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

On the move with electric drives

Electric drive solutions in bus body production, page 4 www.festo.com
In focus: electric drives

As a leading supplier of pneumat- Finding the right partner is just as

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.
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

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

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

Valves and valve terminals

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 In focus

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
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.

Photos on cover and page 6: Mercedes-Benz

trends in automation No. 15, 2009

 5

Located near Istanbul, the time being able to switch quickly

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
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
The exact positioning of the side pillars is essential, as errors at this point would result
emphasises, “The jig enables us in major problems during final assembly.

Six electric toothed belt axes DGE from Festo are used for horizontal positioning of to manufacture body shells for
special carriers into which the vertical side pillars for the bus body shell are clamped.
three or four different vehicle
Each axis is five meters long.
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

trends in automation No. 15, 2009

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

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-
A special jig is used to join the prefabricated components of the bus body shell. The
lar system has been supplemented parts have to be accurately positioned before they are welded together.
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- Nedim Alp, Bus Production Planning
uct data and parts lists. The user Manager (Body Shell), Mercedes-Benz
Türk, emphasises, “The jig enables us to
can then use these for convenient
manufacture body shells for three or four
ordering and machine documenta- different vehicle types with minimum
tion. retooling times.”
Engineering tool ensures efficient
electric drives Mercedes-Benz Türk A. S.
And finally, there is a tool to sup-
port users when commissioning Products Buses and coaches as well as
Festo electric drives: FCT, the Festo light and heavy trucks, semi-
Configuration Tool. With just a few trailers and unimogs.
mouseclicks, this new software Contact TR-34500 Bahçeșehir/Istanbul
platform offers a simple overall www.mercedes-benz.com.tr
solution for the commissioning

trends in automation No. 15, 2009

 Infoservice 7

is 1501
Customised solutions

is 1502
Handling system overview

of electromechanical automation Michael Fraede, Electric Drives

equipment. The tool can be down- Product Manager at Festo:
loaded free from the Internet at “Festo can achieve nearly all
any time. As a platform for simple motions in automation both
commissioning of electric drives, pneumatically and electrically.
FCT configures the functions of the All products and systems are
drives as required. As the drive seamlessly compatible and
function is achieved by a function- easy to combine. That’s the added value that
al chain comprising of controller, customers desire.”
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.

Design Purchasing/ Assembly & Operation

logistics commissioning
• Consulting • Festo Online Shop • Ready-to-install solutions • Modular service contracts
• Design aids • 24-hour delivery services • Commissioning of axis • Spare parts catalog/repair
• Electronic catalog • Logistics optimisation service systems

Cost saving

Time saving

Process reliability

trends in automation No. 15, 2009

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

Mechatronic Motion Solutions:

an overview of the world of electric drives

Management level Management system

Control level SPS Integrated controller Integrated controller

(ABB, Allen-Bradley, CECX FED-CEC
Controller Rockwell, Siemens
etc.)

Servo motor controller Servo motor controller Stepper motor controlle

Motor controller
CMMP-AS CMMS-AS CMMS-ST

Field level Servo motors Stepper motors

Control EMMS-AS EMMS-ST

Drives

Gantry axes

EGC DGE-ZR-RF
Servo-pneumatic
Pneumatic

DGE EGSK/EGSP
Electric

Front unit Grippers

Electric Positioning Parallel Three-jaw Angle and Micro Swivel/
grippers grippers grippers grippers radial grippers grippers gripper unit

trends in automation No. 15, 2009

 9

Robotic controller Axis interface FHPP

CMXR CPX-CMXX Festo Handling and

Ethernet
Positioning Profile

CoDeSys
provided by Festo

FST 4
Festo Software Tool

Fieldbus
r Motor controller
SFC-LAC SFC-DC

Servo motors FCT

MTR-DCI Festo Configuration
Tool
AS-Interface

PositioningDrives

Cantilever axes Handling axis Design and dimen-

HME with linear motor sioning software
EGSA DGEA for electric drives

DNCE Mini slide

SLTE with DC motor

Vacuum Rotary drives Camera systems

Vacuum Vacuum Electric Pneumatic Diagnostics Type, position
grippers generators and com- and rotary orien-
missioning tation recognition

trends in automation No. 15, 2009

10 + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + +
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.
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.
is 1503
Electric cylinder DNCE
trends in automation No. 15, 2009
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.
DSL-B
is 1504 DSM-B
Swivel module DSM-B
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
+ + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + 11

Ballooning Valves and valve terminals

A miracle of airborne energy-efficiency 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.

