Festo Pneumatic

On the move with electric drives Electric drive solutions in bus body production, page 4

No. 15 2009

Interview

“No such thing as either/or”

Dr. Eberhard Veit, Chairman

of the Management Board of

Festo, on factory and process

automation

page 13

Valves and valve terminals

“Soft-start valve ensures

safety”

The standardised valve

terminal with integrated

soft-start valve

page 16

Electric drives

“Fast, compact and precise –

electric axes for every appli-

cation”

Electric axes EGC and EGSK/

EGSP in handling technology

page 18

www.festo.com

As a leading supplier of pneumat-

ics, Festo has been shaping the

world of fluid technology for more

than 50 years. But Festo is contin-

uously expanding its range of

electric drives as well – with the

objective of always being able to

provide you with the most suitable

drive technology for your applica-

tion. You can optimise the produc-

tivity and energy efficiency of your

machines and systems by combin-

ing pneumatic and electric drives.

Short changeover times, more

flexibility with regard to machine

functions, greater modularity and

improved diagnosis capabilities

enhance the operating efficiency

and economy of machinery and

production equipment. Festo

offers a comprehensive product

range of electric drives, motors,

controllers and suitable fieldbus

technology. And your advantages

can be further augmented with

service offerings including pre-

assembled modules and position-

ing systems.

Customer-specific drive solutions

expand our comprehensive cata-

logue assortment of electric

drives. Festo’s engineers develop

product solutions together with

you, which are precisely matched

to your application. Contact us!

In focus: electric drives

Finding the right partner is just as

important as the technology itself.

In your country as well, sales engi-

neers for electric drives provide

you with sound advice, and accom-

pany you in solving your problem.

Automotive body fabrication for

Mercedes-Benz buses in Turkey is

a good example of this. The good

cooperation which has taken place

in this area is documented in the

article on page 4.

Other interesting applications

from all over the world are also

included in this issue of trends in

automation.

I wish you inspiration and pleasant

reading.

Markus Ott

Head of Sales Communication

In focus

On the move with electric drives

Economical and systematic: electric drive solutions

in the production of Mercedes-Benz bus bodies. 4

Newsticker

New products, events and news in brief. 10

Interview

No such thing as “either/or”

Dr. Eberhard Veit, Chairman of the Management

Board of Festo on process and factory automation. 13


Soft-start valve ensures safety

Slow pressure build-up: the soft-start valve VABF

ensures maximum operating safety. 16

Electric drives

Fast, compact and precise – electric axes for every

application

Electric axes EGC and EGSK/EGSP demonstrate

their abilities in handling technology. 18

More than just electric rotation

Powerful: the rotary drive module ERMB enables

free definition of acceleration and speed. 20

Handling and assembly

Fast moving nail varnish bottles

Short cycle time: the rotary indexing table DHTG

performs precise, fast and cost-effective handling. 22

Industry specific solutions

Pneumatic flu jab

Pharmaceutical industry: valve terminals CPV and

MPA control process valves in vaccine production. 24

Robots transport workpieces

Intralogistics: intelligent transport robots get

pneumatic support. 26

Automation worldwide

Applications from all over the world. 29

Infoservice 34

4

Electric drive solutions

Field of application

Final assembly of bus bodies

Benefits

• Flexible assembly through rapid retooling

• Fast positioning with electric drives

• Energy-efficient drive and control concept

In focus

trends in automation No. 15, 2009

On the move with electric drives

Festo electric drive solutions are systematic and economical. Sophisticated

design software ensures that cost traps are precluded from the start. With

the mechatronic multi-axis modular system a whole range of different com-

ponents can be connected. The word is out about our high level of electrical

competence: Mercedes-Benz chose Festo electric drives for the manufacture

of buses and coaches.

Festo electric drives are used in the production of bodies for

Mercedes-Benz Travego, Intouro, Tourismo and Conecto coaches.

The special challenge facing the Hosdere factory in Turkey is

adhering to very tight tolerances for welding of body components

while at the same time ensuring fast retooling for different vehicle

types.

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5


Located near Istanbul, the

Hosdere bus factory is one of the

world’s most modern bus facto-

ries. Some 2,000 employees man-

ufacture Mercedes-Benz Travego,

Intouro, Tourismo coaches as well

as the new Conecto city bus. The

capacity of the Hosdere plant is

an impressive 3,600 vehicles per

year, of which nearly 80 % are for

export. The goal is to increase

capacity to 4,000 units by 2009.

This makes the factory an impor-

tant element in the Mercedes-Benz

commercial vehicle production

network, meeting high internation-

al quality standards.

A grip on electric drive tolerances

This was only possible as the

result of efficient, quality-focused

design of the production plant in

Hosdere. Planners paid particular

attention to the complex step of

final body assembly. First, the sub-

frame, sides, roof, front and rear

frame are welded together, then

final assembly of these subassem-

blies takes place. The challenge

faced by Mercedes was to adhere

to very tight tolerances for the

alignment and welding of the body

components while at the same

time being able to switch quickly

between different vehicle types.

Festo electric drive technology

made a decisive contribution to

meeting these requirements in the

factory in Hosdere.

Minimum retooling times for

various vehicle types

In addition to numerous pneumat-

ic components, the production

planners in Hosdere integrated a

total of six Festo electric toothed

belt axes of the DGE series. The

stable axes, which are five meters

long and have a roller guide, have

a maximum speed of 10 m/s and

a repetition accuracy of ±0.1 mm.

They are used for the horizontal

positioning of several carriers into

which the vertical side pillars of

the bus body are clamped. Driven

by Festo servo motors MTR-AC,

the axes move the carriers, each

weighing several tonnes, with their

three clamping devices into the

exact position required for each

vehicle type. It is the trump card

in the manufacturing process in

Hosdere, as Nedim Alp, Bus Pro-

duction Planning Manager (Body

Shells) at Mercedes-Benz Türk

emphasises, “The jig enables us

to manufacture body shells for

three or four different vehicle

types with minimum retooling

times. This means that, despite

the range of types, we can run

the buses on the conveyor with

shorter cycle times.”

Automation competence decisive

for Mercedes-Benz

Correct positioning of the side pil-

lars is critical for further assembly

of the body. Inaccuracy in this pro-

duction step results in dimensional

deviations in final assembly. Posi-

tive experience with Festo automa-

tion expertise in the past was a

key reason for choosing Festo

electric drive technology. Another

point in favour of Festo was that

the company had shown that it

could deal with any problems that

might arise when using Profibus

for controlling drives. The thirteen

servo motors along the axes com-

municate via Profibus.

Experts appreciate the perfect

match

Examples like Mercedes-Benz Türk

show that Festo – as a full-service

supplier – increasingly acts as a

Six electric toothed belt axes DGE from Festo are used for horizontal positioning of

special carriers into which the vertical side pillars for the bus body shell are clamped.

Each axis is five meters long.

The exact positioning of the side pillars is essential, as errors at this point would result

in major problems during final assembly.

