Trend in Automation 14

No. 14 2008

Vacuum technology “Preventive monitoring in vacuum systems” Vacuum generator OVEM with condition monitoring page 12

Control Systems “Intelligent control of systems” Modular controller CECX for multi-axis motions page 14

Industry specific solutions “Precision in the assembly of vehicle lights” Pneumatic mini slide DGSL in operation on a rotary indexing table page 16

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

Trends in Automation Nr. 11, 2007

www.festo.com

Unique partnerships, unique solutions Why have we dedicated our cover story to the subject of “Limitless partnerships”? The reason is simple: Long-term partnership-based relationships with our customers are the foundation of our success.

Across all the continents of the world.

In addition to the fundamental attributes of efficient partnerships, such as reliability, communication and the ability to develop, there is also a particular emphasis on their unique qualities, since individual partnerships are as varied as the people who enter into them.

From America to Russia, over 1,200 Festo sales engineers and a similar number of project engineers are at your disposal. The personalised services we provide range from planning to the commissioning of automation solutions. You, the customer, can define the framework and the scope of the advice and services which you wish Festo to provide.

The Japanese service robots featured in this magazine were able to come to life only thanks to close cooperation between Kokoro and Festo. Joint development work led to the production of the customerspecific servopneumatic valves which make the human-like movement of the robots’ limbs possible.

For Festo, adaptable services are an integral part of a partnership.

These services comprise everything from free engineering software to individual services relating

to logistics and system operation.

These can be tailored to your specific needs as desired.

Almost every automation solution takes a unique form. This demands a scalable product range. No matter whether as catalogue products or customer-specific solutions, pneumatic and/or electrical, Festo offers the necessary wide choice of automation solutions. These define the depth of the value which Festo can generate, able as we are to provide a full bandwidth with everything from components to ready-to-install positioning systems.

With this edition of “trends in automation”, we in Sales Communication would like to make our contribution towards a unique partnership. I hope that you enjoy reading it!

Markus Ott Head of Sales Communication

In focus Limitless partnerships Life-like robot: customer-specific proportional valves ensure smooth movement.

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Newsticker New products, events and news in brief.

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Bionic Learning Network Seen in nature today – and in technology tomorrow Learning from nature: artificial autonomous jellyfish “AquaJelly” as a self-controlling system.

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Vacuum technology Preventive monitoring in vacuum technology Versatile: the vacuum generator OVEM with condition monitoring and process reliability.

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Control Systems Intelligent control of systems Powerful: the modular controller CECX with the CoDeSys software platform.

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Industry specific solutions Precision in the assembly of vehicle lights Automotive industry: the pneumatic mini slide DGSL is used for the assembly of vehicle lights.

16 Wood joints Woodworking: VUVB valves, standard cylinders and pressure regulators form a powerful solution.

19 An extra helping of oxygen Medical technology: miniature valves MH1 control the output of mobile oxygen units.

22 Automation for medical progress Pharmaceutical industry: ready-to-install control cabinet solutions with a CPX/MPA valve terminal.

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Bavarian biogases Wastewater treatment: Linear and swivel actuators control the butterfly and process valves.

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Automation worldwide From Korea to the Czech Republic Applications from all over the world.

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In focus Customised Solutions In use • Special products and joint developments • Components, systems and services precisely matched to customers’ needs • Ready-to-install systems Benefits • Saving time and money • Enabling customers to concentrate on their core competencies • Supporting customers during the design, procurement, installation and operational phases

Limitless partnerships A sympathetic smile, a friendly wave, a charming conversation – jointlydeveloped proportional valves breathe life into Japanese lady robots.

Special products such as these are only one aspect of a partnership that spans the entire value creation chain.

Human characteristics: Japanese lady robots make a natural impression thanks to proportional pneumatics.

trends in automation No. 14, 2008

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

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Günter Gebauer, Head of Project Management Customized Solutions: “No matter whether for short or long production runs, we have the production technology and know-how to deliver customised solutions in the quantity required by the customer.

Festo’s support throughout the life cycle of customers’ production systems ensures smooth operation and the availability of an agreed range of spare parts. And on a worldwide basis.”

or dirty environments. Or applications involving the control of the expression of a Japanese lady robot.

Fast, durable and inexpensive. Each robot has 50 specially designed MPYE proportional directional control valves that control the actuators, which in turn power the limbs of the robotic woman beneath her smooth silicone skin.

From design to procurement and from assembly to operation, Festo precisely matches components, systems and services for customer installations to the needs of users along the entire value creation chain.

Special applications These go well beyond the possible variants of catalogue products. A project team carefully considers the customer’s specifications and then develops solutions with application-optimised characteris-

tics in terms of functionality and size. Sometimes a slight modification of a standard product is all that is needed to enable its use in an application-specific context, while at other times completely new developments are needed.

Whatever the situation, customers who buy special application products can then concentrate on their core competencies. Frequently, customised solutions would be impossible without these products; for example, for applications in extreme cold or in dusty, humid

Individual wishes In order to ensure that the Japanese lady robot with its human characteristics can genuinely move like a real human being, the manufacturer Kokoro approached Festo.

Kokoro’s wishes were highly specific. In order to meet these, 50 proportional directional control valves type MPYE from Festo were used to control the small actuators that control the robot’s limbs under her smooth silicon skin.

No other automation supplier was able to offer proportional valves of the kind developed by Festo exclusively for Kokoro in accordance with the company’s specific requirements. The project team, consisting of engineers from Festo Japan and Festo headquarters in Esslingen, Germany, translated Kokoro’s wishes into reality. The valves were fitted with special exhaust air flow controls in order to provide even more precise control. This was necessary in part

because the limbs of the robot are equipped with miniature cylinders and very long tubing lengths. To meet this challenge, standard proportional direction control valves MPYE from the Festo catalogue were modified and adapted to meet the robot’s specific needs.

Fast reaction time “We also tested valves from other manufacturers,” explained Kokoro’s Head of Development Takeshi Kira, “but there was nothing else on the market that was comparable to the Festo proportional valves.” Takeshi Kira also went on to explain enthusiastically that the MPYE has a fast reaction time, is very durable and easy to use and is relatively inexpensive.

A true partnership Festo’s partnerships with customers are not confined to individual, specially made products.

There is a spirit of partnership right along the value creation chain, from design to procurement, logistics and assembly to system operation. Even at the design stage, at the start of the value

trends in automation No. 14, 2008

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In focus ... Limitless partnerships

Engineering

Procurement/ logistics

Installation and commissioning

Operation

• Consultancy • Design aids • Electronic catalogue

• • • •

• Ready-to-install solutions • Commissioning of axis systems • Air Consumption Analysis

• • • •

Festo Online Shop 24-hour delivery service Logistic Optimisation Service PrePack

Energy Saving Service Modular service contracts Air Quality Analysis Spare parts catalogue/ repair service

Reduce costs Save time Process reliability

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

Individual and efficient: rodless drive with integrated valve as a “mini” customised solution enabling a spinning machine to produce 1200 m of yarn a minute.

trends in automation No. 14, 2008

Individual and safe: pharmacy robot as a ready-to-install solution with a 3-axis loading gantry, a front-end manipulator and a vision system ensures 100 % safety during the dispensing of medication.