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
is 1506
consumption of the hot-air balloon by more than half. This means
Valve terminal CPV
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. Inside Festo

It is the world’s lightest and most efficient insulating material. Apart
from applications in ballooning, the material is also suitable for insu- 40 years of Festo Brazil
lation of aircraft and material structures.
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
Sensors 1994 the South American company became the first
Brazilian company in the automation industry to be
F for flush mounting awarded ISO 9001 certification. Today, Festo Brazil
has over 470 employees in the São Paulo headquar-
A new addition to the range of sensors: the induc- ters and six branch offices.
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.

trends in automation No. 15, 2009

12 + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + + + +

Valves and valve terminals Inside Festo

Price of Namur valve substantially 30 years of Festo Philippines

reduced
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.
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.

Valves and valve terminals

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
Sensors
simultaneously and more drives can be actuated.

Inductive sensor for type 8 slot

Features:
• Modularity enables easy expansion and conver-
Electric drives and pneumatic grippers are an ideal fit
sion
for SIES-8M, the first inductive proximity switch for the
• Quick connection of the manifold blocks using
type 8 slot. The sensor reliably checks end, reference
only three screws
and intermediate positions. Thanks to central mounting,
• Standard air qualities: filtered, lubricated, unlu-
the sensor can be inserted directly into the slot from
bricated or inert gases
above, allowing easy positioning and secure fitting. The
• New diagnostic functions integrated, e.g. under-
main benefit: two LEDs – to the left and the right of the
voltage
active surface – guarantee that the status display is
always visible, regardless of the side from which the
cushioning elements approach the sensor.

trends in automation No. 15, 2009

Interview 13

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.

trends in automation No. 15, 2009

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
trends in automation No. 15, 2009
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

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-
From the process control technol- tion class of the components is
ogy point of view, many processes of great importance. The overall
are similar or identical – a clear production plant generally con-
advantage for the synergies in sists of several machines from
our development and our use of different manufacturers which
automation components. The are often independently auto-
trend is increasingly towards mated and not infrequently
miniaturisation because of the have different control elements.
small amounts of fluid involved.
Table-sized analyzers and sample Process automation designed
preparation equipment like minia- for continuous processes,
turised factories have already however, has different require-
been around for a while. 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.

trends in automation No. 15, 2009

16 Valves and valve terminals

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

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

Field of application
Automotive industry, packaging industry,
special machines

Key features
• Greater safety through gentle pressure
build-up in automation systems
• Protective functions in systems
Soft-start valve
• No piping or tubing effort
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.

The standardised valve terminal with

integrated soft-start valve – one link in
a chain of safe automation systems.

As for many other compo- This checks whether the valve

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.
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-

trends in automation No. 15, 2009


pressure
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.
Infoservice 17
is 1507
Standardised valve terminals
VTSA and VTSA-F
The integrated soft-start valve VABF for
users of robust modular valve terminals
with extensive pneumatic and electrical
function integration.
time
The soft-start valve enables a gradual Safety functions are required in many industries to protect operator and machine.
build-up of the supply pressure in duct 1 The beverage industry is just one example, as seen in this Veltins brewery system for
of the valve terminal. sorting empties.
If the toggle lever clamping unit this part needs to be repres-
has not reached either its top or surised. Significant advantages
bottom slack point and the over venting via the service unit
employee enters the danger zone are that the response speed is
to eliminate the fault, a safety PLC increased and valuable energy
switches the soft start-valve off is saved.
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
trends in automation No. 15, 2009
18 Electric drives

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
Fast, compact and
precise – electric axes
for 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 EGC – High feed force, high speed

