used for both the

competition and general training.

Valves and valve terminals

Pure modularity

Integration has high priority: VTSA – three valve

sizes without adapter on a single valve terminal

for up to 32 standard 18, 26 and 42 mm valves.

Moreover, where modularity is concerned, inte-

gration is also making waves. Reason: individual

M12 connection, whether the MP2 6-off M12 con-

nection for controlling up to 12 single or 6 double

solenoid valves, or the MP3 10-off M12 connection

for controlling up to 20 single or 10 double sole-

noid valves is involved.

A 5-pin M12 plug is used for electrical connection.

This makes it easy to convert over existing applica-

tions which are equipped with robust, individual

M12 connection technology to the VTSA valve ter-

minal. Due to the fact that the modular system lay-

out is fully retained, it’s also possible to convert

to multi-pin plug connector or fieldbus technology

with the CPX terminal.

is 1306 Safety

technology

guideline

is 1308 Hybrid learning factory MPSμ

is 1307 Robotinoμ


11

Changing over machine tools

In use

Linear drives, toothed-belt axis, gripper and

rotary actuator for feeding tools and work-

pieces to a CNC machining centre

Benefits

• Concentration on core competence

• Minimised changeover times

• Shorter cycle times



Chiron manufactures state-

of-the-art machining centres in

Germany’s wild southwest, more

precisely Tuttlingen – for example

the FZ 08 CNC machining centre, a

compact series produced machine

with up to 5 axes for complete

machining of small workpieces.

As a standard feature, customers

can use 12, 24 or 40 tools.

Long changeover times are a

thing of the past

A single set of tools is usually not

enough to machine complicated

workpieces or larger families of

parts. “When we change over from

one part to another, we also have

to change the tool set. Further-

more, if a large mix of parts is

also being produced, we end up

with immense changeover costs”,

explains Matthias Giesler, produc-

tion manager at Chiron. “Of course

we want to avoid any machine

downtime associated with this

process.”

Background magazine increases

productivity

In order to minimise changeover

time, Chiron has come up with a

sort of “ammunition depot” for

its customers. In cooperation

One thing’s for sure: Whoever was able to reload his six-

shooter fastest was the boss in the wild west. In the field

of machine tool manufacturing, fast reloading – also known

as retooling – is not at all easy, unless you’ve got good

ideas, as well as handling units which not only move the

tools quickly, but also the workpieces. In accordance with

their maxim, “leading by seconds”, Chiron shows how major

players are currently automating.

Well armed

The planar surface gantry withdraws the required tool from

the magazine, and feeds it to a mechanism which delivers it to

the machining station.


12 Handling and assembly ... Well armed


with Festo, a tool magazine with

enough capacity for up to 400

tools was developed for the FZ 08.

Not only did Festo supply the han-

dling technology, but rather the

entire background magazine with

tool holders as well. The required

parts are purchased in accordance

with Chiron’s specifications from

their suppliers, and the complete

tool magazine is delivered to Chi-

ron on rollers. Chiron only needs

to connect the magazine pneumat-

ically and electrically, and insert

the tools.

Tool handling: “You provide the

planar surface gantry!”

A planar surface gantry forms part

of the background magazine which

picks the tools and feeds them

to the machine for the machining

process. The gantry is equipped

with a tandem solution in the hori-

zontal plane which consists of two

DGE toothed-belt axes. The axes

are coupled together by a shaft via

a T- gearbox, in order to ensure

ideal synchronous operation. Tools

are withdrawn from the magazine

in the vertical plane by means of

a DGC pneumatic linear drive with

intermediate position and gripper

system.

Tool transport: the loading unit is

in charge

The unmachined workpieces are

clamped in a fixture. The fixture is

located on a pallet which has been

encoded with a chip, to which the

machining data have been saved.

In this way it’s possible to load

the entire pallet conveyor system

with many different workpieces.

The chip is read and the data is

transferred to the controller at the

transfer station. The machine is

thus capable of flexibly changing

over to various workpieces

autonomously without setup

expenses. Plausibility checks

ensure that the pallet has been

inserted correctly, and that no

collisions occur. After the system

gives the OK, the gripper lowers

the loader handling unit, grips

the pallet with the workpiece and

advances it into the machine. It

picks up the pallet with a finished

part if one is present, and sets

down the pallet with the next

blank to be machined. In order

to reduce machine changeover

time, the loader handling unit is

equipped with a double gripper.

The gripper arm is retracted with

the finished part. The manufactur-

ing process continues, and the

gripper arm sets the finished part

onto the pallet conveyor system.

The primary component of the

loader handling unit is and HGPL

parallel gripper attached to a

DRQD semi-rotary actuator. The

gripper’s large opening stroke

enables it to travel over the work-

piece and then to grip it from

below. The loader handling unit

is advanced in the horizontal axis

by two DGC pneumatic linear

The double parallel gripper passes over the finished workpiece, and is advanced to

a specified withdrawal position underneath the workpiece by the DGC linear drive.

General view of the Chiron FZ 08 machining centre, to which tools and workpieces are

fed by means of handling units.

Dipl.-Ing. Matthias Giesler, product manager for

small machines, CHIRON-WERKE GmbH & Co. KG:

“The background magazine provides us with the

ability to insert tools simultaneously. There’s no

more lost time when we change over to a different

part.”


13


drives. One of these functions as

a drive, and the other as an addi-

tional guide. A DGC pneumatic lin-

ear drive lifts and lowers the verti-

cal axis, and an external clamping

unit prevents the axis from sinking

in the event of a pressure drop.

After the tool magazine is delivered,

it only needs to be pneumatically and

electrically connected. Then it’s loaded

with preselected tools via gates.