Infoservice

is 1401 Customised Solutions

is 1402 Proportional Pressure Regulators and Directional Control Valves

creation chain, customers can benefit from their partnership with Festo by using numerous software tools for selection, simulation, sizing and configuration. 20000 CAD files and FluidDRAW and sizing software are also available on-line and can significantly reduce planning time.

Individual orders Partnership is about respect at every stage, including procurement. Customers choose Festo as a supplier on the basis of costefficiency, speed and efficiency; they can place orders via an individual e-commerce link, the Festo Online Shop or the Festo Hotline.

Respect also applies to delivery times. The Festo Customer Service Centre in St. Ingbert/Rohrbach, for example, supplies customers throughout Europe and Festo companies worldwide on time; delivery

of special customer requests within 24 hours to the 20 European countries is also possible.

Ready-to-install systems Customer-specific pneumatic solutions, such as ready-to-install handling or control cabinet units, are the result of partnerships during the assembly phase. Ready-toinstall systems are pre-tested and supplied in accordance with the customer’s design data and circuit diagrams. They shorten the time from the original idea to its implementation and cut down the number of interfaces which customers have to deal with. In addition, they come with a comprehensive functional and fixed-price guarantee. Ready-to-install systems are delivered as complete solutions, ready for immediate installation in the machine, thus reducing system design costs and the demands

placed on the customer’s technical staff. These systems simplify the procurement process and reduce process costs thanks to the singlesourcing principle and order processing with a single part or project number.

and condition monitoring systems offered by Festo as part of its innovative products based on the CPX environment. This keeps partnerships dynamic throughout their lifespan – and not just in the case of seductive lady robots from the Land of Smiles ...

Partnership-based solutions also benefit the operational phase, the last link in the value creation chain. This phase includes maintenance contracts, help lines and hot lines or advice on Total Productive Maintenance. It can also comprise services such as the Festo Air Quality Analysis or the Festo Energy Saving Service, which enables customers to save up to 60 % of their compressed air costs.

A lifetime We should not forget the new Festo Energy Monitoring System GFDM. Or the diagnostic features

Alfred Weibel, engineer at Teca-Print: “At the heart of the machine is Festo’s integrated pneumatic controller based on a PU duct block. This technology enables us to achieve the very high functional we require with great efficiency. The pneumatic components are made for the machine and can thus easy to integrate.”

Individual and space saving. The integrated controller which Festo supplied as a readyto-install solution for a pad printing machine enabled Teca-Print to save 75 % of the space which would be required by a conventional solution in a control cabinet.

trends in automation No. 14, 2008

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Drives

Valves and valve terminals

Twice the gripping force, half the stroke

Performance-optimised: Valve series VB12

A powerful newcomer to the gripper series HGDT: the 3-jaw T-slot gripper HGDT-F with a gripping force of up to 4000 N. In any given size, it offers twice the gripping force of a conventional gripper and half the stroke. The result is more secure gripping with heavier loads and increased productivity.

From individual valves to a multi-pin terminal – the valve series VB12 stands for individual configuration and complements Festo’s existing polymer valve series VB (VUVB, VTUB). Flexible, universal, easy to use and with an outstanding price/performance ratio; these are just some of the distinguishing features of this valve series. What is more, the valves’ polymer bodies and weightoptimised metal manifolds are very advantageous.

It is ideal for use in harsh ambient conditions. The heavy-duty T-slot plain-bearing guide and the gripper jaws that are precisely matched to the gripper body ensure high rigidity and precision.

Internal purging air provides a seal to prevent the ingress of dust and drilling coolant, while the integrated gripping force backup function prevents the gripper fingers from opening and thus losing the gripped workpiece as a result of a compressed air supply failure.

is 1404 Valve series VB

is 1403 Three-point gripper HGDT

Electric Drives

Linear axes for heavy loads Maximum dynamics and speed with excellent torsional rigidity.

These are the features of the electric linear axes EGC with recirculating ball bearing guides which come in numerous variants and sizes, from mini to maxi. No matter whether they are used as stand-alone components or complete system solutions, these electric axes have a more rigid aluminium profile, thus withstanding higher loads and torques. The axes are an integral part of Festo’s modular multi-axis and positioning system and offer standard interfaces to other drives and motor packages. And that is not all: the use of “Positioning Drives” software for sizing simplifies system design work and helps to avoid costly oversizing.

Sensors

Ready to install: fork light barrier Reliability, efficiency and secure detection – this is what the fork light barrier SOOF stands for.

There is a choice of two robust housings: metal (SOOF-M) or reinforced polycarbonate (SOOF-P).

The U-shape of the robust housings, with a transmitter and receiver on opposite sides, enable them to be installed particularly quickly and easily.

Set-up using a potentiometer or the teach-in method is simple. And there’s more. With its high switching frequency and resolution it can detect very small workpieces at a very high speed.

For installation in places that are not easily accessible, the first choice is the SOOF-P: Thanks to its LEDs, which are visible from all sides, the switching status of the light barrier can be seen from any angle. In addition to a standard mounting, the fork light barrier has a dovetail fitting on its plug sides and undersides. This provides a further degree of freedom during installation.

is 1405 Fork light barrier SOOF

trends in automation No. 14, 2008

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Germany, Energy Efficiency Award

Valves and valve terminals

1st place for Festo

Ethernet node for EtherCat

Around 90 companies with exemplary projects for increasing energy efficiency entered the Energy Efficiency Award 2008 competition. Festo won over the jury with the way energy is generated at its St. Ingbert/Rohrbach site and took 1st prize. This project resulted in an energy saving of 38 % in comparison with a new building with conventional technology, corresponding to 366,000 euros per year. The use of innovative components such as a fuel cell, a cogeneration plant and a photovoltaic installation also have an ecological benefit: 3,750 tonnes of CO2 a year less are released into environment.

CPX-FB38 EtherCAT fieldbus node – this is the key to the easy integration of four valve terminal families, a CPX terminal and the CPI installation system into a Beckhoff automation environment.

is 1406

Valves and valve terminals

Energy efficiency

The benefits at a glance • Optimised pneumatics, electrics and networks • Comprehensive diagnostics and function integration • Digital and analogue I/Os, valves, sensors, proportional pneumatics and axis interfaces for electric drives in IP65/67 • 4 centralised pneumatic platforms on CPX • 3 decentralised pneumatic platforms on CPI • 3 installation concepts (centralised, decentralised, hybrid)

Safety@Festo: CPX/VTSA Valves and valve terminals

Valve terminals for ex zones 2, 22 Nearly 4,000 Festo products have already been certified for explosion protection categories. It is now also possible to install the high performance combination of electrical terminal CPX and valve terminal MPA in areas with a potentially explosive atmosphere (zones 2 and 22). For the first time, all the required modules can be individually evaluated and selected in a configurator in accordance with explosion protection requirements. Thanks to the new certification, it is possible to select and install pneumatic components and subsystems which are matched even more closely to the requirements of individual stations.