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.
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

trends in automation No. 15, 2009


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.
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
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.
Infoservice 19
is 1508
Electric axes EGC
Electric axis EGC with servo motor
EMMS-AS
EGSP – low-noise and long-life and controllers EMMS-ST and
The EGSP axes are identical to the CMMS-ST or with servo motors
EGSK series except that they have and controllers EMMS-AS and
an innovative caged ball chain CMMS/P-AS. Users will find every-
technology instead of the recircu- thing they need, from simple, low-
lating ball bearing guide. Depend- cost drives to powerful solutions
ing on the size, the ball chain is for complex tasks.
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
trends in automation No. 15, 2009
20 Electric drives

Electric rotary drive module ERMB

Field of application
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
More than just electric
• Definition of impermissible zones by means
of sensors
rotation
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.

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.

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.

trends in automation No. 15, 2009


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.
Infoservice 21
is 1509
Electric rotary module ERMB
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.
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
• Repetition accuracy
with MTR-DCI Max. ± 0.05 degrees
• Repetition accuracy
with stepper motor type EMMS-ST Max. ± 0.08 degrees
Position sensing for the rotary module
is via SIEN-M8 inductive sensors.
trends in automation No. 15, 2009
22 Handling and assembly

Packaging for nail varnish bottles

In use
Pneumatic rotary indexing table DHTG

Benefits
• Transfer of bottles onto a conveyor belt
• Safe and smooth acceleration

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.

trends in automation No. 15, 2009


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
Infoservice 23
is 1510
Rotary indexing table DHTG
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
Functional principle: two vertical indexing cylinders hold the
position while two horizontal cylinders supply the necessary
motion via a drive pinion.
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
Runs smoothly and accelerates surely but gently: the rotary
very rugged, precise and economi-
indexing table DHTG handling nail varnish bottles.
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
trends in automation No. 15, 2009
24 Industry specific solutions

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 Under one roof

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.
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.

trends 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.
Infoservice Infoservice 25
is 1511 is 1513
Valve terminal MPA Partner to the biotech/
pharmaceutical industry
is 1512
Electrical terminal CPX
GlaxoSmithKline Biologicals
Branch of SmithKLine Beecham
Pharma GmbH & Co. KG
Analogue values for measuring Contact www.glaxosmithkline.de
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
Control cabinets full of valve terminals MPA. They control the process valves on the
valve terminals. feed lines to the batching vessels in the various production stages.
Valve terminal MPA for control of process valves in ultrapure water systems.
trends in automation No. 15, 2009
26 Industry specific solutions

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 transport
workpieces
Servus is Latin for ‘servant’. And that’s exactly what the Servus transport robot is – a smart RAFI is a specialist in electro-
mechanical components and in
and flexible servant. Always in the right place at the right time, Servus helps electronics
operating, communication and
manufacturer RAFI to optimise its intralogistics. The Manhattan software keeps the robot on control systems. Producing thou-
sands of products with many cus-
the right path, while pneumatic components take care of loading and unloading workpiece
tomised variants naturally leads
carriers. 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.

trends in automation No. 15, 2009


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.
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.
27
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.”
Space saving: the Servus track system is suspended from the ceiling.
Pneumatic support for robots the slides and the yoke plate. The
Dynamic DGC drives with recircu- guide unit achieves a repetition
lating ball bearing guide – featur- accuracy of 0.01 mm and offers
ing high precision and high load linearity and parallelism in the
capacity – take care of the routes 1/100 mm range, even at maxi-
for the conveyor system that con- mum stroke. Rodless drives DGP
nects production to the test facili- move the workpiece carriers up
ty. Pneumatic mini slides DGSL are and down in the loading and
piggybacked. Thanks to an innova- unloading lifts. Compact short-
tive guide unit, they combine pre- stroke cylinders ADVC are used
cision and load-bearing capacity in in the recharging stations.
a compact design. Highly precise
feeding, picking up and inserting is Highly modular MPA valve termi-
not a problem for the DGSL, even nals control the compressed air
under great mechanical loads. This drives. Easy to convert and
is made possible by the rigidity of expand, they offer customised
trends in automation No. 15, 2009
28 Industry specific solutions ... Robots transport workpieces Festo components

at RAFI

Pneumatic linear
drive DGC

Pneumatic mini
slide DGSL

Pneumatic linear
drive DGP

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- Short-stroke cylin-
matic drives. der ADVC