6 In focus ... On the move with electric drives


Mercedes-Benz Türk A.S.

Products Buses and coaches as well as

light and heavy trucks, semi-

trailers and unimogs.

Contact TR-34500 Bahçeșehir/Istanbul

www.mercedes-benz.com.tr

Nedim Alp, Bus Production Planning

Manager (Body Shell), Mercedes-Benz

Türk, emphasises, “The jig enables us to

manufacture body shells for three or four

different vehicle types with minimum

retooling times.”

design partner to customers.

Whether pneumatic components,

electric drives, complete handling

solutions – whoever, like Mer-

cedes, buys from Festo can be sure

that the components communicate

in an optimum way, that parts fit

together, and that numerous con-

nection possibilities and interfaces

are available, even across sys-

tems. The Festo mechatronic multi-

axis modular system offers hun-

dreds of matching and freely com-

binable components for gripping,

joining, rotating or positioning.

Energy chains, integrated tubing,

sensors, motors and drives are, for

example, all part of complete han-

dling systems. Recently, the modu-

lar system has been supplemented

by additional electric drives such

as the rotary drive module ERMB

and the spindle driven cantilever

axis EGSA.

Design software provides support

Festo customers can also count on

competent support for optimum,

energy-efficient and cost-effective

design of their electric drive sys-

tems. Experience shows that cost

traps often find their way into elec-

tric drive solutions during the

design stage, for example when

the individual components such

as drive mechanisms, gear unit

and motor are designed separate-

ly. Safety factors of 1.3 to 2 are

used to cover all eventualities. As

a result, this safety factor is includ-

ed several times in a single axis

and a motor is chosen that is twice

as powerful as necessary. This

often results in a drop in efficiency

by over 50 percent.

In order to help the user develop

the optimum design and select the

most suitable components, Festo

offers special dimensioning soft-

ware to support competent con-

sulting by Festo sales engineers.

The PositioningDrives program

quickly and reliably calculates

characteristic load values for the

selected drive in a maximum of

four steps. Application parameters

and the required cycle times are

entered, travel cycles processed

and the desired solution package

selected. The software then deliv-

ers detailed results such as motor

characteristics, system data, prod-

uct data and parts lists. The user

can then use these for convenient

ordering and machine documenta-

tion.

Engineering tool ensures efficient

electric drives

And finally, there is a tool to sup-

port users when commissioning

Festo electric drives: FCT, the Festo

Configuration Tool. With just a few

mouseclicks, this new software

platform offers a simple overall

solution for the commissioning

A special jig is used to join the prefabricated components of the bus body shell. The

parts have to be accurately positioned before they are welded together.

7


is 1501Customised solutions

is 1502Handling system overview

Infoservice

Michael Fraede, Electric Drives

Product Manager at Festo:

“Festo can achieve nearly all

motions in automation both

pneumatically and electrically.

All products and systems are

seamlessly compatible and

easy to combine. That’s the added value that

customers desire.”

of electromechanical automation

equipment. The tool can be down-

loaded free from the Internet at

any time. As a platform for simple

commissioning of electric drives,

FCT configures the functions of the

drives as required. As the drive

function is achieved by a function-

al chain comprising of controller,

motor and axis, the software sys-

tematically harmonises these com-

ponents, including automatic

transfer of all physical characteris-

tics of the electric drive.

With this in mind, it is no wonder

that customers like Mercedes-

Benz wish to benefit from Festo

expertise in areas in which electric

drives are the technology of

choice. After all, Festo’s competen-

cy in automation always ensures

economical and systematic drive

solutions.

Festo customers get professional support for the optimum design of their electric drive

systems. The range of services extends from PositioningDrives design software and the

FCT commissioning tool to intensive on-site discussions with a Festo sales engineer.

All along the value creation chain, Festo

helps customers to design, purchase and

operate optimal electric drive solutions.

• Consulting

• Design aids

• Electronic catalog

Design Purchasing/logistics

• Festo Online Shop

• 24-hour delivery services

• Logistics optimisation service

Assembly & commissioning

• Ready-to-install solutions

• Commissioning of axis

systems

Operation

• Modular service contracts

• Spare parts catalog/repair

Cost saving

Time saving

Process reliability

8 In focus ... On the move with electric drives


Mechatronic Motion Solutions:

an overview of the world of electric drives

Management level

Control level

Field level

Pn

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tic

Se

rvo

-pn

eu

ma

tic

Ele

ctri

cController

Motor controller

Control

Drives

Front unit Grippers

Management system

Integrated controller FED-CEC

Integrated controller CECX

SPS (ABB, Allen-Bradley,Rockwell, Siemens etc.)

Stepper motorsEMMS-ST

Servo motorsEMMS-AS

Electric grippers

Positioninggrippers

Parallelgrippers

Three-jawgrippers

Angle and radial grippers

Swivel/gripper unit

Micro grippers

DGE

DGE-ZR-RF

EGSK/EGSP

Servo motor controllerCMMP-AS

Stepper motor controlleCMMS-ST

Servo motor controllerCMMS-AS

Gantry axes

EGC


9

FHPPFesto Handling andPositioning Profile

CoDeSysprovided by Festo

FST 4Festo Software Tool

FCTFesto ConfigurationTool

PositioningDrives

Design and dimen-sioning software for electric drives

Axis interfaceCPX-CMXX

Robotic controller CMXR

Motor controllerSFC-LAC SFC-DC

Servo motorsMTR-DCI

Vacuum

Vacuumgrippers

Vacuumgenerators

Rotary drives

Electric Pneumatic

Camera systems

Diagnosticsand com-missioning

Type, positionand rotary orien-tation recognition

DGEA

DNCE

EGSA

Cantilever axes

Mini slide SLTE with DC motor

Handling axisHME with linear motor

Eth

ern

et

Fie

ldb

us

AS

-In

terf

ace

r

Electric drives

Electric cylinder with DeviceNet

Maximum positioning and retooling flexibility in

the form of a cylinder – that’s the electric cylinder

with piston rod DNCE. Combined with the intelli-

gent motor unit MTR-DCI or a servo motor, it is

offered and supplied as a pre-assembled system

solution and has shown itself to be an ideal unit.

But there’s more: integrated controller, power elec-

tronics and gear unit, now also with DeviceNet.

This is the solution of choice when freely program-

mable positioning, stick-slip-free behaviour,

smooth acceleration or an application-specific

path profile is required.

Motion control

Integrated controller FED-CEC

The Festo FED-CEC with integrated FED Front End

Displays offers a space-saving control concept that

has everything, from an integrated Ethernet port

and diagnostic functions to the CANopen master

interface for simple control of both valve terminals

and electric drives from Festo. The optional FED-

UIM I/O module offers 20 digital and 8/4 analogue

inputs and 12 digital and 4 analogue outputs.

And programming is as simple as could be via the

CoDeSys software platform provided by Festo.

is 1503 Electric cylinder DNCE

Drives

New stopper cylinder generation

More force for smaller-scale solutions.