Safety technology as an integrated function on a VTSA valve terminal. Festo offers pneumatics, electrics and networking with integrated diagnostic functions as a solution package from a single source.

Integrated safety functions 1. Slow pressurisation after switch-on with integrated safety startup and quick exhaust valves. Enables the safe start-up of installations or sections of installations via an individual parameterisation function. An integrated sensor monitors the piston position.

2. Valves with integrated switching position sensing, optionally linked via one or two channels, for higher-order control systems, e.g. press control systems.

3. Special valves with integrated safety functions for lifting and rotary cylinders or manual workstations with manually operated pneumatic clamps.

is 1407 Safety Technology Guide

trends in automation No. 14, 2008

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Bionic Learning Network AquaJelly An artificial autonomous jellyfish with electric drive and intelligent, adaptable mechanical components.

Seen in nature today – and in technology tomorrow Learning from nature and gaining access to new realms of automation technology – this is the objective of the Festo Bionic Learning Network. An excellent example of this concept is the jellyfish, which uses the recoil principle to generate a floating motion. This bionic imitation – the Festo “AquaJelly” – uses a mechatronic system consisting of an electric drive, sensors and an intelligent controller.

“Bringing together nature and technology” – this is the motto of the Festo Bionic Learning Network.

Working together with students, well-known technical universities, institutes and research and development companies, Festo supports projects and experimental and technological ideas which may well be interesting areas of application in tomorrow’s world. The aim is to use bionics to make automated motion sequences even more efficient and productive.

Moreover, “the Bionic Learning Network is part of our commitment to basic and vocational technical training,” says Dr. Eberhard Veit, Chairman of the Board of Directors at Festo.

Autonomous control: AquaJelly This artificial, autonomously controlled jellyfish is a self-controlling system in water which emulates schooling behaviour. It consists of a translucent hemisphere and eight tentacles for propulsion.

At the centre of the AquaJelly is a watertight laser-sintered body which houses a central electric motor, the two lithium-ion polymer

trends in automation No. 14, 2008

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Attractions at the Hanover Fair: AquaJelly in an aquarium

batteries, the recharging control unit and the servo motors for the swash plate. The AquaJelly’s control in a three-dimensional space is by shifting weight.

Lights on for communication Eleven so-called environmental sensors in the form of infrared LEDs on the dome of the creature provide intelligent schooling behaviour, permitting, among other things, evasive manoeuvres and the establishment of a hierarchy for charging their batteries.

Internal sensors direct the peristaltic drive in four possible directions. A pressure sensor not only determines AquaJelly’s depth and position in the pool but is also used to pick up energy. When an AquaJelly is charging its batteries at the charging station, it sends an “Occupied” signal to its shoal.

Each AquaJelly decides for itself what to do based on its state, which in turn depends on its charge, the position of its drive and also its closeness to other AquaJelly creatures. The resulting schooling behaviour occurs without any pre-assigned control of the overall system.

Elegance under water: the structure of each tentacle is based on the Fin Ray Effect®.

... and AirJelly in the air.

autonomously using autonomous or semi-autonomous systems that act separately but communicate with one another.

Floating on air: AirJelly This type of drive was hitherto completely unknown in the history of aviation. AirJelly is the first flying machine ever to “swim” in air like its water-borne cousin via an intelligent and adaptive use of peristaltic motion. The lightness of the AirJelly is thanks to the helium-filled ballonet.

AirJelly’s sole source of power is two lithium-ion-polymer rechargeable batteries connected to a central electric drive. It transmits power via a bevel gear to a succession of eight spur gears, which move the eight tentacles of the jel-

lyfish via cranks. Each tentacle is designed as a structure with Fin Ray Effect®. This, in combination with an intelligent mechanism, creates fascinating prospects for electric drives in lighter-than-air powered flight.

Prospects for the future The prospects for future applications are not yet clear. However, with these and other exhibits Festo is showing a workable vision for automation technology and is playing a pioneering role by asking questions regarding the future.

This underlines its high level of innovation both in automation and in the didactic field. AquaJelly and AirJelly are excellent examples of how the Bionic Learning Network helps Festo to achieve this aim.

In terms of future automation, it is very probable that major tasks can be carried out independently and

trends in automation No. 14, 2008

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Handling and vacuum technology Vacuum generator OVEM Field of application All applications that require not only specific functionality but also condition monitoring and process reliability Key features Vacuum sensor with LCD display and air-saving function

Preventive monitoring in vacuum systems

The monitoring of operating parameters in vacuum handling systems means that it is at last possible to monitor and thus optimise cycle times directly.

This is made feasible by the condition monitoring capability of the vacuum generators used.

With the vacuum generator OVEM, users have a choice of three performance classes and numerous models with different functionalities. All models have an integrated air-saving function.

trends in automation No. 14, 2008

Reliability through condition monitoring. This is future-oriented monitoring, with measurements against a setpoint entered by the user. What does this mean in practice? It means that the vacuum generator itself can detect a slow or sudden leak or any deterioration in the evacuation time for the build-up of vacuum. The master value is the cycle time, which represents the speed of a handling operation and thus the productivity of an installation. The purpose of the vacuum generator OVEM with condition monitoring facilities is to prevent machine failures and downtime by taking action before they occur, such as through preventive maintenance. For specific

applications the diagnostic criteria can be set to more or less stringent values.

OVEM has it all OVEM is a new modular vacuum generator series which can be configured as needed. It expands Festo’s modular vacuum system with the availability of nozzle diameters of 05, 07 and 10. Since May 2008, 24 models have been available; by the end of the year, all variants and sizes will be available.

Process reliability is an important factor with the OVEM. For example, the easy-to-read LCD display with additional barograph (with

Infoservice

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is 1408 Vacuum generator OVEM

is 1409 “Vacuum Technology” poster

Vacuum [%] Cycle time

100 Monitoring

Monitoring

Monit.

Monitoring

TE: Evacuation time (200 ms) T1: Transport time (500 ms) TA: Ejection time (100 ms) T2: Return time (500 ms)

85 50

TE

0,2

T1

0,7 TA

0,8

T2

1,3

Zeit [s]

OVEM makes it possible: condition monitoring functionality for the most important operating parameters.

Wolfgang Hanold, Product Manager Vacuum Technology at Festo: “Our new vacuum generator series OVEM reflects our customer’s demand for high reliability and safety, simple installation and energy-efficient vacuum generation. Festo’s modular handling and assembly technology system now offers a full range of options, from basic, low-cost functions to intelligent solutions.”