CHIRON-WERKE GmbH & Co. KG

Products Vertical CNC machining centres

5-axis universal milling machines,

long-bed machining centres

Flexible manufacturing systems

Contact D-78532 Tuttlingen, Germany

Festo components

at Chiron

Electric toothed

belt axis DGE-ZR

Pneumatic linear

drive DGC

Semi-rotary drive

DRQD

Parallel gripper

HGPL

The loader handling unit withdraws a blank from the pallet conveyor system, and

advances it through a lift gate to the machining station.


14

Spindle driven cantilever axis EGSA

Field of application

Handling applications with short cycle times

and strict precision requirements

Key features

• High dynamics

• High positioning accuracy

• Working loads of up to 6 kg

• Drive and installation flexibility



Strong arm

The powerful new cantilever

axis EGSA can be easily integrated

into machines and systems, and

it's distinguished by outstanding

positioning accuracy and also a

large effective load capacity. Repe-

tition accuracy is highly precise at

±0.01 mm, but the axis neverthe-

less leaves virtually nothing to be

desired (for the engineer) where

speed and acceleration are con-

cerned. With a maximum speed

of 1.5 metres per second, the can-

tilever axis dynamically transports

loads of up to 6 kg over the

respective working area.

Flexible drive

Users are able to decide for them-

selves how the drive unit will be

configured. Whether a space sav-

ing solution is used with the motor

parallel with the axis, or with a

conventional in-line layout, the

overall drive package offers many

possibilities.

Festo also offers matching motors

and controllers for the new linear

axes: easy to put together using

Just as accurate as the time tested electro-mechanical

mini-slides, but configured for longer strokes and greater

loads: the new EGSA cantilever axes. Thanks to integrated

“drive” and “guide” functions, as well as practical attach-

ment options, they’re used to create multi-axis pick & place

systems.


15


Festo’s “Positioning Drives” selec-

tion software, and simple to order

thanks to well structured, clearly

defined accessories. Furthermore,

the adaptation of motors and con-

trollers from other manufacturers

to Festo’s belt driven reduction

gear units and couplings is just as

easy.

Flexible connections

The EGSA series will be launched

with four types that differ with

regard to size and nominal stroke.

Whereas the EGSA-50-100 has a

drive width of 50 mm and a nomi-

nal stroke of 100 mm, the 60 mm

wide EGSA-60 variant is available

with nominal strokes ranging from

100 to 300 mm. Maximum axial

feed force of the EGSA-60 variant

is 200 N. Adapter kits can be used

to connect two EGSA axes, as well

as for mounting grippers to the

cantilever axis and attaching EGSA

axes to profile constructions. The

setup of complete pick & place

systems is thus supported.

Beyond this, a mounting kit is

available which enables integra-

The EGSA fits seamlessly into the mecha-

tronic multi-axis modular system without

a hitch.

Technical data

• Sizes (drive width):

50 and 60 mm

• Stroke lengths: 100, 200 and

300 mm

• Repetition accuracy: ±0.01 mm

• Max. effective load: 6 kg

Mini-slides

Linear modules

Parallel grippers

3-jaw grippers

is 1309Spindle driven cantilever

axis EGSA

Infoservice

tion of EGSA cantilever axes into

Festo’s mechatronic multi-axis

modular system.

Convenient integration of the axis

into existing constructions, its long

service life of roughly 20 million

cycles and outstanding perform-

ance make the EGSA cantilever

axis a component to which the

motto “fit and forget” truly

applies.

Semi-rotary drives


16

Comparison of single and multi-stage vacuum

generators

Key features

VN single-stage vacuum generators are entirely

on par with multi-stage versions.

Benefits

VN single-stage vacuum generators are light-

weight, small, low-maintenance and inexpensive.



Who’s the winner?

With their high suction rates, multi-stage vacuum generators

are thought to deliver higher performance than single-stage

vacuum generators. However, a direct product comparison

offers a different picture.

Single or multi-stage – which

vacuum generator is better? With

the new VN single-stage generator,

a rival that must be taken seriously

has entered the arena along with

the multi-stage products which are

customary within the market.

Six performance criteria under

scrutiny:

1. Achievable partial vacuum (pu)

in bar

The degree of partial vacuum

determines the suction gripper’s

retention force. VN series vacuum

generators reach a vacuum of -0.9

bar with a supply pressure of only

4 bar, and are second to none in

relation to multi-stage vacuum

generators.

2. Suction flow rate (l/min)

Multi-stage vacuum generators

often claim to have many times

the suction flow rate of single-

stage units. However, this state-

ment makes reference to zero bar

underpressure and is not meaning-

ful, because this does not suffice

to transport a workpiece. If we

consider the suction flow rate over

the entire underpressure range

from -0.1 to -0.9 bar, both types

of vacuum generators are compa-

rable at -0.4 bar. Only with very

minimal underpressure down to –

0.4 bar do the multi-stage vacuum

generators have a clear advantage

(see graph).

3. Size and weight

This point is clearly awarded to the

single-stage VN generator: Thanks

to its lightweight compact design,

it can be mounted directly within

the gripping area. Tubing with

very short lengths can be used for

direct, on-site installation which

results in short evacuation times.

4. Maintenance-free

The motto “fit and forget” is truly

valid for VN vacuum generators.


17


This is ensured by the open

silencer and the use of non-moving

parts (basic version). This is not

the case with multi-stage vacuum

generators: These have several

series chambers. Elastomer flaps

are used to seal the chambers

after the respective degree of

underpressure has been reached.