Depending on the application, the stopper

cylinders DFST reliably stop loads of 1 kg

to 800 kg with full, half-full or empty work-

piece carriers – smoothly and above all

vibration-free. This flexibility makes it

possible to achieve optimum through-

put times in a transfer system using

only one cylinder size. Humidity and

dirt do not cause malfunctions, even

under heavy load. In the event of

wear, the shock absorber is simply

replaced without the need to disman-

tle the cylinder. Free selection of the

air connection on any side of the

flange plate or from beneath in the

profile facilitates simple assembly

even in cramped conditions.

is 1505 Stopper cylinder DFST

10


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Drives

Swivel module with new precision

As the new flagship of the Festo swivel module series

DSM, the size 63 offers cost-effective, space-saving

sensing options with SMx-8F switches. The DSM with

new powerful integrated shock absorber can be used

wherever swivel motion is required in machine and

system construction.

The combination of the two cylinders DNC with the opti-

mised DSM-B to create the DSL-B swivel/linear unit has

the same benefits as the DSM-B. Linear motions can be

executed in different stroke lengths and X-stroke lengths.

Thanks to the new shock absorber elements with fixed

stops on the DSM-B, a repetition accuracy of 0.1° can

be achieved. Two types are available: a low-cost variant

with plain bearing guide and a backlash-free and thus

accurate variant with ball bearing guide.

is 1504Swivel module DSM-B

DSL-B

DSM-B

11


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Inside Festo

40 years of Festo Brazil

In 2008 no less than three companies celebrated their

40th anniversary. In Europe Festo Great Britain, in

Asia Festo Malaysia, and as the first company on the

American continent, Festo Brazil. It all started there

with the sale of pneumatic components, and only five

years later it was upgraded to a production site. In

1994 the South American company became the first

Brazilian company in the automation industry to be

awarded ISO 9001 certification. Today, Festo Brazil

has over 470 employees in the São Paulo headquar-

ters and six branch offices.


Non-return valve for greater safety

The valve terminal CPV10 with integrated non-return

valve prevents backpressure from the exhaust duct

entering the associated valve output. This feature

increases the safety of downstream components.

The valves are ideally suited for general tasks in pro-

duction automation, preventing feedback from bel-

lows cylinders or clamping cylinders. But they can

also be used in process automation, as applications

in this area require reliable, feedback-free switching

operations to increase safety.

Ballooning

A miracle of airborne energy-efficiency

With innovative membrane flock insulating material, Festo’s hot air

balloon demonstrates another breakthrough in energy efficiency for

lighter-than-air craft. An insulation layer only 6 mm thick cuts fuel

consumption of the hot-air balloon by more than half. This means

a saving of at least one bottle of propane per trip – and additional

space for passengers. It also considerably extends the service life

of the balloon envelope due to minimal thermal load.

The development of the aerofabríx insulation is a technical revolution.

It is the world’s lightest and most efficient insulating material. Apart

from applications in ballooning, the material is also suitable for insu-

lation of aircraft and material structures.

Sensors

F for flush mounting

A new addition to the range of sensors: the induc-

tive sensor SIEF-xxB Factor 1 for flush mounting.

All proximity switches in the SIEF series are char-

acterised by a high level of immunity to magnetic

fields, making them ideal for use near welding

machines. A further benefit: in addition to Factor 1

technology, the SIEF has a greater switching dis-

tance than conventional inductive sensors.

is 1506Valve terminal CPV


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Price of Namur valve substantiallyreduced

The new valves VSNB replace the existing Namur

valves MN1H-5/2K-FR-NA. Thanks to a drop in

development costs, the valve’s list price has been

reduced by 46 %.

Compact and small, the double pilot valve is ideal

for applications with small rotary actuators in the

process industry, particularly where several valves

are installed together. Damp and dirty environ-

ments don’t affect the Namur valve – a special

connection prevents fluids and dirt from being

sucked in.


Higher flow rate in the same space

New for the MPA valve terminal: new manifold

blocks that increase the flow rate through the valve

terminal by a factor of three to up to 900 l/min.

This means that multiple valves can be switched

simultaneously and more drives can be actuated.

Features:

• Modularity enables easy expansion and conver-

sion

• Quick connection of the manifold blocks using

only three screws

• Standard air qualities: filtered, lubricated, unlu-

bricated or inert gases

• New diagnostic functions integrated, e.g. under-

voltage

Sensors

Inductive sensor for type 8 slot

Electric drives and pneumatic grippers are an ideal fit

for SIES-8M, the first inductive proximity switch for the

type 8 slot. The sensor reliably checks end, reference

and intermediate positions. Thanks to central mounting,

the sensor can be inserted directly into the slot from

above, allowing easy positioning and secure fitting. The

main benefit: two LEDs – to the left and the right of the

active surface – guarantee that the status display is

always visible, regardless of the side from which the

cushioning elements approach the sensor.

Inside Festo

30 years of Festo Philippines

In October 2008, Festo Philippines celebrated its 30th

anniversary. On the guest list were apart from Festo

management and staff, several customers, business

partners, as well as representatives from the German

Embassy and the German Philippine Chamber of Com-

merce. Prior to the event, several symposiums were

held at the offices in Manila and Cebu as part of the

annual Technology Day. Festo Philippines currently has

48 employees in its São Paulo headquarters and two

branch offices.

13Interview


No such thing as “either/or”

According to Dr. Eberhard Veit, Chairman of the Management Board of Festo, there’s no such

thing as “either/or”. In this discussion about process and factory automation, he doesn’t see

two different views, but rather synergies resulting from the two areas of expertise.

Originating in factory automation

(FA) and now increasingly involved

in process automation (PA),

automation specialist Festo has

cross-disciplinary expertise in

mechanical engineering. As the

industries expand, process

automation is taking on a domi-

nant role as a result of the huge

potential in this area.

Dr. Veit, why is a company that

started out in pneumatics and

developed expertise in automation

now moving increasingly into the

area of process automation?

Markets change and compa-

nies have to stay up-to-date to see

and grasp opportunities. If you

look at the market for process

automation, the opportunities for

growth in PA are significantly high-

er than for FA. Festo is particularly

interested in developing the possi-

ble synergies throughout the

entire value creation chain, both at

product level and in relation to the

potential in development, produc-

tion, global logistics and distribu-

tion. In particular, the so-called

hybrid industries offer enormous

potential for companies like Festo

that have expertise in both FA

and PA.

14 Interview ... No such thing as “either/or”


What, in your opinion, are the

main differences between the two?

Factory automation normally

involves indoor systems where

speed, throughput, fast motions

and precise transport of heavy

loads are the main factors. Process

automation is different. These are

normally huge outdoor plants with

different climatic conditions and

safety regulations in the event of

incidents. Despite the seemingly

very different focus, there are

approaches to the development

of automation applications that

facilitate cross-fertilisation of the

two worlds.