Mounting options for the OVEM: on an H-rail, from the front, the side or the rear.

choice of modes) enables continuous status monitoring of a complete vacuum system. For this purpose, the integrated solenoid valve is used to control the compressed air supply. This valve can be operated in 2 modes: NC (normally closed, no vacuum generation) or NO (normally open, as a safety function with vacuum generation). An integrated non-return valve prevents the vacuum from collapsing.

OVEM helps to save time The vacuum generator and ejector pulse are controlled by two integrated solenoid valves. Short tubing lengths ensure fast switching times, which in turn mean that

workpieces are set down quickly and reliably; there is even a regulating screw to adjust the ejector pulse. All operator controls and display components are located on the front of the generator. The OVEM is also extremely easy to maintain. An integrated filter means clean process air, which can be checked through an inspection window, also located on the front.

The vacuum generator is thus virtually maintenance-free.

i

Do you have a concrete application for which you would like help?

The fast way to help yourself: the free “Vacuum Selection” software tool available in the Festo digital catalogue on DVD or as a download from www.festo.com/download

trends in automation No. 14, 2008

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Control Systems CECX modular controller with CoDeSys software platform Field of application • Controlling machines and installations • Motion control applications Key features • Fieldbus master functionality • Programming in accordance with IEC 61131-3 (CoDeSys) with optional SoftMotion software package • Easy programming and commissioning • Graphic editors for planning of motions • Versatile communication interfaces

Intelligent control of systems The modular controller CECX means that Festo’s range of products now includes models with fieldbus master functionality and for motion-control applications. The CECX is fully compatible with a wide spectrum of fieldbus systems such as CAN-Bus and Profibus.

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Machines and installations fully under control. The modular controller CECX is Festo’s new fieldbus master controller. This means that the Festo product range has now gained a high performance control unit which, depending on the version, can provide both comprehensive PLC functions as well as multi-axis motions.

Thanks to the wide choice of functional modules available, for example digital, analogue or counter modules, the CEX is a universal controller which covers a broad range of applications in the general machine construction sector.

The controller is suitable for the automation of both complete machines and installations and separate machine units which are then integrated into a larger installation.

Adapting control systems to customers’ needs In addition to offering controller functions, the CECX is also designed for use in actuating electric drive systems. Says Achim Kottmann, Product Manager Control Systems at Festo: “Wherever PLC functions and motion control meet, the CECX is an ideal choice, since, when used together with CoDeSys software, it offers a uni-

Achim Kottmann, Product Manager Control Systems at Festo: “Thanks to this controller’s high performance, it is quite easy for us to match the degree of automation to customers’ requirements. This is an important step which supports Festo’s offer of customised solutions.”

form programming interface for control tasks and motion sequences.” Thanks to these universal capabilities of the modular controller CECX, its applications are not limited to specific industries. Possibilities include the packaging industry, assembly systems and handling. Moreover, it can easily be combined with all Festo components, thereby greatly reducing the amount of programming work to be done by customers.

Multi-axis motions possible The controller is available in two variants: type CECX-X-C1 without motion control functions and as the motion controller type CECXX-M1. The major difference is that type CECX-X-M1 can, thanks to the additional “SoftMotion” software package, carry out coordinated multi-axis motions. Both variants are equipped with the CoDeSys software package, which defines the controller functions. This software platform, which conforms to IEC 61131-3, enables fast and simple configuration of the CPU and I/O modules, together with easy programming and commissioning of pneumatic and electrical automation solutions. Comprehensive module libraries facilitate the

realisation of coordinated motions, including interpolations. Users can call on graphic editors to carry out easy planning of motions. And integrated visualisation is a useful way of testing sequences before commissioning. With these features, the CECX is the ideal choice when a combination of PLC and motion control functions is required.

ter/slave and Ethernet (TCP/IP, Easy IP). The controller is thus fully compatible with a wide range of control system architectures and can be used virtually universally.

Universal As the CECX has to be as compatible as possible with other control system components, it is important for it to offer a wide range of communication interfaces to other systems. It therefore offers the interfaces CAN Bus, Profibus mas-

Technical data

Electric drives, valve terminals to actuate pneumatic cylinders, sensors, vision systems and operator panels can be found in large numbers in modular machine and assembly systems, such as this one at MAT in Althütte. This is one of the many possible applications for the new modular controller CECX.

• Fieldbus master interfaces: CAN-Bus on board, Profibus master DP V1, Profibus slave DP V1 • Optional modules with further interfaces: optional Ethernet module RS422/RS485, optional CAN module (2nd CAN interface) • Digital and analogue peripheral modules • Modern programming system CoDeSys in accordance with IEC 61131-3 • Modular IP20 system • Easy mounting of control system on an H-rail • UL/CSA and C-Tick approval certificates

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Industry specific solutions Automated assembly machines for vehicle lights In use • Pneumatic mini slide type DGSL Benefits • Drive and guide in one unit • High torsional rigidity and precision • Transport and separation functions

Precision in the assembly of vehicle lights

The great strengths of the mini slide DGSL are brought to the fore in the fully automated assembly machine for vehicle lights. Its rigidity is invaluable for all handling motions, while its precision deals efficiently with the separation of all components involved.

The lights are given a brightness test before final assembly.

Technical data • Sizes: 4 to 25 mm • Cushioning: metal stop, P and polymer cushioning • Workpiece mass: up to 6,139 grams (size 25) • Repetition accuracy: linearity and parallelism in the 1/100 mm range • Safety functions: clamping cartridge or end position locking • Easy mounting thanks to precision interfaces • Easy stroke adjustment and fitting of air connections, all from the same side

trends in automation No. 14, 2008

Mini slide type DGSL

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Fichter Maschinen GmbH specialises in the design and production of assembly machines for workpieces measuring 3 to 200 millimetres and with cycle times of 2 to 15 seconds. To this end, Fichter installed pneumatic and electric actuators, sensors and test equipment supplied by leading manufacturers. Among the customers who appreciate the quality of Fichter’s products is a major supplier to the automotive industry, who relies on Fichter for fully automated assembly machines for light bulbs with cycle times of less than 2 seconds. Each machine assembles plastic bases, metal contacts and pre-sealed glass envelopes into finished lights and all components are fed in automatically. The overall assembly process is split between two motorised rotary indexing tables. One table is used for function testing and separates out

incorrectly assembled or defective light bulbs, while the other carries out the actual final assembly and checks the finished product. This is where the mini slide DGSL comes into play. It provides all the vertical motions for the pick and place handling units and separates the components.

Assembly indexing table The light sockets pass via a spiral conveyor and a linear conveyor to a transfer station. To ensure smooth and trouble-free transfer, the fittings are first separated by a mini slide DGSL. A pick and place handling unit then picks up each fitting and turns it before placing it in a workpiece carrier on the rotary indexing table for processing.

Dipl.-Ing. (FH) Jürgen Stiedl, General Sales Manager at Fichter: “It is vital for us as a machine builder to be able to carry out planning work quickly and easily. We use standardised system concepts and modules to do that. This makes for a better overview, simpler technical procedures, faster throughput and, of course, ultimately leads to lower costs. We depend on close cooperation with our suppliers to achieve this level of standardisation in our machines. In the field of pneumatics, our partnership with Festo has proved valuable. Its innovative products, such as the new guide unit DGSL, help us to achieve our objectives.”