Depending on ambient conditions,

they become contaminated more

or less quickly and can no longer

be fully closed – adequate under-

pressure can no longer be generat-

ed. The consequence is time con-

suming, costly maintenance at

short intervals.

Everyone who wants to double check things carefully ...

... is well advised to take advantage of Festo’s efficiency formula. It takes the relation-

ship between air consumption (input) and evacuation time (output) into consideration.

This enables an objective comparison of single and multi-stage vacuum generators.

Compressed

air

Vacuum

Silencer or ducted

exhaust air

VN single-stage vacuum generator.

Multi-stage vacuum generator

1.200

1.000

800

600

400

200

0

-0,8 -0,90

Vacuum [bar]

Su

ctio

n f

low

ra

te [l

/min

]

-0,1 -0,2 -0,3 -0,4 -0,5 -0,6 -0,7

Suction flow rate in relation to underpressure. Evacuation time in relation to underpressure.

Multi-stage vacuum generator

VN 30 L vacuum generator

VN 30 H vacuum generator

0,6

0,5

0,4

0,3

0,2

0,1

0

-0,80

Vacuum [bar]E

vacu

ati

on

tim

e [s

]

-0,1 -0,2 -0,3 -0,4 -0,5 -0,6 -0,7

Compressed

air

Vacuum

Silencer or ducted

exhaust air

Single-stage vacuum generator

η Vacuum generator efficiency in relation

to vacuum pressure

tev,pu Evacuation time [s]

qn Vacuum generator air consumption [l/min]

v Volume to be evacuated [l] (standard volume: 1 l)

Vacuum generators function in accordance with the

venturi principle. The difference is the fact that single-

stage vacuum generators (above) only have one receiver

nozzle, and multi-stage vacuum generators (top) have

two or more receiver nozzles.

1η=

tev,pu · qn1+

v · 60


18 Handling and assembly ... Who’s the winner?


5. Noise level [dB(A)]

Connecting receiver nozzles in

series on multi-stage vacuum

generators reduces air exhaust

velocity as well as sound level.

This is a decisive advantage with

regard to noise emission. Single-

stage vacuum generators are not

necessarily louder. The small sized

units have a sound level of only

approximately 55 dB(A). Vacuum

generators with especially large

diameters achieve acceptable

sound levels of approximately 70

to 75 dB(A) in the vacuum operat-

ing mode thanks to the new open

UOM silencer with expansion kit.

6. Costs

The single-stage VN vacuum

generator wins on costs as it is

significantly less expensive than

its multistage counterpart.

And the winner is ...

Single or multi-stag – which vacu-

um generator is better? With

regard to size and weight, as well

as maintenance and price, the sin-

gle-stage VN vacuum generator

takes the lead. Where achievable

underpressure is concerned, the

scores are level. In the case of suc-

tion flow rate, who wins the race

depends on how much underpres-

sure is required. Even if there’s no

clear winner, the contest indicates

that single-stage vacuum genera-

tors are a solution of entirely equal

value in comparison with their

multi-stage counterparts.

Vacuum cleans printing stencils

and prevents printing errors

Space and money saving

technology

Where surface mounting technolo-

gy is concerned (SMT), screen and

stencil printers from EKRA ensure

precision manufacturing of PCBs –

for cell phones, computers and

toys. In order to connect electronic

components to the printed circuit

board, solder paste is applied to

the board with the help of EKRA

printing systems. Automatic inser-

tion machines then place the com-

ponents onto the printed solder

deposits, after which soldering

takes place in an oven.

Faster and more reliable stencil

printing

With its compact “X4 Profession-

al”, EKRA offers a printer which

is capable of furnishing even the

smallest SMD components with

solder paste. And this makes it

all the more important to avoid

contamination which results in

printing errors. Faulty contacts

or short circuits would otherwise

be the consequence. For this rea-

son, cleaning cycles can be freely

programmed for the X4, as is the

case with all of EKRA’s printers.

A liquid cleaning agent wets the

mat and the stencil simultaneous-

ly. In order to vacuum remove the

liquid again, underpressure with

a correspondingly adequate volu-

metric flow rate is required. Festo’s

VN vacuum generator is used to

this end. As opposed to a vacuum

pump, it not only saves a consid-

erable amount of space, it’s also

quicker to install and less expen-

sive. Even explosion protection is

ensured with the vacuum genera-

tor (the cleaning agent contains

a solvent).

www.ekra.de

VN vacuum generator with double ducted

exhaust air in EKRA’s X4 Professional

is 1310VN vacuum generator

Infoservice


19

Air consumption


Compressed air networks for machines and

systems

Key features

Cost reductions by means of continuous moni-

toring of flow rates and air consumption using

flow sensors

Sensors


Those who instigate an ener-

gy debate within their own compa-

ny usually get things moving more

quickly than national politics do.

Environmental protection and cost

reductions become feasible. The

prerequisite, however, is a reason-

able amortisation period for the

required investments and careful

consideration is required in this

respect.

After electricity, compressed air

is the second most important

industrial source of energy. There’s

hardly a production system, not

even in medical technology that

can function without pneumatics.

Within the framework of an inter-

nal energy discussion, companies

should also scrutinise their com-

pressed air systems. Festo offers

a broad spectrum of services to

this end.

Compressed air is valuable

As shown in figure 1, 15% of the

costs for compressed air systems

are attributed to investment, and

an additional 6% to maintenance.

But the lion’s share, namely 79%,

is attributed to the electrical ener-

gy required for generating com-

pressed air. It therefore makes

good sense to ensure that valu-

able compressed air is not wasted.

Above all air leaks are expensive,

involving costs amounting to sev-

eral thousand euros are incurred

much more quickly than one might

think, thus eating up the profits.