Can you give an example?

How specific is the synergy from

production automation?

Take, for example, Interpack,

the international trade fair for

processes and packaging. It is

characterised by a hybrid use of

PA and FA. Machines and systems

are considered from a point of

view of life cycle costs – and in

most cases processes are mixed.

Factory automation products can

be found in process automation

systems. We should no longer be

looking at individual steps, but at

a mix of circulating media and con-

trolled movement of materials. A

machine tool has lubricant and

coolant circuits as well as surface

treatment.

So do we need new products

for these hybrid applications?

Yes and no. New products

round off the hybrid portfolio and

standard solutions open up inter-

esting cost opportunities. To begin

with, Festo will launch new prod-

ucts specifically for PA at the end

of 2008. These will include the

CPX-P remote I/O for process

automation. In addition to the pilot

valves VOFC and the VOFD valves,

we will introduce the DFPI, a com-

pact and robust regulated linear

drive with integrated position con-

troller and displacement encoder.

And at the beginning of 2009, we

will supplement the product range

with sensor boxes.

Functionality from FA can be

adapted to the areas of bio-phar-

ma and fine chemistry. Valve termi-

nals can be used, offering clear

cost benefits over solutions using

individual valves. A prime example

for pneumatics in PA is the quar-

ter-turn actuator, which offers

great cost benefits in comparison

to electric solutions, but also

offers reliable switching and over-

load protection and is mainte-

nance-free. It is ideal for use in

food and water & waste water

applications.

What specific tasks lie ahead

and how will customers benefit?

Up to now, the focus has been

on expanding PA. Now Festo has

to do its homework and determine

industry requirements, for exam-

ple with regard to explosion pro-

tection in the development of

products. This is the only way in

which Festo can service all eight

process automation segments

professionally and offer a single

source for automated process

valves.

It will be important to leverage our

strategic advantage by servicing

all three levels in PA, from control

with valves to pneumatic drives to

process valves.This will ultimately

significantly reduce the engineer-

ing effort for automation. What is

also needed is a significant partner

in the international arena who can

safely and surely marry the two

worlds in a lasting way.

If you take factory automation

and process automation: in which

industry does the mix of the two

areas of expertise really come

together?

“Life science” is a trend for

both areas. Automating laboratory

processes in medical technology

offers huge growth potential. Med-

ical diagnostics and the develop-

ment of active ingredients are the

keywords. Basically, successful

processing requires both PA and

FA expertise. Liquid handling and

sample handling are key technolo-

gies. On the one hand this involves

the discrete conveying and posi-

tioning of vials for analysing sam-

ples or micro-approaches to

research into active pharmaceuti-

cal ingredients, on the other it

involves the precise handling of

small amounts of fluid.

15


From the process control technol-

ogy point of view, many processes

are similar or identical – a clear

advantage for the synergies in

our development and our use of

automation components. The

trend is increasingly towards

miniaturisation because of the

small amounts of fluid involved.

Table-sized analyzers and sample

preparation equipment like minia-

turised factories have already

been around for a while.

Factory automation or process automation?

Continuous or discrete?

Factory automation is primarily concerned with the rapid execution

of (intermittent) motions.This frequently involves highly dynamic

motion of large machine parts that must nonetheless be moved and

positioned with great precision. The machines are normally moder-

ately sized and they are usually installed in closed halls. This means

that the requirements for temperature resistance of the components

used are not particularly strict. But as components are frequently

mounted directly on the

machines – without a protective

control cabinet – the IP protec-

tion class of the components is

of great importance. The overall

production plant generally con-

sists of several machines from

different manufacturers which

are often independently auto-

mated and not infrequently

have different control elements.

Process automation designed

for continuous processes,

however, has different require-

ments. The first thing you

notice is that there isn’t much movement within the processing plant –

except in the event of incidents, in which case the plant operator’s

personnel spring into action very quickly. Otherwise, the plant con-

sists of closed systems which, at first glance, reveal nothing of the

actual production process. Pumps are mainly used to pump media

through pipes and valves from

container to container, in which

materials are added and mixing

and temperature control takes

place.

16

Soft-start valve VABF-S6-1-P5A4 with manifold

sub-base VABV-S6-1Q on valve terminal VTSA


Automotive industry, packaging industry,

special machines

Key features

• Greater safety through gentle pressure

build-up in automation systems

• Protective functions in systems

• No piping or tubing effort



Soft-start valve ensures safety

The new soft-start valve VABF can be easily integrated into the Festo stan-

dardised valve terminal VTSA and reduces risks for users, for example in the

automotive and packaging industries and in special machine construction

by ensuring slow build-up of pressure in automation systems.

As for many other compo-

nents of the modular valve termi-

nal system, the soft-start valve

VABF fits the description ‘small

component, big impact’. The VABF

is integrated into the valve termi-

nal VTSA to ensure smooth pres-

sure build-up that meets the

requirements of the various pneu-

matic devices.

With the adjusting screws both the

switching pressure and the filling

time can be set. A sensor option

is available to monitor the piston

position of the soft-start valve.

This checks whether the valve

has switched. If not, duct P of the

downstream power valves are

switched to unpowered. Up to five

soft-start valves can be integrated

into the valve terminal with one or

more pressure zones. All down-

stream valves are supplied via the

soft-start valve.

VABF in practice: safely switched

to unpressurised

Users, such as in the automotive

industry, use the safety concept of

the soft-start valves VABF whenev-

er operating safety plays an impor-

The standardised valve terminal with

integrated soft-start valve – one link in

a chain of safe automation systems.

is 1507Standardised valve terminals

VTSA and VTSA-F

Infoservice 17


tant role, for example in body

welding stations. In this case the

pressure build-up valve operates

as a soft-start valve and switches a

toggle lever clamping unit which

clamps the sheet metal. If a toggle

lever is not in its initial or operat-

ing position because of a jammed

part, there is a danger that the

clamp could move suddenly as a

result of operator intervention,

resulting in a high risk of injury.

The soft-start valve has the task of

switching the system to an unpres-

surised state, thus removing the

danger.

If the toggle lever clamping unit

has not reached either its top or

bottom slack point and the

employee enters the danger zone

to eliminate the fault, a safety PLC

switches the soft start-valve off

and vents the system. The system

can now be entered safely.

... and rapid restart

The benefit of repressurising with

the soft-start valve is a fast restart

of the automation system. The

VABF does not exhaust the entire

system, but only the part of the

system concerned, so that only

this part needs to be repres-

surised. Significant advantages

over venting via the service unit

are that the response speed is

increased and valuable energy

is saved.

The integrated soft-start valve VABF for

users of robust modular valve terminals

with extensive pneumatic and electrical

function integration.

Safety functions are required in many industries to protect operator and machine.

The beverage industry is just one example, as seen in this Veltins brewery system for

sorting empties.