The left and right-hand contacts for the light fitting also pass via a spiral conveyor and a linear conveyor to a second transfer station.

General view of the fully automated assembly machines for vehicle lights Mini slides type DGSL provide all the vertical motions required for the pick and place handling units on the machines.

trends in automation No. 14, 2008

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

Infoservice

is 1410 Mini slide DGSL

Fichter Maschinen GmbH Products

Contact

Valve terminals type CPV 10 control the pneumatic actuators in the installation.

After the functional testing is complete, the light bulbs are fitted into sockets by a handling unit.

Another pick and place handling unit picks up one left-hand and one right-hand contact and places them in the appropriate positions in the light socket.

Test indexing table The next station checks the light sockets to ensure that the contacts are present and are inserted to the correct depth. A handling unit separates out flawed workpieces.

At the same time, a pick and place handling unit on the first indexing table picks up a light bulb from the separator and places this in a carrier. In a next step, the light bulb is subjected to a brightness and dimming test. Flawed workpieces are immediately separated out. After this, a pick and place handling unit removes the tested light bulb from the carrier on the test indexing table, turns it and inserts it into a socket. A final test is then carried out to ensure that the finished

trends in automation No. 14, 2008

light works correctly. On the last station a specific mark is imprinted on the product for identification.

Two handling units, one for correct workpieces and one for rejected ones, pick up the finished products and put them in the appropriate containers. All the pneumatic actuators in the system are controlled by valve terminals type CPV 10.

Innovative system solutions ranging from semi-automated assembly machines through to complex fully automated assembly lines for suppliers to the automotive and electrical industries D-79356 Eichstetten www.kfm-fichter.de

Industry specific solutions

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Woodworking industry: Edge banding machine and CNC machining centre In use • VUVB valves on mounting plates • Standard cylinders DSNU and DNC • Pressure regulators DB • Cylinders ADNP made of high performance polymer Benefits • Complete system solutions save time and money • VB valve system is easy to retrofit • Faster cycle times thanks to higher flow rate • Attractively priced pneumatic components

Wood joints Boards are fed in, the edges are glued and pressed, an edge banding is applied, the projecting ends are trimmed and the top and bottom edges are milled flush. The Contriga edge banding machine operates quickly and precisely. To ensure that the machine itself can be assembled equally quickly, its manufacturer Reich Spezialmaschinen GmbH uses ready-toinstall pneumatics, developed by working hand in hand with specialists from Festo.

Innovative design: the Contriga edge banding machine.

Wood is a material which is easy to work and is found almost everywhere. Woodworking is as old as the human race; woodworking tools such as drills, axes and splitting wedges have been known since the Stone Age. These simple tools have now been developed into highly technical and complex machines in which the driving force is no longer muscle power but instead pneumatic and electric. The special machine builder Reich Spezialmaschinen GmbH in Germany produces woodworking tools under the brand name HolzHer. Its products range from circular saws to CNC machining centres for woodworking to meet the most critical requirements and incorpo-

rate high performance pneumatic components from Festo. The latest result of the cooperation between Reich and Festo is the Contriga edge banding machine, which applies edge trims to finished wood workpieces.

Prize-winning design The innovative design of the Contriga has won prizes; it received the reddot design award 2007 and the iF-Design Prize 2008. The pneumatically-controlled sliding covers move up and down at the touch of a button and uncover the working units – thanks to Festo standard cylinders type DSNU. The Contriga thus not only requires significantly less space than com-

trends in automation No. 14, 2008

20 Industry specific solutions ... Wood joints

Pneumatically-controlled sliding covers move up and down at the touch of a button to allow access to the working units.

A spray unit applies a releasing agent to the surfaces and edges of the panels.

The regulator controls the volume and pressure of the spraying operation.

parable machines but also offers users a facility for rapid tool changing.

The objectives for the design of this new machine were to increase its speed and simplify its assembly as much as possible. The developers, working with Festo specialists, therefore chose Festo VUVB valves with a high flow rate. These were supplied ready assembled on mounting plates and all set up together with pressure regulators type DB, tubing and labelling. The valves control the cylinders which clamp the workpieces during processing.

trends in automation No. 14, 2008

Systems instead of components The VB valve system was chosen as it is easier to retrofit. Any spare positions on the mounting plate can be effortlessly fitted with additional valves and each valve can be replaced individually, while installation is greatly simplified by the pre-assembled systems. Installation technicians need only install and connect the complete units and need not worry about the time-consuming task of fitting individual tubes. The system solution was specially developed for Reich.

The idea of using pre-assembled systems has already gained ground: “As a result of working with Festo, Reich now makes sure

VUVB valves with high flow rates are supplied pre-assembled and pre-set on mounting plates, together with DB pressure regulators, tubing and labelling.

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In the CNC machining centre Easy Master 7018, wood workpieces are shaped and processed fully automatically, for example, for the production of the frame of a bay window as shown here.

Denis Lorber, Head of Development at Reich Spezialmaschinen GmbH: “Thanks to our close cooperation with Festo, our work was significantly reduced. Ready-to-install pneumatics save time and money. In future, I can even imagine that Festo could produce system solutions on demand at short notice.”

that designers think in terms not of individual components but of complete systems,” confirms Denis Lorber, Head of Development at Reich Spezialmaschinen GmbH. Development through teamwork During this project Festo developers worked closely together with Reich, both on the development at the company HQ in Nürtingen and on the production of woodworking machinery by the subsidiary company Reich-Austria Ges.m.b.H. in Austria. This enabled Reich’s designers to contribute their knowledge to Festo’s development process. “In the course of this joint project, we were particu-

larly impressed by the fact that, although Festo is a large company, we were always able to contact the right people and obtain a solution which was ideal for our needs,” explains Denis Lorber.

Ready-to-install pneumatics reduce system designers’ workload and ease the burden on budgets. From procurement to logistics, system design and documentation, installation and commissioning, Festo offers everything from a single source with just one project or order number. Complete solutions make installation and commissioning easier and save time and money. Components with standard

A wooden door with a different view. The CNC machining centre mills the shape and then edge banding is applied by the Contriga.

functions are more than adequate for the requirements of the woodworking industry where the main emphasis is on an attractive price/performance ratio.

The joint venture continues The system concept developed for the Contriga is now also being used for the CNC machining centre Easy Master 7018.This machine processes wood workpieces fully automatically into, for example, doors, handrails for stair or shelves. The machine, which was launched by Reich in May 2008, also features VUVB valves preinstalled on mounting plates and ADNP cylinders, attractively priced components which are made from high performance polymer and are

used as feed cylinders. The cylinders advance plastic runners, which transport the workpieces from the vacuum holding devices and through the machining centre.

In the development of Easy Master 7018, Reich was able to draw on the experience gained with Contriga; this resulted in another joint project between Reich Spezialmaschinen GmbH and Festo.