What to do? A time tested solution

is continuous monitoring of flow

rates and air consumption.

Hope is good but control is better!

Let’s assume that the compres-

sors, the compressed air distribu-

tion system and the pneumatic

drives are all correctly sized. Are

further measures still necessary

in order to avoid leakage losses?

Yes, because the one does not

exclude the other! In fact, air loss

is more frequently detected coin-

cidentally than as the result of

targeted searching.

Previous methods of leak

detection:

A common procedure for the pre-

vention of leaks involves searching

For marathon runners, insufficient energy leads to a quick

withdrawal from the race. The same can be said for con-

trollers in the field of automation. But help is never far

away – because as a technology enterprise, Festo pays close

attention to the efficiency of its components. Nevertheless,

performance stands or falls on the condition of the entire

production system. As an experienced coach, Festo can offer

many tips. Today: war on leaks.

Improving conditions

Investment costs

79%

15%6%

Maintenance costs

Costs for electrical energy

for generating compressed air

Figure 1: Costs of operating compressed

air systems (source: ISI 2000)


20 Sensors ... Improving conditions


If compressed air consumption monitoring is envisaged when the system is first

installed, costs for mounting and installation are minimal. The example below shows an

MS series service unit (left) and a electrical CPX terminal with MPA valve terminal (right).

for them at regularly scheduled

intervals. To achieve this, a com-

plete inspection of all air lines is

required several times a year –

with the disadvantage that despite

all of the effort the quality of the

results remains questionable. This

is because the inspector might not

hear or see smaller leaks in noisy

industrial environments.

Leak detection today:

Continuous monitoring of com-

pressed air consumption with

the help of flow sensors is a much

better solution. Increases in con-

sumption, and thus in costs, are

quickly detected. The sensors

register deviations and indicate

exceeded tolerances. If necessary,

an alarm is triggered and thus

undetected cost increases are

ruled out.

Automated leak detection: how

quickly are investments amor-

tised?

A practical example provides us

with the answer:

• System pressure: 6 bar

• Several leaks which together

amount to a hole with a diameter

of 3 mm and a loss of 666 litres

of air per minute

• System operation: 24 hours a

day, 7 days a week

• Observation time period: 50

weeks

This results in air consumption

of 335,664 cubic metres. A figure

that provides us with a clue

regarding the considerable costs

that result from wasted com-

pressed air.

Results: With compressed air costs

of 8.00 euros per 1000 cubic

metres, total costs of 2685 euros

are incurred. If we assume that

leaks are detected and repaired

without delay through the use of

a flow sensor, the sensor is amor-

tised in just a few weeks.

Easy measurement of total air

consumption!

In addition to other values, SFE1

and MS6-SFE flow sensors also

indicate total compressed air con-

sumption. In this case, the flow

sensor functions as a compressed

air consumption meter. The sen-

sors are also capable of monitor-

ing with reference to a consump-

tion value which is specified by

system users themselves. Each

time this value is exceeded a digi-

tal output signal is generated,

after which consumption is meas-

ured and documented. This is


is 1311MS6-SFE flow sensor

is 1312SFE1 flow sensor

Infoservice 21


Udo Matheis, director of product management for

sensors at Festo:

“I’m frequently asked what can generally be done in

order to prevent leaks on machines and systems. My

advice is simple, and it applies in all cases: Use top

quality pneumatic components and size them correct-

ly. Again and again, when we perform comparative

measurements on commercially available products,

we discover that there are considerable differences in quality that influ-

ence service life, wear and leakage. But regardless of this, the use of flow

sensors is advisable in order to monitor entire compressed air systems,

or parts thereof. Basically it’s like a telephone bill where the list of indi-

vidual calls exposes any erroneous entries and cost drivers.”

especially useful when the con-

sumption of a given volume of

air needs to be monitored over a

certain period of time.

From theory to practice: installing

flow sensors

Up until recently, there were no

flow sensors available on the mar-

ket which, on the one hand, func-

tioned as stand-alone units like

the SFE1 and, on the other hand,

could be combined with service

units like the MS6-SFE. Both flow

sensors can be used:

• In new systems

• In existing systems

• In parts of pneumatic systems

• For temporary installation

The operator doesn’t need to have

any specific knowledge of aerody-

namics in order to use Festo’s flow

sensors, because they're designed

such that no special installation

conditions need to be fulfilled in

order to receive reliable results.

For example, the SFE1 flow sensor

is equipped with a laminar flow

inlet section which stabilises the

flow of air. The MS6-SFE is used

in combination with an inlet seg-

ment or a sieve arrangement which

prevents erroneous measurement

data.

Conclusion: he who controls,

saves! There’s no doubt

about it.

Technical data

SFE1 flow sensor

• Measuring range: 0.5 to 200 l/min.

• Large format, illuminated LCD panel

• Display can be rotated 270°

• Absolute flow rate values or overall consumption

• Threshold values and switching points can be

adjusted via the display

• Compact and robust (IP 65 protection)

• Numerous installation options

• Range of applications: leak detection in production,

leak testing of finished goods, flow monitoring for

parts feeding

Technical data

MS6-SFE flow sensor

• Constituent of the MS6 range of service units

• Measuring range: 200 to 5000 l/min.