The soft-start valve enables a gradual

build-up of the supply pressure in duct 1

of the valve terminal.

pressure

time

18

Electric axes EGC and EGSK/EGSP

Field of applications

Handling technology, for example palletising,

sorting or feeding

Benefits

• High speeds and heavy loads

• High repetition accuracy and precision

• Flexible motor installation

• Compact design

Electric drives


Fast, compact and precise – electric axesfor every application

A new generation of electric linear axes. The EGC with recirculating ball bearing guide offers high speed and dynamic

response as well as great rigidity. Suitable for all motor types, it supplements the Festo mechatronic multi-axis modular

system.

Whether electric, pneumatic

or servo-pneumatic, the technolo-

gy used depends on the applica-

tion. So machine builders have

plenty of choice with the Festo

mechatronic multi-axis modular

system. It combines all function-

alities and technologies, from

drives, grippers and rotary mod-

ules to basic components and con-

nection elements and the energy

chain; and it is supplemented by

camera systems and the motion

controller. Hundreds of matching

and freely combinable compo-

nents are available for positioning,

joining, gripping and rotating, as

well as standardised handling sys-

tems. The new electric linear axis

EGC now considerably extends the

range of applications.

EGC – High feed force, high speed

The EGC axis with spindle or

toothed belt belongs to the new

generation of electric linear axes.

Its high feed force and speed make

it fit for handling technology, for

example, for palletising, sorting,

feeding or handling. The broad and

rigid aluminium profiles on the

axis enable it to carry heavy loads.

In addition, the guide is closer to

the load and small lever arms

ensure high permissible loads and

torques. This enables the user to

select a smaller size for the same

load, thus saving installation

space as well as costs.

With the toothed belt axis variant

the motor can be mounted on both

sides and both ends. The user can

thus reposition the motor at any

Electric axis EGC with servo motor

EMMS-AS

is 1508Electric axes EGC

Infoservice 19


time as the position doesn’t have

to be predetermined. The small

drive pinion means that frequently

there is not need for a gear unit,

resulting in a further cost saving.

This means that the EGC is of inter-

est to industries that require pow-

erful and cost-efficient solutions,

for example the electronics indus-

try or food & packaging with a

focus on the packaging process.

PositioningDrives software is

designed for the layout of drive

solutions. It calculates the load

characteristics for the selected

drive and gives detailed results

such as motion profiles, system

and product data as well as a parts

list with which users can easily

generate orders and machine doc-

umentation.

EGSK – precise and compact

For applications in electronics or

precision engineering that require

a particularly high level of preci-

sion, the spindle axis with recircu-

lating ball bearing guide EGSK is

the perfect fit. The EGSK demon-

strates its level of precision when

handling delicate chips or in pick

& place applications. At the same

time, the design is compact. The

guide rail is incorporated into the

stainless steel axis profile and the

spindle nut is integrated directly

into the slide. This enables

machine builders to make the best

use of space. The design also pre-

vents unfavourable tolerances,

contributing to the high repetition

accuracy of the EGSK.

EGSP – low-noise and long-life

The EGSP axes are identical to the

EGSK series except that they have

an innovative caged ball chain

technology instead of the recircu-

lating ball bearing guide. Depend-

ing on the size, the ball chain is

either integrated into the guide

only or into the guide and the spin-

dle. In addition to a long service

life, the caged ball chain enables

especially smooth operation with

very low noise. This is important in

the electronics industry, for exam-

ple, where low noise emissions are

essential.

Stepper motor or servo motor?

Festo has suitable drive solutions

for the new electric axes. The axes

EGC and EGSK/EGSP can be com-

bined with either stepper motors

and controllers EMMS-ST and

CMMS-ST or with servo motors

and controllers EMMS-AS and

CMMS/P-AS. Users will find every-

thing they need, from simple, low-

cost drives to powerful solutions

for complex tasks.

Technical data: electric axis EGC

• Size: 50/70/80/120/185

• Drive: spindle drive/toothed belt

• Guide: recirculating ball bearing guide

• Max. stroke: 3,000/10,000 mm

• Max. speed: 2/5 m/s

• Repetition accuracy:

±0.01 – 0.02 mm

• Max. force Fx: 3,000 N

• Max. torque load:

Mx 580 Nm, My 1,820 Nm, Mz 1,820 Nm

• Options: guide axis, extended slide, additional

slide, protected version, central lubrication

20

Electric rotary drive module ERMB


General and special machine building, electron-

ics industry, handling technology

Key features

• Any rotation angle

• Freely definable acceleration and speed

profiles for rotation

• Compact design and low weight

• Definition of impermissible zones by means

of sensors

Electric drives


More than just electric rotation

With freely definable acceleration and speed pro-

files, the electric rotary drive module ERMB enables

applications to be customised to exact requirements.

At the same time, soft-stop into the end positions

reduces vibration and wear compared to solutions

with end stops.

The new electric rotary drive module ERMB is a versatile turning point for

automation. Products or handling modules can be rotated up to 360 degrees

as often as required. The powerful module can even be used as a numerically

controlled rotary table.

In keeping with the rule that

the most important facts are

always at the beginning of a

report, here are the key advan-

tages of the electric rotary module

ERMB in a few words. Freely posi-

tionable with additional trip cams

for easy setting of end positions,

drive via servo motor, stepper

motor or intelligent servo motor

MTR-DCI, dynamic but smooth

approach into the end positions,

optional definition of an impermis-

sible zone with the aid of two

inductive sensors and trip cams,

and specially weight-optimised

design. The fact that the rotary

module ERMB not only offers tech-

nical but also economic advan-

tages is an invitation to take a

closer look.

Degrees of freedom for automa-

tion

Wherever automation of produc-

tion, assembly or test processes

requires freely programmable rota-

tion of products, handling axes or

devices, the electric rotary module

ERMB is an asset. Particularly as

the broad range of motors, cou-

plings and mechanical adapters

make it very adaptable to your

specific automation task, while

the high degree of modularity also

means optimum functionality.

is 1509Electric rotary module ERMB

Infoservice 21


Compatible with the Festo mecha-

tronic modular system

The rotary flange has a hollow

shaft with an exemplary large

diameter. A rotary distributor sim-

plifies the supply of grippers with

compressed air or current. Many

grippers, such as the HGPL, HGPT,

HGPP and HGP, as well as adapters

from the modular system for han-

dling and assembly technology,

can now be combined with the

ERMB module. This also applies

for the electric linear axes DGEA

and EGSA and pneumatic units

DGSL and SLT.

Loads of up to 15 kg can be rotat-

ed, with repetition accuracy vary-

ing between ±0.03 and ±0.08

degrees according to the motor

type. The rotary modules are

designed for 30 to 40 million load

changes and maximum rotary

speeds of 1800 degrees per sec-

ond at the output.