HOLZ-HER Reich Spezialmaschinen GmbH Products Contact

Woodworking machines D-72622 Nürtingen www.holz-her.com

trends in automation No. 14, 2008

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Industry specific solutions Medical technology: mobile oxygen kits for patients with chronic obstructive pulmonary disease In use Miniature valves MH1 with approval for use with oxygen Benefits • Compact installation • High flow rate • Fast cycle times

More freedom of movement for COPD patients thanks to mobile oxygen supply.

An extra helping of oxygen

Millions of people suffer from shortage of breath due to illness. With the miniature valve MH1, which can be installed in very confined spaces, Festo helps to provide a mobile oxygen supply, enabling these patients to enjoy a significantly better quality of life.

trends in automation No. 14, 2008

Infoservice

is 1411 Miniature valves MH1

Miniature valve MH1: extremely versatile, approved for use with oxygen.

Technical data

Studies reveal that more people are suffering from Chronic Obstructive Pulmonary Disease (COPD) than had previously been assumed. According to The European Lung Foundation approximately 44 million COPD patients worldwide increasingly deal with their illness using oxygen therapy.

Solutions for every situation Different systems are available for long-term oxygen therapy.

Patients whose general condition only rarely allows them to leave their bed receive the oxygen via a concentrator that converts room air into concentrated oxygen gas.

The inhaled air is enriched with oxygen by a compressor that presses the air into a molecular filter that in turn filters out nitrogen N2. This increases the amount of oxygen in the remaining gas mixture.

Mobile patients satisfy their oxygen requirement by mobile compressed gas cylinders or standard liquid oxygen systems. Mobile liquid oxygen systems weigh 1.5 kg.

They comprise a portable unit with a tank and a stationary reservoir.

It takes only 40 seconds to fill the mobile unit, which then gives patients up to 13 hours of full freedom of movement with a stable

oxygen supply. Oxygen is fed over the breathing apparatus and a nasal cannula.

Breathe deeply with MH1 valves This is where Festo gets involved, because the very small and versatile Festo miniature valve MH1 in mobile oxygen systems regulates oxygen delivery to precisely meet requirements. The advantage lies in the lower oxygen consumption compared to standard systems.

Patients experience improved mobility and quality of life as the air supply is available for longer.

MH1 valves are extremely small and are ideal for the tightest installation spaces. The 2/2-way version with oxygen approval supplies 25 l/min. The LED display on the MH1 valves enables visual monitoring of the operating status from all sides.

• Nominal flow rate: 25 l/min.

• Switching times: 4/5 ms • Overall width: 10 mm • Maximum pressure: 1.8 bar • Approved for use with oxygen • Average temperature: -5 to + 60 °C • Max. permissible temperature: +100 °C

What is COPD? COPD stands for “Chronic Obstructive Pulmonary Disease”. It is a term for chronic bronchitis and emphysema, i.e. when the airflow to the lungs is constantly restricted. The most important symptoms of COPD are breathlessness and a severe cough.

The main reason for the development of COPD is smoking. Nine out of ten COPD patients smoke or have previously smoked. Non-smokers can, however, also be affected, since prolonged exposure to dust or hazardous gases in the workplace can also cause this illness.

COPD is fundamentally incurable. Treatments simply aim to ease symptoms, delay the spread of the disease and increase patients’ expectation and quality of life. A distinction is made between three degrees of severity. The first two degrees are treated by medication, while for the third, long-term oxygen therapy improves patients’ quality of life by ensuring a stable concentration of oxygen in the blood.

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Industry specific solutions Pharmaceutical industry: production of injection media such as anti-infectives and cardiac drugs In use Ready-to-install control cabinet solutions with CPX/MPA to control diaphragm valves Benefits • Ready-to-install • Fewer interfaces • Simplified documentation

Automation for medical progress “We had absolutely no time to think about details,” says Manfred Broustin, Head of PLT at the Parenteral Medication Production Leverkusen facility of Bayer HealthCare, describing the conversion of a production facility at the company’s Leverkusen site. “We reduced the risks of this project by asking Festo to supply ready-to-install control cabinets.

In only four weeks, the project team completed the conversion of the plant for the production of infusion and injection solutions such as anti-infectives and cardiac drugs. “We eventually needed to start production again, longer downtimes would not have been acceptable,” explains the automation expert.

In 2007 18 million infusion and injection bottles were produced using ten filtrate tanks and four mixing tanks for anti-infectives and cardiac drugs.

trends in automation No. 14, 2008

The parenteral medication production facility ... ... in Leverkusen alone produced over 18 million bottles and more than 1.5 million freeze-dried vials in 2007. These were used by Bayer HealthCare to produce over 16 million packing units. “Our markets are characterised by continuous growth,” says Broustin. In order to increase production capacity

and cut costs, the company has decided in favour of further automation. Before conversion, the automation in the plant was only limited and it was thus more costly to operate it and maintain documentation.

“Automation has enabled us to monitor and document the complete production process fully

Infoservice

is 1412 Biotech/Pharmaceuticals Products and Services

is 1413 Ready-to-install Pneumatics

Reliable control: ready-to-install control cabinets shortened the time from the initial idea to a functional installation.

automatically, continuously and without paper,” is how Broustin explains the reason for the conversion. A process control system records measured values and transfers these to a master EDP system. Validation of processes is vital if manufacturers wish to maintain a leading position in world markets and meet legal requirements such as those of the FDA. Vertical production Bayer HealthCare operates a socalled vertical production process.

Following the procurement of raw materials and packaging at the right price, three steps are required for the actual production process: 1. Chemical or biotechnological processing of active ingredients 2. Formulation of active ingredients to create finished medication 3. Packaging The plant for the production of parenteral medication operates on the same principle. On the upper level, solutions are made up in mixing

tanks in accordance with recipes and transferred to filtrating tanks for filling. On the lower level, the finished medication is filled into bottles, bags or vials on five filling lines.

An important factor at the planning stage was to subdivide the plant so that the plant sections could be cleaned individually. With around 60 different recipes and over 20 plant sections, the plant needs to be wet cleaned and sterilised at least five times a day.

Ready-to-install control cabinet systems Modular Festo valve terminals type CPX/MPA are used to control the diaphragm valves in the plant, while a CPX electrical terminal is used to process the analogue values for the measuring systems and control valves. The CPX/MPA terminals accommodate control valves and analogue and binary I/Os in a single unit, which means that only one bus node is required.

Field devices from the explosion protected area of the plant are also linked to the CPX via firewalls.

Continuous documentation: the automation of the parenteral medication production plant has brought genuine progress in data management.