• Absolute flow rate values or overall consumption

• Large LCD panel with background illumination

• Compact and robust (IP 65 protection)

• Digital outputs: two PNP or two NPN

• Analogue outputs: 0 to 10 V or 4 to 20 mA

• Range of applications: consumption monitoring of

systems, documentation of consumption values,

allocation of compressed air costs to cost centres

and leakage monitoring in pneumatic systems


22 Control technology


Pure function integration

Maximised modularity, flexi-

bility and function integration: The

CPX terminal enables simple con-

nection of pneumatic and electri-

cal control loops to an automation

system. Depending on the respec-

tive configuration, it offers up to

512 I/Os throughout the entire

system. The fieldbus interfaces are

especially versatile. They’re not

only possible using various field-

bus protocols such as Interbus,

DeviceNet, Profibus-DP, CANopen

and CC-Link, but also via industrial

Ethernet as well, for example Mod-

bus/TCP, Ethernet/IP, Profinet and

EtherCat. Status and diagnosis of

the CPX system and the connected

Modbus/TCP, Ethernet/IP, Profinet, EtherCat

Interbus, DeviceNet, Profibus-DP, CANopen, CC-Link

SBOX compact

vision system

FED

front-end display

Position

Digital/analogue sensors Pneumatic cylinders/drives

Machine Vision

Proximity

Pressure

Temperature

Colour

Compact

CPX

electrical terminal

Standard

Vacuum/gripping

Guided

Distance Rotation/swivel

Gripping

FieldbusEthernet

Consistent system concepts using the electronic

CPX terminal


Machinery and equipment manufacturing

Key features

• Soft-stop function and servo-pneumatic

positioning with new characteristic quality

• Multi-axis interface for electrical drives

• Saves time and money by means of integrated

functions

Object detection

23


Holistic solutions and consistent system concepts are primary success factors in the field of automation technology. Where

the electrical CPX terminal is concerned, CMPX, CMAX and CMXX servo-pneumatic and electric axis interfaces will constitute

the next step towards comprehensive function integration.

peripherals can be visualised

according to modules and chan-

nels, and condition monitoring for

the valves is integrated. Depend-

ing on performance of the con-

nected Ethernet network, the CPX

web server can be accessed from

each PC – expensive service calls

are thus avoided, and downtime

is reduced in an enduring fashion.

Integrated solutions ex-works

The integration of functions into

the CPX electrical periphery is a

central success factor for the

implementation of comprehensive

automation tasks using an on-site

valve terminal: Components and

their functions no longer have to

be selected, ordered, installed and

configured separately; they’re

provided by Festo as integrated

solutions instead. Thanks to func-

tion integration, use of the valve

terminal with CPX as a central

unit reduces the price per channel

by as much as 50% – and reduced

efforts required for ordering,

setup, configuration and commis-

sioning result in time savings of

more than 60% in some cases.

CMPX soft-stop

Thanks to the CMPX, soft-stop

functionality is now available in

the CPX environment. In addition

to fast, vibration-free travel

between fixed limit stops, the sys-

tem also offers the option of travel

to one or two freely selectable

intermediate positions. As com-

pared with standard pneumatics,

travel time is reduced by approxi-

mately 30%. Applications demon-

strate moving loads of 1 to 300 kg

with a maximum stroke length of

2 metres. Depending on the select-

ed fieldbus and other utilised

modules, up to 10 modules can

be installed on a CPX terminal.

CMAX servo-pneumatic position-

ing system

Positioning technology using

servo-pneumatics is advantageous

wherever moving loads are typi-

cally within a range of 1 to 300 kg,

and accuracy to a few tenths of a

millimetre is adequate. The CMAX

servo-pneumatic positioning sys-

tem is equipped with up to 64 con-

figurable motion sets, and sup-

ports the FHPP protocol. Configu-

ration and commissioning is exe-

cuted via the central interface on

the fieldbus node, via the fieldbus

or via the CPX-FEC/CECX controller

module.

Depending on the utilised drive,

travel speeds of up to 3 m/s, accel-

eration values of approx. 30 m/s2

Festo configuration tool FCT

CPX-CMXX

Motor

Controller

SFC-DC

Motor

Controller

SFC-LAC

Servomotor

Controller

CMMP-AS

Stepper

Motor controller

CMMS-ST

Intelligent

servo motor

MTR-DCI

Linear drive

DGPL

CMPX

Linear drives with displace-

ment encoder DGPI/L

CMAX

Pneumatically controlled

cylinders/drives

Cylinders/drives as

positioning system

Electric drives/axes

Proportional

valve VPWP

VPWP propor-

tional valve

Drivebus

24 Control technology ... Pure function integration


and accuracies down to 0.2 mm

can be achieved. Standstill control,

force control and monitoring in the

target position are new features

now included with the CMAX – no

correction is required in the target

position. Depending on the select-

ed fieldbus and the other modules

in the CPX terminal, up to eight

pneumatic positioning axes can

be installed.

CMXX multi-axis interface for

electric drives

Planar surface and 3D gantries

are the appropriate solution where

workpieces need to be moved

along several axes. Parameter con-

figuration and control for this type

of axis system with electric drives

is no problem for the CPX-CMXX

multi-axis interface. Simple param-

eter configuration using the Festo

configuration tool (FCT) is a great

advantage: Only the target posi-

tions need to be specified as input

quantities for the CMXX, which

autonomously controls the individ-

ual axes via speed and position.

The FHPP profile which has been

expanded for multi-axis operation

permits set selection operation, as

well as direct operation with direct

position specification by means of

a PLC. The interface is suitable for

single-axis applications and simple

multi-axis applications in Carte-

sian systems.

Pre-processing

Simple, but efficient: In terms of

control technology, the master PLC

and the CPX terminal constitute a

perfectly harmonised unit which,

together with several CMXX or

CMAX modules, comprises a PLC

compatible interface. Cycle times

are significantly shortened thanks

to decentralised motion control at

the CPX modules – and the master

PLC’s workload is reduced at the

same time. The servo-pneumatic

Positioning of electric and pneumatic axes during manufacturing and packaging of

ceramic tiles: a case for the new modules on CPX.