Ideal installation options

Thanks to the six-sided mechan-

ical interfaces, the unit can be

installed in almost any position,

either as a front-end solution or by

recessing the rotary flange in a cir-

cular hole in a plate. In contrast to

other systems that cannot be used

with a brake, the rotary module

ERMB can be braked by the motor,

if necessary. As the output inter-

face corresponds exactly to the

pneumatic semi-rotary drive

DRQD, existing systems can simply

be converted to the freely posi-

tionable electric rotary module

ERMB.

Versatile in application

This “turning point for automa-

tion” is proving its strengths in

many industries. For example, for

packaging pharmaceuticals and

food, in complex handling systems

with grippers and vacuum technol-

ogy and in rotating, swivelling and

orienting workpieces or automa-

tion components.

Technical data

• Sizes 20/25/32

• Maximum drive torque 3.15/8.8/25.5 Nm

• Gear ratio 4.5:1/4:1/3:1

• Permissible radial force at flange

– Maximum dynamic 170/260/500 N

– Static 1.200/1.500/1.750 N

• Maximum output speed 300 rpm

• Repetition accuracy

with servo motor type EMMS-AS Max. ±0.03 degrees


with MTR-DCI Max. ±0.05 degrees


with stepper motor type EMMS-ST Max. ±0.08 degrees

Position sensing for the rotary module

is via SIEN-M8 inductive sensors.

Using adapters, the module can be very

flexibly connected to linear axes and grip-

pers from the Festo mechatronic multi-axis

modular system. This minimises the user’s

time spent on project planning and

design.

22

Packaging for nail varnish bottles

In use

Pneumatic rotary indexing table DHTG

Benefits

• Transfer of bottles onto a conveyor belt

• Safe and smooth acceleration

Handling and assembly


Fast moving nail varnish bottles

Installed upside down: the DHTG moves nail varnish bottles from one conveyor to

another at a rate of 40 per minute.

is 1510Rotary indexing table DHTG

Infoservice 23


Trendy, sexy or classical, nail varnish is attractive and with the advent of nail design studios,

finger nails and toenails have become real small works of art. Fiabila is one of the world’s

largest manufacturers of nail varnish. The French company relies on rotary indexing table

DHTG from Festo for automation.

The beauty business is inter-

national. Fiabila manufactures on

nearly all continents – in France,

India, Japan, the US and Mexico –

for many well-known cosmetic

brands. The company is a leader

in researching and developing new

technologies. This year, it entered

a development partnership with

the American company Nano Natu-

ral, Inc. to produce even more

durable nail varnishes using nan-

otechnology.

Customised machines

The French market leader uses reli-

able packaging equipment from

CMAS Packaging Systems to pack

the tiny nail varnish bottles. Cus-

tomised to the nail varnish manu-

facturer’s needs, these machines

pack the nail varnish bottles into

boxes.

CMAS Packaging Systems designs

and manufactures vertical and hor-

izontal packaging machines that

pack food, parts or pharmaceutical

products into compact boxes. The

machines are flexible so that for-

mats can be changed without a

change of tools. And now the

rotary indexing tables DHTG from

Festo are also used in the Fiabila

application.

The rotary indexing table solution

“We were looking for a solution

to transfer the bottles onto the

conveyor belt,” reports Daniel

Rehlinger, Managing Director of

CMAS Packaging Systems. “And

then Festo sales engineer Nicolas

Croizier suggested the solution

with the pneumatic rotary indexing

table DHTG.”

“Installed upside down, it now

moves the nail varnish bottles

from one conveyor belt to the

other at a rate of 40 per minute,”

explains Rehlinger. It proves to be

very rugged, precise and economi-

cal in operation and runs smoothly

and accelerates surely but gently.

“Exactly the attributes essential

for handling nail varnish bottles

that are small, delicate and expen-

sive,” says the CMAS managing

director. So they had the solution

nailed.

CMAS Packaging Systems

Products Vertical and horizontal packaging

systems

Contact F-47310 Moirax-Agen

www.cma-packaging.com

Functional principle: two vertical indexing cylinders hold the

position while two horizontal cylinders supply the necessary

motion via a drive pinion.

Runs smoothly and accelerates surely but gently: the rotary

indexing table DHTG handling nail varnish bottles.

Technical data

• Plate diameter: 65, 90, 140, 220 mm

• Repetition accuracy: <0.03°

• Max. plane parallelism: <0.04 mm

• Max. switching frequency: 20 – 200 min

24

Pharmaceutical industry:

Manufacture of influenza vaccines

In use

CPV and MPA valve terminals for control of

process valves

Benefits

• Safety and reliability

• Flexible system concept with modular valve

terminals



Pneumatic flu jab

Chills and fever, aching head and limbs – what appears to be a harmless cold

can often be the symptoms of an epidemic. Only 30 years ago, the Russian

flu cost the lives of nearly 4 million people. And what was lacking? Effective

vaccine. Today, GlaxoSmithKline Biologicals (GSK) in Dresden ensures that

there is always enough vaccine – and relies on pneumatic automation tech-

nology to achieve this.

To prevent such devastating

epidemics, health authorities

organise national vaccination cam-

paigns. As a result, GSK in Dresden

has been able to step up annual

vaccine production from two mil-

lion units in 1992 to today’s capac-

ity of 70 million units. In 2007, the

plant was the first worldwide to

receive European certification for

its influenza pandemic vaccine.

At the same time, the plant was

approved by the Food and Drug

Administration for the huge US

market.

Under one roof

In 2005, the company put 125 mil-

lion euros on the table to double

its capacity by 2007 by building

a new facility not far from the

famous Frauenkirche (Church of

Our Lady) in Dresden.

From the manufacture of active

ingredients to filling and packag-

ing to quality assurance, Glaxo-

SmithKline has the entire value

creation chain under one roof.

Batching vessel for flu vaccines at GlaxoSmithKline in Dresden.

is 1513Partner to the biotech/

pharmaceutical industry

Infoservice

is 1511Valve terminal MPA

is 1512Electrical terminal CPX

Infoservice 25

trends in automation No. 15, 2009trends in automation No. 15, 2009

“Without reliable automation tech-

nology, a production increase of

this scale at high quality would be

unthinkable,” explains Florian

Köpsel, process engineer in the

GlaxoSmithKline Technical Service

in Dresden.

Vaccine manufacture

The flu vaccine contains antigens

of three circulating virus strains

as per the World Health Organiza-

tion’s annual recommendation.

First, the viruses are cultured in

the laboratory and then bred for

seed stock. From these, the com-

pany uses fertilised chicken eggs

to produce large quantities of

monovalent inactivated split-virus

solutions, so-called monobulks.

Split-virus vaccine is easier to tol-

erate than a full-virus vaccine.

The sterile monobulks of the three

virus strains are then mixed with

additives in defined proportions.

The resulting final bulk is filled

into ready-to-use syringes which

are then and packaged with coun-

try-specific labels.

Three-week production process

The production of the vaccine

takes nearly three weeks: one

week for processing the fertilised

chicken eggs, one week for purifi-

cation and 3 to 5 days for inactiva-

tion of the virus.