Bayer HealthCare AG – a subsidiary of Bayer AG Products:

No. of staff Contact

1. Animal health: veterinary drugs and care products for farm and domestic animals 2. Bayer Schering Pharma: diagnostic imaging, general medicine, specialised medicine, health care for women 3. Consumer care: prescription-free medication, food supplements 4. Diabetes care: glucose measuring devices, test strips 51,500 D-51368 Leverkusen www.bayerhealthcare.com

“Given the tight deadline for the conversion work, having valve terminals that were supplied fully configured and protected in stainless steel control cabinets was ideal; we only needed to integrate them in our production plant,” reports automation expert Broustin enthusiastically.

Supplied fully tested, together with all design data, circuit diagrams and a comprehensive func-

tional and fixed-price guarantee, ready-to-install control cabinets shortened the time from the initial idea to a functional machine and reduced the number of interfaces required. Documentation for the cabinets was generated using EPLAN. It was therefore very simple to integrate it into Bayer’s overall documentation. Automation technology has made a real contribution towards medical progress.

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Industry specific solutions Wastewater treatment: Gut Großlappen sewage treatment plant in Munich In use Linear and swivel actuators for process automation

Bavarian biogases

Benefits • Opening and closing of butterfly and process valves • Cost advantage of more than 50 % • Robust and corrosion resistant

Striking architecture: the digester tanks of the Gut Großlappen sewage treatment plant run by the local utility Münchner Stadtentwässerung.

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The city of Munich has set itself an ambitious project. The river Isar, which flows through this Bavarian metropolis, is to be cleaned up so that people can once again swim in it. To achieve this, the city operates a network of two sewage treatment plants to purify the wastewater generated by 1.5 million people. Pneumatic automation technology ensures reliable operation of the new digester tanks in the Gut Großlappen sewage treatment plant.

The sewage treatment plants operated by the utility Münchner Stadtentwässerung purify 560,000 m3 of wastewater every day. The Gut Großlappen sewage treatment plant is one of the largest plants in Germany. It comprises mechanical and biological cleansing, a phosphate precipitation plant, a sand filter, sludge treatment in digester tanks, sludge incineration, energy recovery and gas collection. The biogas generated during the digestion process in the tanks is used to meet the energy needs of the sewage treatment plant.

The four digester tanks are 31.5 m high and have a capacity of 14,500 m3 each and cost the Münchner Stadtentwässerung 63 million euros. The designers chose striking architecture as a counterbalance to the Allianz Arena, the home stadium of the football team FC Bayern München.

They also chose pneumatic automation technology.

Why pneumatics in a sewage treatment plant?

Pneumatic automation technology reduces investment, installation and operation costs in comparison with conventional electrical installations. Cost advantages of more than 50 % can be realised. Many system planners choose pneumatic actuators to open and close butterfly and process valves because of their continuous operation, long service life and overload protec-

Maintenance-free and overload-proof: Copac linear actuators (DLP) open and close the gate valves in the pig trap stations.

tion. Compressed air is intrinsically safe, since it opens and closes valves without the need for electricity. In practical terms, this means that pneumatics are easy to work with, robust and ensure high plant availability.

Maintenance-free and overload protected Pneumatic actuators are maintenance-free for their entire service life, which, at more than a million switching cycles, means that a pneumatic actuator will outlast any process valve. As the shut-off valves in sewage treatment plants

are actuated only at irregular intervals, the tolerance of pneumatic actuators to overload should not be forgotten. Deposits or cakedon material on valves may lead to considerably higher breakaway torque values. Pneumatic actuators are overload proof, while electric drives will reach their torque limits in cases where greater than normal torque or force is required.

With pneumatic actuators, it is possible to increase the operating pressure and thus the force and torque output. As most valves in sewage treatment plants are oper-

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28 Industry specific solutions ... Bavarian biogases

Infoservice

is 1414 Process Technology

is 1415 Partner to the Process Industry

ated in open/close mode or as manually operated valves, pneumatic technology opens up a considerable potential for rationalisation.

Pneumatic cylinders provide reliable control They are robust and corrosion resistant and thus suitable for harsh environments; they only have a few moving parts and are easy to operate. Pneumatic cylinders involve no additional costs, even for explosion protection zone 1. Particularly in digestion towers, in which the process of digesting sludge at temperatures of around 40° C produces gases containing methane and carbon dioxide, explosion protected actuators to open and close the shutoff valves are vital. Electric actuators, on the other hand, require monitoring for overtemperature, torque, switching frequency and servicing and maintenance intervals, which means an enormous number of I/Os to wire up.

In the digester tanks ... ... of the Gut GroĂ&#x;lappen sewage treatment plant, Festo pneumatic actuators are installed for gate valves (Copac actuators) and butterfly valves (Copar). Copac linear actuators (DLP) open and close the gate valves in the pig trap stations used to clean the sewage sludge pipes. Further large size linear actuators are installed at the floating sludge drainage stations. Copac actuators are ideal for controlling gate valves. They act directly on the gate plate and make it possible to approach various different positions.

Copar semi-rotary actuators (DRD/DRE) are fitted to butterfly valves as safety devices to shut off digester gas lines. Copar actuators are used for open/close functions; in conjunction with commercially available electro-pneumatic position controllers they ensure accurate travel to various different positions, particularly for ball valves, stopcocks, shut-off valves

560,000 m3 of sewage per day: the city of Munich operates two sewage treatment plants to purify the wastewater generated by 1.5 million people

and butterfly valves. Pneumatic components keep the Bavarian biogases firmly under control and the water quality of the river flowing through Munich is once again good enough to swim in.

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

trends in automation No. 14, 2008

automation worldwide

automation worldwide

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Korea

Korea Reliable coatings

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Germany Hand in hand

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Taiwan Precision lens production

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Germany Magical water games

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Italy Firmly wrapped up

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Czech Republic More energy with Festo

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Reliable coatings Rotary machines for tablet production, capsule filling machines and high speed mixers are just a few examples of the output of the Korean manufacturer Pharm Tech Korea. No matter whether for the pharmaceutical, medical or packaging industry, more than 70 % of the machines which this company produces are exported. And they feature Festo components, as in this example of a tablet coating machine.

A pressure regulator type MS4-LR and a valve terminal type MPA are installed in a separate control cabinet. The pressure regulator provides precisely the right pressure required for the operation of the machine, while the valve terminal actuates and deactuates the nozzles on the coating machine. The semi-rotary actuator DSM is used to switch the feed of coating material on and off.

For Pharm Tech Korea as a strongly export-oriented company, it is not only high quality components that are important.

Consistent quality, worldwide delivery and a spare parts service are also decisive factors.

Also much appreciated by Pharm Tech Korea’s customers is the detailed product documentation that Festo provides.

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automation worldwide

automation worldwide

Germany

Hand in hand Integration into the world of work.

At Nordbahn gGmbH, handicapped people carry out all kinds of tasks, from simple assembly to working on complex machine tooling stations. In order to be able to offer a wide range of employment, the company also accepts orders from industry, including the biochemical and automotive industry. One example is the test machine for plastic tubes for blood plasma, which Nordbahn designed itself, working hand in hand with ifc intelligent feeding components GmbH, which integrated a complete vision system into the machine.