Input/output modules

Inputs Outputs

Digital 4, 8, 16 4, 8

Analogue 2x16, 4x16 2x16

Valve terminals – 8, 16, 24, 32

MPA modular – 4, 8, 12...128

CMPX 48 48

CMAX 1 axis 64 64

CMAX 2 axes 2 x 64 2 x 64

CMAX 1 axis group 128 128

CMAX 2 axis groups 256 256

3 dimensional X-Y gantry with several

DGE electric axes, Z-axis with HMPL

pneumatic handling module and com-

plex rotation/gripping. Can be com-

pletely implemented using the new

CPX/MPA platform.

DGPL: fast travel with soft-stop: simple

gantry design, with SLT and gripper at

the front-end.

25


consistent systematic package.

In combination with the CPX-FEC/

CECX controller module, the CPX

terminal is transformed into a

complete automation system with

motion control for electric and

servo-pneumatic axes with direct

connections to electrical I/Os and

pneumatic functions such as rota-

tion, swivel motion, gripping and

vacuum.Definitions

Set selection operation

Selection of positions saved on the CMAX/CMXX

Direct operation

Direct specification of positions via a PLC

FHPP

Festo handling and positioning profile for direct specification

of positions from a PLC

FCT

Festo configuration tool for parameter configuration for drives,

motion profiles etc. using a PC

Cartesian system

All axes are arranged at right angles

and electric drives are started and

advanced to their positions by

means of simple commands from

the PLC program via a fieldbus.

Additional reliability is provided by

the preliminary test: FCT software

is used to determine whether or

not the motion sequences for the

multi-axis handling unit are OK.

Package solutions for motion con-

trol and handling/assembly

The electrical multi-axis interface

and servo-pneumatic applications

expand Festo’s modular mechani-

cal axis system into a complete,

* Only in combination with the CPX-FEC/CECX controller

** Depending on application and pneumatic drive or electric linear unit, controller, motor/gear unit

is 1303CPX electrical terminal

Infoservice

Pneumatic drive

Electric drive

Number of axes

Number of positions

Accuracy **

Load **

Travel/stroke **

Coordinated drives

Number of motion sets

Direct control

Key features

CMPX

Soft stop end-position controller

Yes

–

10

2 + 2

±2 mm

1 ... 300 kg

Up to 2

No

1

Yes

• Sturdy, simple system

• 30 % faster than standard

pneumatics

CMXX

Electrical multi-axis interface

–

Yes

8

As desired

30 ... 200 μm

Up to 200 kg

Up to 10 m

No

1024

Yes

• Integrate dynamic calculation

• Simple thanks to table assisted

sequence description

CPX goes motion control – a selection tool

CMAX

Servo-pneumatic positioning

system

Yes

–

8

As desired

±0.2 mm

1 ... 300 kg

Up to 2

Yes *

64

Yes

• Integrated position and force

control

• Sturdy, space-saving positioning

system

26

Laboratory automation

Key features

Handling solutions for specimen containers and

liquids for laboratory procedures

Benefits

Synergies between factory and process

automation



Active ingredient: automation

When Alexander Fleming was busy discovering penicillin in 1928, most

laboratory procedures were strictly manual. Much has changed during the

following 80 years. Today, fully automated laboratory machines execute

time consuming routine tasks and handle hazardous substances.

Health is extremely impor-

tant; in times of increasing life

expectancy, everyone wants to

remain active and fit right up into

old age. However, visits to the doc-

tor are necessary, whether for pre-

ventive checkups or for treatment.

Doctors don't place faith in a gut

feeling, but rely on systematically

ascertained values from the analy-

sis of blood counts or from the

preparation of tissue specimens.

Testing and research processes in

laboratories are currently running

at full speed. In order to be able

to complete routine procedures

quickly, reliably and economically,

laboratories are taking advantage

of modern automation technology

to an ever greater extent. Grippers,

drives and valves are ever-present.

Laboratory automation – what’s

involved?

Laboratory automation is subdi-

vided into three areas. In the

specimen handling section, test

tubes, other miniaturised liquid

containers and specimen strips

are removed from and placed into

storage or fed to automatic analy-

sis equipment. The area for fluids

handling encompasses analysis

procedures, usually involving the

use of pipetting techniques. The

third area includes hybrid systems,

i.e. a combination of specimen and

fluids handling, for example auto-

Sa

no

fi A

ven

tis


27


matic analysis equipment with

integrated specimen handling.

Factory and laboratory

automation ...

... go hand in hand. Many standard

components which have proven

their worth in the field of industrial

automation are also used in labo-

ratories. The emphasis is on com-

pact, cost optimised components.

This means that compact and

miniature drives, as well as micro,

high precision and vacuum grip-

pers take centre stage.

Door open – door closed

This is the principle on which so-

called patch clamping systems

are based that involve automatic

analysis equipment from the field

of drug and active ingredient

research in order to examine cell

characteristics and ion currents.

Cells must be introduced into a

nutrient solution. Tiny “intake

nozzles” then draw the cells in –

always exactly one cell per nozzle.

It’s important to ensure that the

cell is only drawn up to a certain

point within the nozzle, and that

the cell membrane is slightly

“perforated” in the process. The

active ingredient to be examined

can then be introduced into the

solution, and the cell’s ion chan-

nels are measured. These “doors”

in the cell membrane control the

flow of ions in and out of the cell.

The measured values provide

information which indicates how

the cell assimilates or expels the

active ingredient.

An extremely steady hand ...