Control of process valves

Pneumatic automation technology

helps to make the processes safe

and reliable. CPV and CPX/MPA

valve terminals are used for con-

trol of the process valves in the

production plant.

Analogue values for measuring

equipment and process valves are

processed using the electrical ter-

minal CPX. The CPX/MPAs combine

control valves and analogue and

binary I/Os in one, so that only

one bus node is required. The CPV

valve terminals offer a high flow

rate in a small space. The compact

valve terminals’ fieldbus node is

directly integrated into the electric

valve terminal controller, requiring

minimal space.

Product life cycle

“Our expertise is in the production

process, not in machine building,”

Köpsel points out. “That’s why we

wanted our systems to have reli-

able, standard automation compo-

nents to minimise maintenance.”

The life cycle of the equipment was

a key factor in the selection of sup-

pliers. Training and maintenance

offered by the pneumatics manu-

facturer were also selection crite-

ria that worked in favour of Festo

valve terminals.

GlaxoSmithKline Biologicals

Branch of SmithKLine Beecham

Pharma GmbH & Co. KG

Contact www.glaxosmithkline.de

Valve terminal MPA for control of process valves in ultrapure water systems.

Control cabinets full of valve terminals MPA. They control the process valves on the

feed lines to the batching vessels in the various production stages.

26

Intralogistics:

‘Servus’ intelligent transport robot

In use

Pneumatic DGC axes, DGSL mini slides und MPA

valve terminals

Benefits

• Reliability and precision

• Modularity and flexibility



Robots transportworkpieces

Servus is Latin for ‘servant’. And that’s exactly what the Servus transport robot is – a smart

and flexible servant. Always in the right place at the right time, Servus helps electronics

manufacturer RAFI to optimise its intralogistics. The Manhattan software keeps the robot on

the right path, while pneumatic components take care of loading and unloading workpiece

carriers.

RAFI is a specialist in electro-

mechanical components and in

operating, communication and

control systems. Producing thou-

sands of products with many cus-

tomised variants naturally leads

to small batch sizes. But instead

of shorter throughput times for

the products being manufactured,

the result was high in-process

inventories – bad news in the high-

ly competitive markets of automo-

tive industry suppliers, machine

building and telecommunication.

One-piece flow

In order to get a grip on our costs,

we had to rethink,” says Albert

Wasmeier, Managing Partner of

The intelligent, self-guided transport robot Servus always

knows precisely when and at which stations which materials

are needed, thus avoiding unnecessary idle time.

27


RAFI. The internal CIP process

developed a one-piece flow. “We

discovered Servus at a fair and

realised it would enable us to

implement a one-piece flow,”

says Wasmeier enthusiastically.

The goal was to link the fully auto-

mated flow-soldering station with

the test facility to support inline

repair. This would dispense with

intermediate storage of semi-fin-

ished subassemblies and manual

transport.

Avoiding waste

The Servus system at RAFI com-

prises two transport robot systems

in two production halls and a con-

veyor system that links the two

Servus systems and acts as a

dynamic buffer. The entire trans-

port network is suspended from

the ceiling so that the system

does not take up space.

Staff take PC boards out of the five

THT flow-soldering systems, test

and scan them. Scanning auto -

matically triggers a route for each

product. The system generates the

pick-up point, the assignment to

the dynamic buffer and the test

station position.

No unproductive journeys

Every year, some 10 million PC

boards are placed on workpiece

carriers. The workpiece carriers

enter the 16 loading and unload-

ing lifts and are transported up to

a transport robot already waiting

with an empty workpiece carrier.

The full workpiece carrier is

pushed out of the lift onto the

transport robot. In return, the lift

brings back an empty workpiece

carrier. In this way, the Servus

system avoids unproductive jour-

neys – thus avoiding waste.

The 25 transport robots travel

from the loading lift to one of four

conveyor systems, each of which

is assigned to a particular prod-

uct. Here they hand over the work-

place holder. The conveyor sys-

tems connect production to the

test facility. At the testing station

the operator presses a button to

request a Servus transport robot.

Pneumatic support for robots

Dynamic DGC drives with recircu-

lating ball bearing guide – featur-

ing high precision and high load

capacity – take care of the routes

for the conveyor system that con-

nects production to the test facili-

ty. Pneumatic mini slides DGSL are

piggybacked. Thanks to an innova-

tive guide unit, they combine pre-

cision and load-bearing capacity in

a compact design. Highly precise

feeding, picking up and inserting is

not a problem for the DGSL, even

under great mechanical loads. This

is made possible by the rigidity of

the slides and the yoke plate. The

guide unit achieves a repetition

accuracy of 0.01 mm and offers

linearity and parallelism in the

1/100 mm range, even at maxi-

mum stroke. Rodless drives DGP

move the workpiece carriers up

and down in the loading and

unloading lifts. Compact short-

stroke cylinders ADVC are used

in the recharging stations.

Highly modular MPA valve termi-

nals control the compressed air

drives. Easy to convert and

expand, they offer customised

The sophisticated Servus system puts an end to unproductive journeys. Whenever the

transport robot picks up a full workpiece carrier, it brings back an empty one.

Space saving: the Servus track system is suspended from the ceiling.

Christian Beer, Managing

Partner of Servus Robotics:

“Like a New York cab driver,

the transport robot always

finds the fastest route to its

next destination because, as

in the Big Apple, every station

is clearly identified by streets and avenues.”

28 Industry specific solutions ... Robots transport workpieces


Festo components

at RAFI

Pneumatic linear

drive DGC

Pneumatic mini

slide DGSL

Pneumatic linear

drive DGP

Short-stroke cylin-

der ADVC

Valve terminal

CPX/MPApneumatics for a broad range of

applications, from single valves

to multipin plug and even an entire

fieldbus terminal.

The smart robots know which

materials are required at which

workstations. Using the pull princi-

ple, Servus supplies parts and

materials on a ‘just in time’ basis.

Manhattan software

And just what is Servus doing in

Manhattan? It orients itself com-

pletely independently – without

GPS or system layout – even in

structures as complex as the map

of Manhattan. Developed in-

house, the Manhattan software

even enables it to orient itself in

changed systems and extremely

large systems. “Like a New York

cab driver, the transport robot

always finds the fastest route to

its next destination because, as

in the Big Apple, every station is

clearly identified by streets and

avenues,” says Christian Beer,

Managing Partner of Servus Robot-

ics in Dornbirn, Austria, explaining

his protégé’s unusual abilities. So

the Austrian transport robot never

gets lost – neither in the concrete

jungle of Manhattan, nor in factory

halls.

Servus Robotics GmbH

Products Application engineering, pro-

duction and sale of turnkey sys-

tems for intralogistics, assembly

and storing small parts

Contact A-6850 Dornbirn

www.servus.info

RAFI GmbH & Co. KG

Products Electromechanical components,

operating, communication and

control systems

Contact D-88276 Berg

www.rafi.de

The upper part of the 16 loading and unloading lifts: this is where the robot is supplied

with workpiece carriers. MPA valve terminals control the motion of the appropriate pneu-

matic drives.

