Festo Electric Automation for Intralogistics Drives Competitiveness

By standardizing on Festo electric and pneumatic automation solutions, original equipment manufacturers (OEMs) not only gain design symmetry and a sleek, high-tech look for their Intralogistics systems, they can also manufacture more compact, flexible, and high-performance solutions. Through partnership with Festo, OEMs simplify their design and acquisition process for faster time to market.

Electrics with the simplicity of pneumatics

The Simplified Motion Series (SMS) electric axes feature a motor with integrated servo drive and IO-Link that, for the first time, makes electric axes comparable to pneumatics in terms of cost and installation ease. SMS machine-mounted electric axes offer low energy consumption and the data generation characteristics of mechatronic systems. No other supplier offers a line of electric axes with comparable capabilities, advantages, and price of the SMS.

SMS actuators are ideal for picking and placing, dropping, pushing, lifting, or trapping products on a conveyor line. The series has a simplified form factor and dynamics. SMS adds flexibility to the system while minimizing energy costs and costs per I/O point by utilizing IO-Link communications rather than analog signals.

Axes are available in ball screw, toothed belt, mini slide, electric cylinder, piston rod, and rotary actuator configurations. With onboard push button commissioning, users commission two-position actuation in minutes with no additional software required. Like pneumatics, the system uses two inputs and two outputs to perform controlled pressing, force functionality, and end-to-end positioning.

SMS is designed with economies of scale in mind. SMS decreases costs by high volume standardized production. This eases supply chains issues and means customers receive electromechanical actuators in a variety of form factors quickly and at an industry leading price point.

IO-Link programming through the PLC unlocks infinite positioning and enables diagnostics, including cycle count, alarm data, and the typical process data experienced with servo systems. IO-Link also delivers operational data for improved quality and predictive analytics ‒ another key differentiator compared to pneumatic actuators. PLC speed control is based on application dependent requirements.

Next generation remote and decentralized I/O

CPX-AP-A is Festo’s next generation modular, lightweight, and flexible remote I/O system with IP65/IP67 protection. CPXAP-A supports flexible placement of Festo’s SMS products. CPX-AP-A remote I/O has a real-time transmission rate of 200 Mbps full duplex. It is parameterizable and scalable to up to 15 modules in one automation system. CPX-AP-A features a complete IO-Link master data storage mechanism, including a device parameterization tool. CPX-AP-A can be adapted to Festo valve terminals.

In addition, CPX-AP-I decentralized I/O with IP65/ IP67 protection seamlessly integrates with Ethernet communications networks from Rockwell, Beckhoff, Siemens, and other leading PLC manufacturers. CPX-AP-I modules accommodate over 80 digital and analog input blocks, valve manifolds, and IO-Link master modules for extensive control and data acquisition capabilities per interface. CPX-AP-I supports up to 50-meter distance between SMS devices, IO modules, valve terminals, and CPX-AP-A nodes. With 50-meter capabilities, locating valve manifolds close to pneumatic actuators significantly improves performance and lowers energy consumption. The extensive range of compatible Festo and third-party I/O gives OEMs the flexibility to create unique customer solutions.

Festo’s I/O integrates remote I/O and decentralized topology into the PLC. Festo I/O enables a single IP address to connect a fieldbus node and over 80 I/O modules, including valve terminals (which count as one I/O module) into a single networked string. Festo I/O supports device level ring, linear, and star networked topologies. Festo CPX-AP-A and CPX-AP-I support Ethernet/IP, EtherCAT, PROFINET, and Modbus TCP/ IP.

Connect remote and decentralize inputs and outputs to achieve the I/O density the layout requires. For example, place 80 digital inputs plus valve terminals in one location and connect 50 centralized SMS and additional IO-link devices or analog devices. Further downstream and with a singular fieldbus node, the OEM can string together another mixture of 80 modules that are 50 meters apart. These remote and decentralized I/O solutions feature industry leading speeds using a single network and IP address. The only limiting factor is the PLC processing speeds and native communication protocol.

In the current climate where it can be a time-consuming process to find, order, and receive I/O modules, networked valve terminals, and electromechanical actuators with servo control, it makes sense to turn to Festo. Festo provides a one stop shop for rugged, dependable integrated pneumatic, servo-controlled motion, and networked I/O through its always-in-stock Stars of Automation program. (See online catalog for Stars of Automation information.)

Productivity tools

Festo engineering productivity tools for electrics and pneumatics include SMS solutions finder, Electric Motion Sizing, and Pneumatic Sizing for error free sizing of linear and rotary systems. Festo features Automation Suite for simplified electrics commissioning. The Festo configuration tool for the CMMT-ST motor controller saves considerable time and ensures accuracy. Using PartdataManager, OEMs receive CAD data in 2D/3D for the entire catalog of 33,000 products. These and other productivity tools are free and accessible online.

Training from mechatronic experts

Festo Didactic – the educational arm of Festo ‒ takes lifelong learning and mechatronic technical training to a new, higher level. Festo Didactic assesses levels of mechatronic knowledge and prepares a learning curriculum based on individual needs. The Festo Learning Experience (Festo LX) is a new online portal to make it easier to create individual learning experiences for personnel.

Electrics, pneumatics, seamless connectivity, productivity tools, an AI/machine learning platform for predictive analytics with integrated maintenance functionality, and training make Festo the partner of choice for top-flight Intralogistics systems. Because it is more than a supplier of diverse and high-quality products, Festo lowers engineering overhead, boosts engineering productivity, and brings systems to market faster.