... is required when drawing in the

cells. That’s why Danish company

Sofion Bioscience uses piezo

valves from Festo for its automat-

ed patch clamping machines. The

valves regulate the movement of

fluid into the channels on the test

panel within a pressure range of -

500 to +500 mbar, and control the

suction system for drawing in the

cells accurately to ±3 mbar at

extremely small volumes.

The benefits ...

... are clear, because the automat-

ed patch clamping system enables

an increased specimen through-

put: 48 cells are drawn in simulta-

neously during each cycle, and

are tested on various substances.

In comparison, systems without

piezo valve technology are only

capable of processing 16 cells

per cycle. In addition, precision

control of pressure ratios made

possible by piezo technology

results in considerably longer

lifetimes for the highly sensitive

cells. This, in turn, increases the

success rates achieved for the

individual tests.

Dipl.-Chem. Peter Jaschke from Festo’s medical

technology and laboratory automation division:

“We anticipate increasing degrees of automation

in laboratory processes. The reasons for this

include growing demands for the reproducibility of

results and flexibility in analysis processes and

specimen throughput, as well as results availabili-

ty. Festo is preparing itself for this trend by expanding its range of

miniaturised automation components and systems in a targeted fash-

ion, and by means of more complex integrated solutions which take

advantage of the most up-to-date technologies.”

... control the 56 intake nozzles in the

patch clamp systems.

Rear view of the valve manifold.

Concentrated valve power: seven Festo

valve manifolds with 8 valves each ...

is 1302Partner to the biotechnology

and pharmaceuticals industry

Infoservice


28

“Genuine” travel in a virtual world with a

driving simulator

In use

SPC200 axis controller combined with DNCI

standard cylinder and FENG guide unit

Benefits

Constant distance from the laser to the

spinning tyre



No risk, but fun!

Racing or cruising through the desert with one’s own car – and without any risk. Impossible? Not anymore since TAG Systems

in Australia developed its simulator which makes these extraordinary driving experiences possible.

The SPC200 axis controller, in combination with the DNCI stan-

dard cylinder and the FENG guide unit, ensure that the laser is not

too close to the tyre.

The car is

mounted on a

dynamometer and

is thus perfectly

safe for the driver.


29


The difference in comparison

to conventional simulators is the

pioneering technology. TAG Sys-

tems takes an actual car and trans-

plants it into a virtual world. This is

why TAG Systems calls its newest

product the assimilator. A unique

driving experience is created with

the help of a specially produced

dynamometer, laser controlled

sensor technology and computer

generated images. The car runs on

dynamometer rollers while data

regarding force, speed, torque and

braking action is transmitted con-

tinuously to the TAG Systems com-

puter in order to generate life-like,

3D motion sequences – synchro-

nised with the running car. An

image generator processes the

data into images and projects

them onto three large screens in

front of the car. The screens are

four meters high, have a range

of 200° and thus encompass the

driver’s peripheral vision as well –

a perfect virtual driving experi-

ence! The screen in the middle also

serves as an exit gate; it is lifted

and held in place by a DNC-KP

cylinder with clamping cartridge.

Everything safe?

Securely mounted on the

dynamometer, the car is prevented

from moving in an uncontrolled

fashion so that the driver always

has everything under control.

Steering action is measured by

means of a double laser which

detects the distance from the front

wheels to the laser and is connect-

ed to the image generator, so

that actual steering action is trans-

ferred simultaneously to the virtu-

al world. The SPC200 axis con-

troller with DNCI standard cylinder

and FENG guide unit ensures that

the laser is kept at a constant

distance from the revolving tyres,

without mechanical contact.

Undreamed of possibilities ...

... are made accessible by this

system. From initial training to

prepare drivers for real traffic con-

ditions, to international driving

instructions which, for example,

provide drivers with the opportu -

nity of practising driving on the

“wrong” side of the road. Testing

newly planned roads is also

conceivable, as is training for

advanced drivers who want to

test their skills in precarious traffic

situations in a risk-free environ-

ment.

DRAG TAG – the racing simulator

Competing against one another is made possible

with DRAG TAG. Any desired number of assimila-

tors can be connected to each other, allowing driv-

ers to compete simultaneously in a race. The driv-

ers steer, accelerate and brake just like they would

in the real world, and they can see each other and

interact in the virtual world – and even crashes! A

high scores table enables the drivers to compare

themselves with each other. Well known interna-

tional race tracks can be selected, as well as the

desired card – from everyday passenger cars to

race cars.

TAG Systems Australia

Products Development and implementation

of innovative driving simulators

Contact AU Victoria 3061

[email protected]

is 1313SPC200 axis controller

Infoservice

The idea

One of the first demands placed on the system was that it would have

to function with normal cars. In order to make TAG Systems commer-

cially viable, cars would have to be connected to and disconnected

from the system very quickly, thus avoiding extended idle time and

protracted changeovers. This type of driving simulation, which

includes a DRAG TAG operating mode, was intentionally developed

in order to counter illegal motor racing, and thus to ensure greater

road safety.


30


automation worldwide

USA

Packaged passion 30

Singapore

Dosing chemicals 31

Finland

Clever automation 32

Canada

Pneumatics help prevent RSI 32

Vietnam

Powders, pellets and pneumatics 33

automation worldwide USA

Who has never experienced the

passion for nuts, cashews and

pistachios? Setton International

Foods in Commack on Long Island,

New York, has turned this passion

into a commercial business. Setton

has the entire value creation chain

for pistachio production under

control – from pistachio cultivation

in its own fields in California,

through to packaging in con-

tainers for retail sale. A typical

American success story: With

its passion for nuts, the compa-

ny has become the second

largest pistachio and cashew

processor in the United States!