29


automation worldwide 29

Brazil

Remote access via Internet 29

Norway

Fresh fish 30

Canada

Quality control: smarter SMAT 30

South Africa

Optimum leaflet insertion 31

Germany

Safety first 32

Indonesia

Tsunami early warning system on Sumatra 33

automation worldwide Brazil

MasterFoods Brasil Alimentos Ltda

not only invested in automation

technology at its new production

plant in Guararema, but also

looked for ways to improve plant

layout and maintenance. Master-

food decided to use Ethernet to

achieve this.

The company chose the valve ter-

minal MPA with Ethernet/IP pro-

tocol, used in production equip-

ment for Twix, Snickers and M&Ms.

A total of nine decentralised valve

terminal modules are now

installed, mounted directly on the

I/Os. The biggest benefit for Mas-

terFoods: the Ethernet/IP protocol

not only works in the standard

Ethernet network, it also enables

connection to the Internet – and

remote access makes mainte-

nance and technical planning

much easier.

Another important improve-

ment resulting from the valve

terminal MPA was the reduction

in the size of the tubing. This

not only helped to improve the

project layout by reducing the

number of PLC inputs but also

shortened installation time,

thus reducing costs.

www.masterfoods.com.br

Remote access via Internet

30


automation worldwide

Norway


Trust is good, control is better.

That's what a Canadian automo-

tive company thought when plac-

ing an order with Trillium Machine

and Tool Inc. for a machine to

check centring pins on the front

of two new car models. The task

consists of checking that the 20

or more manually preinstalled rivet

nuts are inserted to the correct

depth and are correctly seated in

the plastic frame.

The solution: twenty analogue

SMAT sensors – directly mounted

on ADN, DNC and DFM cylinders –

check whether all the required

rivet nuts are fully inserted. The

position transmitters read the

position of the magnets in the pis-

tons until the piston rods touch

the rivet nuts. The SMAT then

sends an analogue signal back

Fresh fish

Fish tastes best immediately after

it has been caught, but frozen fish

also contains important nutrients

such as protein, vitamins, miner-

als, and healthy fatty acids. This

is certainly true of salmon, which

is processed and exported across

the world by Austevoll Fiskeindus-

tri, one of the largest and most

modern fish factories in Norway.

Once the fish have been gutted

and cleaned, they are sorted and

packed.

Festo and Austevoll Fiskeindustri

have been jointly testing new

Festo components for the fish

industry for more than a decade.

Today, highly corrosion-resistant

aluminium cylinders such as DNC

and DSNU are used for sorting

fish. With their heat-resistant seals

they meet all requirements, such

as protection against seawater

and detergents.

www.auss.no

Quality control:

smarter SMAT



South Africa

Optimum leaflet insertion

Canada

to an analogue module located

on a CPX I/O terminal, which trans-

mits the information via Ethernet

to the PLC. The signal is compared

with a reference value in the PLC

and the rivet nut is categorised as

“good” or “bad”.

www.trilliummachine.com

31

Headquartered in Pretoria, Inge-

nior designs and supplies cus-

tomised equipment for applica-

tions such as a high-speed

machine for inserting information

leaflets into drug packages. A

leading pharmaceutical company

needed to overcome two prob-

lems: guiding the container onto

the belt and back within 30 cm

and inserting the leaflets in such

a way that they open up in the

container to make space for the

tablets. In addition, the system

had to handle four different tablet

containers and information leaflets

of different sizes. And all this with

a setup time of less than 10 min-

utes.

The solution: the insertion

machine uses a clever rolling

mechanism, which first rolls the

information leaflet into a tube and

then shoots it into the container.

The leaflet uncurls a little and then

sits tightly against the inside wall

so that the container can be filled

with tablets or capsules. For the

project, Festo supplied pneumatic

linear drives, double-acting cylin-

ders, rotary drives, valves, venturi

nozzles, suction cups, pressure

regulators, connectors and tubes.

They control all critical movements

and functions of the system.

www.ingenior.co.za

32


32

Germany

Safety first

In an emergency, seconds count.

And it is important to keep calm

and take the right action. That is

why flight crew of all airlines are

trained in emergency situations.

At China Eastern Airlines, for

example, the training takes place

in faithful mock-ups of aircraft

built by RST Rostock System-Tech-

nik GmbH, which supplies hi-tech

solutions for the shipbuilding and

aerospace industries, as well as in

the field of safety. RST has been a

100 % subsidiary of EADS since

1991.

Two escape slides are inflated in

seconds by compressed air. Festo

pressure switches and valves pre-

vent overpressure. The cabin doors

are opened by pneumatic cylin-

ders. Problems such as jammed

or stiff doors are emulated using

pneumatic actuators. Aircraft safe-

ty equipment also includes fire

extinguishers – and here com-

pressed air is made available at

a filling station for training pur-

poses.

www.rst-rostock.de

33


Indonesia

Tsunami early warning system on Sumatra

On 26 December 2004, a seaquake

150 km west of Sumatra triggered

a devastating tsunami. The huge

wave inundated entire coastal

regions and islands, costing the

lives of more than 220,000 people.

Fears of another catastrophe still

run high. For this reason, the gov-

ernment in Padang developed a

tsunami early warning system into

which numerous systems are inte-

grated: from tide gauges, wave

sensors and network communica-

tion to the media that can quickly

spread confirmed details about an

approaching tsunami.

The electronic modules for the net-

work and control system – devel-

oped by Bandung-based IT compa-

ny PT Bernama Informatika Nusan-

tara – were installed at nine loca-

tions in Padang City. One of the

modules acts as the Master Opera-

tion Control & Monitoring Unit,

monitoring system components at

other locations. Each console con-

tains a Festo FEC 440 as controller.

Its ability to communicate with

other devices using the TCP/IP

protocol is a great benefit. The PLC

also has the key task of controlling

the activation of sirens.

www.berka.co.id

1501 Customised solutions

1502 Handling system overview

1503 Electric cylinder DNCE

1504 Swivel module DSM-B

1505 Stopper cylinder DFST

1506 Valve terminal CPV

1507 Standardised valve terminals VTSA and VTSA-F

1508 Electric axis EGC

1509 Electric rotary module ERMB

1510 Rotary indexing table DHTG

1511 Valve terminal MPA

1512 Electrical terminal CPX

1513 Partner to the biotech/pharmaceutical industry

Please do not send me

“trends in automation” in future.

Fax-reply

To

From

infoservice “trends in automation” 15

Take advantage of your personal info service!

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

is 1500

Impressum

trends in automation 15

January, 2009

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 15, 2009”

On target: energy efficiency

Whether it’s about life cycle costs for

systems or process optimisation: with

solutions and services from Festo, you’ve

got lots of options for more energy-

efficient automation!

www.festo.com

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

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27833362

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HanoiTel: +84 4 974 68 33

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