The handicapped workers lay the tubes on a conveyor belt that feeds the tubes to workpiece carriers, each holding ten tubes. In the test chamber vacuum grippers type ESS-10-BS pick up the tubes and turn them 360°. While the tubes are being turned, a compact vision system SBOC-Q-R2B from Festo records up to 12 images of the tubes and detects scratches, cracks and splits. The vision system software transmits the result to the master controller, which separates out any defective tubes.

Once they have passed this inspection stage, the tubes are packed by hand ready for transportation. www.ifc-online.com

trends in automation No. 14, 2008

Precision lens production GLA-2AS is an assembly machine for optical lenses made by the Taiwanese manufacturer Guann Way Technologies Co, which specialises primarily in programming for automated installations and also in improving and maximising the output of production lines and processes.

When linked to a bonding machine or a loading/unloading system, the GLA-2AS can form a complete production line for the manufacture of optical lenses. This features a highly efficient lens changer, equipped with a HGP gripper. Its strengths are the versatility and extremely adaptability of the gripper fingers. With its slim design, the pneumatic mini slide DGSL from Festo also proved ideal for the customer’s requirements and has been extremely reliable. The combination of a mini slide and the swivel/linear unit HGDS also saved installation time. www.guannyinn.com.tw

automation worldwide

Taiwan

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Germany

Magical water games

Rapture among the audience.

Logos and figures slide down a wall of water of up to 10 metres high, while dynamic lighting creates graphics and scripts in all kinds of colours and shapes. The Magic Waterfall is truly eye-catching. It is constructed like a print head 1 to 10 metres long, with 100 MHE4 valves per metre. The individual water streams are created by several nozzles, resulting in an opaque water curtain that is highly suitable for use as a projector screen. The valves’ switching times are faster than the human eye can follow, creating messages for the viewer that float down the waterfall and disappear in a basin.

Parallel gripper HGP

Swivel/gripper unit HGDS

The water wall is an invitation not only to viewers but also to those wishing to play. Speed is the key when it comes to reaching through a programmed hole in the waterfall and wet shirtsleeves are the result of being too slow. The closed water loop not only offers magic and fun but also has a practical side. The Magic Waterfall acts as a high-tech air humidifier to improve the atmosphere in enclosed rooms.

Fast-switching valve MHE4

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automation worldwide

Italy

Firmly wrapped up The manual preparation of plastic pipe and tubing for transport is a tedious job, and extremely inefficient. Automatic wrapping machines supplied by Italian manufacturer Campetella provided the solution by utilising pneumatic automation technology.

The system wraps polypropylene straps around pipe or tubing at a speed of 80 metres per minute, binding it firmly together. The flexi-

ble machines are capable of automatically controlling tubing length, diameter, the thickness of the rolls and the strapping, and counting the number of rolls. “Our goal was a compact, clear-cut design, and Festo’s reliable standard drives, MS series modular service units, flexible MPA terminal with multipin connection and above all the CPV-SC miniature valve terminal were just what we needed�, explains managing shareholder Carlo Campetella. www.campetella.it

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Czech Republic

More energy with Festo Sewage sludge is full of energy and the operator of the city sewage treatment plant in Karlsbad, Czech Republic, is well aware of this fact. Working together with KV engineering Karlovy Vary, Skanska CT and K&H Kinetic, the operator developed a two-stage system for the processing of primary and excess sludge which involves anaerobic stabilisation in a digester tank. The aim was to improve the sludge treatment process and make effective use

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of biogas. The valves in the gas flow control system, which were mainly electrically controlled, were replaced with pneumatic valves. Installed products at present include the heavy-duty semirotary actuators DRD to operate the butterfly valves in the pipeline through which biogas is fed to the boiler system. Their strength is their precision, which enables travel to a number of different positions, particularly for the butterfly shut-off valves and gate valves.

Once the installation had been upgraded, there was not only an improvement in the mechanical dewatering of the digested sludge but the production of biogas also increased – and was exploited efficiently as electrical and heat energy.

trends in automation No. 14, 2008

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1401 Customised Solutions 1402 Proportional Pressure Regulators and Directional Control Valves 1403 Three-point gripper HGDT 1404 Valve series VB 1405 Fork light barrier SOOF 1406 Energy Efficiency 1407 Safety Technology Guide 1408 Vacuum generator OVEM 1409 “Vacuum Technology” poster 1410 Mini slide DGSL 1411 Miniature valves MH1 1412 Biotech/Pharmaceuticals: Products and Services 1413 Ready-to-install Pneumatics 1414 Process Technology 1415 Partner to the Process Industry Impressum trends in automation 14 September, 2008 Published by: Festo AG & Co. KG Ruiter Straße 82 D-73734 Esslingen Chief editor: Markus Ott, Sales Communication mott@de.festo.com

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Pune Tel: +91-20-25521401/ 25512227

Branch Offices Nagoya Tel: +81-(0)52-937-39 10 Osaka Tel: +81-(0)6-6320-34 27 Korea Head Office Festo Korea Co., Ltd. 470-1 Gasan-dong Geumcheon-gu Seoul #153-803 Tel: +82-(0)2-850 7114 Fax:+82-(0)2-864 7040 Branch Offices Busan Tel: +82-(0)51-205 4921

Branch Offices Christchurch Tel: +64-(03)-348 87 96 Wellington Tel: 0800 433 78 Hamilton Tel: 64-(07)-846 60 80 Philippines Head Office Festo Inc Festo Building KM 18, West Service Road South Super Highway 1700 Paranaque City Metro Manila Tel: +63 (2) 77 66 888 Fax: +63 (2) 82 34 219 Branch Offices Cebu Tel: +63 (32) 345-1120 Baguio Tel: +63 (74) 447-0394 Cagayan de Oro Tel/Fax: +63 (88) 857-4904

Taiwan Head Office Festo Co.Ltd 9 Kung 8th Road Linkou 2nd Industrial zone 24450 Taipei Hsien Taiwan, R.O.C. Tel: +886-2-2601-92 81 Fax: +886-2-2601-92 87 Branch Offices Hsinchu Tel: +886-3-658-8318, 658-8307 Kaohsiung Tel: +886-7-384-2856 Taichung Tel: +886-4-2475-7278 Thailand Head Office Festo Ltd. 67/1 Phaholyothin Road Klong 1, Klong Luang Pathumthani 12120 Tel: +66 (0) 29 01 88 00 Fax: +66 (0) 29 01 88 33 Branch Offices Saraburi Tel: +66 (0) 36 31 54 10 Laemchabang/Chonburi Tel: +66 (0) 38 33 06 04 Northern Branch/Lamphun Tel: +66 (0) 53 58 13 37-9 Vietnam Festo Pte Ltd. Vietnam Rep. Office 206, Tran Nao Street, Binh An Ward District 2 Ho Chi Minh City Vietnam Tel: +84 (8) 7406909 Fax: +84 (8) 7406910 DID:+84 (8) 7406908 Hanoi Tel: +84 4 974 68 33