Automation of the packaging

sequence is becoming more

and more important in order

to be able to meet continuous

demand for the company’s

snack products: The plastic

containers are now transferred

from a feeder to a conveyor

belt, on which they are filled

with nuts via a pick and place

system designed by Festo.

“We weren’t just supplied with

reliable automation products,

we also received extensive

consultation and support for

setup and commissioning of

the system”, explains Shawn

Noren, automation manager

at Setton International.

www.settonfarms.com

Packaged passion


automation worldwide 31


Singapore

Dosing chemicals

DAPS quarter-turn actuator

The CWRP project in Singapore

(Changi Water Reclamation

Plant) – the first phase of a

massive wastewater and

sewer system project known

as the “Deep Tunnel Sewage

System” – is a construction

project of superlatives. The

wastewater treatment plant

has been initially designed to

process 800,000 cubic metres

of wastewater every day, but

can be expanded to a capacity

of 2,400,000 cubic metres per

day.

Numerous international com-

panies are involved in this

enormous project, for example

Festo who is providing solu-

tions for dosing chemicals.

United Engineers Singapore

(UES), specialists in the fields

of drinking water and waste-

water treatment, have specified

requirements in this area with

regard to ambient conditions

(Ex zone 2) and actuation of the

process valves via Profibus and

remote I/O stations. Ball valves

with V orifice in combination with

DAPS quarter-turn actuators are

being used in order to ensure lin-

earity of flow control. Festo also

supplied the solution for the inter-

faces and the overall control sys-

tem.


automation worldwide32


Finland

Clever automation

Canada

Average growth in turnover of 15 %

per year – this is only possible

with clever automation solutions.

Finnish family enterprise Orfer

secures growth rates of this mag-

nitude using combination packag-

ing and palletising lines which are

individually customised.

The systems integrate robots and

gripper solutions that are config-

ured according to available space

at the customers’ facilities com-

prising food processing, printing,

packaging and pharmaceuticals

industries, as well as in the fields

of plastics processing, woodwork-

ing, metalworking and paint manu-

facturing. Special gripper systems,

matched to the various types of

products, are at the heart of these

automation solutions which are

designed in-house by Orfer. A com-

plex vacuum gripper, equipped

with a compact CPV valve terminal,

opens up new perspectives for

handling parquet and plywood in

the woodworking industry.

www.orfer.fi


For quite some time now, repeti-

tive strain injury (RSI syndrome)

has been a familiar problem in

many companies. Monotonous

movements over long periods of

time result in damage to the mus-

culoskeletal system. Nobel Metal

Processing Canada Inc., manufac-

turers of customised blanks for

the automotive industry, has also

been affected by this issue. Hun-

dreds of laser welded steel parts

with weights ranging from 13.5

to 22.5 kg had to be manually

inspected on a daily basis for

defects. This resulted in employ-

ees having symptoms of fatigue

and stress in the joints. A solution

was sought and found in coopera-

tion with Edwards Pro-Tech Ltd.

Thanks to the development of a

vertically arranged rotary table

platform, RSI is now a thing of the

past. The use of vacuum grippers

in combination with cylinders,

for example the DGPL linear drive,

makes it possible for the employ-

ees to inspect the welding seams

without any great physical exer-

tion.

Pneumatics help

prevent RSI

VTSA valve terminal

DRQD semi-rotary drive


33



The rotary table moves on a DRQD

semi-rotary drive. CPV and VTSA

valve terminals are used to control

the system.

www.nobleintl.com

Vietnam

Powders, pellets and pneumatics

DGPL linear drive

The production of medication such

as tablets, powders, capsules and

pellets, is a complex procedure

for which each step is precisely

planned and strictly controlled.

For Tien Tuan Pharmaceutical

Machinery Ltd, specialised in the

production of processing and

packaging machines for pharma-

ceuticals manufacturing compa-

nies, adherence to applicable

international standards is a top

priority. For years now, the compa-

ny has placed its faith in Festo’s

quality and performance in this

respect.

Festo components are utilised in

the company’s latest systems for

fluid bed drying and granulation.

The standard cylinder DNC for

example, with a stroke length of

2500 mm for shaking and pressing

the powder through a filtration

unit. In order to facilitate stop-

ping at different stroke lengths,

it's connected to a rodless DGPL

drive. Control is handled by

means of a VTSA valve terminal.

In combination with the cylin-

ders, the efficiency of the

machine was significantly

improved as compared with pre-

vious models.

www.tientuan.com.vn


1301 Partner to the food and packaging industries

1302 Partner to the biotechnology and

pharmaceuticals industry

1303 CPX electrical terminal

1304 MS series service units

1305 Sensors, image processing systems, controllers

1306 Safety technology guidelines

1307 Robotinoμ

1308 Hybrid learning factory MPSμ

1309 Spindle driven cantilever axis EGSA

1310 VN vacuum generator

1311 MS6-SFE flow sensor

1312 SFE1 flow sensor

1313 SPC200 axis controller

infoservice “trends in automation” 13

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Convenient – fast – direct – free of charge – without obligation.

is 1300

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From

trends in automation 13

May 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 13, May 2008“


Pneumatic? Electrical!Your application is the decisive factor. Whether

pneumatic, servo-pneumatic, electrical drives

or a combination is involved, Festo guarantees

a systematic and highly economical solution –

including service.

www.festo.com/en/edrives


Festo AG & Co. KG

P.O. Box

D-73726 Esslingen

Phone +49 711 347-0

Fax +49 711 347-2144

[email protected]

www.festo.com


trend in automation 13

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