Valve terminal
pneumatics for a broad range of Managing Partner of Servus Robot- CPX/MPA

applications, from single valves ics in Dornbirn, Austria, explaining

to multipin plug and even an entire his protégé’s unusual abilities. So
fieldbus terminal. the Austrian transport robot never
gets lost – neither in the concrete
The smart robots know which jungle of Manhattan, nor in factory
materials are required at which halls.
workstations. Using the pull princi-
RAFI GmbH & Co. KG
ple, Servus supplies parts and
materials on a ‘just in time’ basis.
Products Electromechanical components,
operating, communication and
Manhattan software
control systems
And just what is Servus doing in
Contact D-88276 Berg
Manhattan? It orients itself com-
www.rafi.de
pletely independently – without
GPS or system layout – even in
structures as complex as the map
of Manhattan. Developed in-
house, the Manhattan software Servus Robotics GmbH
even enables it to orient itself in
changed systems and extremely Products Application engineering, pro-
large systems. “Like a New York duction and sale of turnkey sys-
cab driver, the transport robot tems for intralogistics, assembly
always finds the fastest route to and storing small parts
its next destination because, as Contact A-6850 Dornbirn
in the Big Apple, every station is www.servus.info
clearly identified by streets and
avenues,” says Christian Beer,

trends in automation No. 15, 2009

 automation worldwide 29

automation worldwide Brazil

Brazil
Remote access via Internet 29
Remote access via Internet
Norway MasterFoods Brasil Alimentos Ltda Another important improve-
Fresh fish 30 not only invested in automation ment resulting from the valve
technology at its new production terminal MPA was the reduction
Canada plant in Guararema, but also in the size of the tubing. This
Quality control: smarter SMAT 30 looked for ways to improve plant not only helped to improve the
layout and maintenance. Master- project layout by reducing the
South Africa food decided to use Ethernet to number of PLC inputs but also
Optimum leaflet insertion 31 achieve this. shortened installation time,
thus reducing costs.
Germany The company chose the valve ter-
Safety first 32 minal MPA with Ethernet/IP pro- www.masterfoods.com.br
tocol, used in production equip-
Indonesia ment for Twix, Snickers and M&Ms.
Tsunami early warning system on Sumatra 33 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.

trends in automation No. 15, 2009

30 automation worldwide automation worldwide

Norway

Fresh fish Quality control:

Fish tastes best immediately after
smarter SMAT
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
Trust is good, control is better.
and DSNU are used for sorting
That's what a Canadian automo-
fish. With their heat-resistant seals
tive company thought when plac-
they meet all requirements, such
ing an order with Trillium Machine
as protection against seawater
and Tool Inc. for a machine to
and detergents.
check centring pins on the front
of two new car models. The task
www.auss.no
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

trends in automation No. 15, 2009


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
automation worldwide 31
South Africa
Optimum leaflet insertion
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 project, Festo supplied pneumatic
tablets. In addition, the system linear drives, double-acting cylin-
had to handle four different tablet ders, rotary drives, valves, venturi
containers and information leaflets nozzles, suction cups, pressure
of different sizes. And all this with regulators, connectors and tubes.
a setup time of less than 10 min- They control all critical movements
utes. and functions of the system.
The solution: the insertion www.ingenior.co.za
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
trends in automation No. 15, 2009
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

trends in automation No. 15, 2009

 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 tains a Festo FEC 440 as controller.
other locations. Each console con- 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

trends in automation No. 15, 2009

Fax-reply

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is 1500 infoservice “trends in automation” 15

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

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

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
mott@de.festo.com

Reproduction of excerpts is permissible,

Please do not send me provided that the source is acknowledged
“trends in automation” in future. 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
tia15_en_Asien:tia13_druck_Asien.qxd 14.01.2009 13:52 Seite 1

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