trends in automation The Festo Customer Magazine 1.2009
Inspiration
“Achieving the optimum every day.� Interview with Anton Milner of Q-Cells SE
Ideas
From gentle to tough Grippers for all occasions
Synergy Effects
Festo India Automation technology for the booming south
In Focus
Renewable Energy Sources Technology, Innovations, Perspectives
Grab the oppportunity! Sunlight, wind and renewable resources: energy for tomorrow. Available and affordable today through innovative technologies and intelligent automation from Festo.
www.festo.com
Innovation – an opportunity in difficult times Dear readers, What is your first impression of the new edition of “trends in automation”? We have not only given our customer magazine a new visual appearance – we have made changes to the contents as well. This Asia-Pacific edition will enable us to provide you with even more relevant information on pneumatic and electric drive technology and present the latest technological trends and their potential to achieve greater efficiency. By linking global themes and trends to examples of regional applications in Asia, we are able to focus on regional aspects without losing the perspective of global developments in the field of automation technology.
Dr. Thomas Rubbe, Director of Region and Sales Asia Pacific
The current situation is characterised by economic uncertainties and social challenges, for example climate change. It is particularly at times like these that it is important for us to develop innovative solutions in order to strengthen the competitiveness of our customers. This is an objective which we are pursuing not only in our traditional industries but also in the industries of the future, including those concerned with developing energy from renewable sources such as solar/photovoltaic power, wind power and biofuels. Without automation, it would scarcely be possible for these industries to produce the necessary technologies economically. And yet this is vital in order to exploit the associated potential on a global scale. You can find more on this subject in this edition of “tia” under the “Focus” heading of “Renewable Energy Sources”. In the region-specific article, we bring you information on the development of the automation market in India. I hope you enjoy this edition of trends in automation!
Thomas Rubbe
In Focus Renewable energy sources represent our future, together with the equipment required to utilise them. The main theme of this edition of “trends in automation” is about some of the associated technologies. We will also demonstrate how automation technology can help reduce manufacturing costs – and thus also help combat climate change.
trends in automation
1.2009 Editorial 3 Panorama 6 New products 8 Festo worldwide 38 About this magazine 41 Soft Stop 42
12
“The aim remains to produce electricity from sunshine at an acceptable price.”
Inspiration In Focus The “Sun King” of Bitterfeld An interview with Anton Milner, CEO of Q-Cells, the world’s largest producer of solar cells, on his strategy for success. 12
1.2009 trends in automation Contents 4 5 –
16
The most important source of renewable energy is the sun.
30
Automation technology in India is still an attractive market.
Compass In Focus Endless energy and sheer vitality As prices for generating renewable energy fall, the proportion of Europe’s electricity and heat which is supplied by renewable energy is rising. The plans are for it to reach 20 % by 2020. 16 Small talk with sensors The new IO-Link interface expands digital communication between controllers, sensors and actuators. 20
Synergies
22
Festo’s range of grippers covers all kinds of applications.
Impulse
India’s “Magnificent South” India’s economy remains on course for growth, despite the current crisis. This means that demand for automation technology is also rising, particularly in the south of the subcontinent. 30
Keeping a grip New grippers complement our product range. And dimensioning software helps find the right gripper for every application. 22
In Focus Automatic testing Will the test device “quickCONNECTfixture” by balticFuelCells help achieve a major breakthrough for fuel cells in the near future? 34
Self-adjusting cushioning for pneumatic cylinders PPS ensures perfect cushioning and a jerk-free approach to the end position – without the need for manual adjustment of the cylinder. 25
In Focus Spotlighting faults The compact vision system SBOC-Q enables RENA GmbH to provide seamless automation of its wet-chemistry process installations for solar cells without compromising quality. 36
Are you sure you’re safe? The new EU Machinery Directive: engineering support, services and training help make the transition to the new Directive and reduce safety-related shutdowns to a minimum. The start of a series of articles on safety measures based on the example of a typical installation. 26
Poul la Cour
The father of wind power (1846 – 1908)
Just 100 years ago, the rural population of Denmark – with just a few exceptions – went to bed when the sun went down. Poul La Cour was one such exception. By day, La Cour, born in 1846, taught at the local school in Askov. At night, he often used to work until late by dim candlelight on a visionary idea: decentral power supply for the country using wind generation. In 1891, this persistent pioneer erected a wind energy generator within the school grounds. It was one of the first anywhere in the world. His research in his own wind tunnel showed that generators with especially fast-turning rotor blades were able to achieve a very high degree of efficiency. He also gave some thought to energy storage and experimented with hydrogen. This initially led to a number of blown-out window panes, but eventually he was able to use hydrogen gas, obtained through electrolysis and stored in special tanks, to light the entire school building. This Danish Edison did not become rich through his inventions. Quite the opposite: he invested almost his entire salary in his projects, driving his family to the edge of poverty. His work was, however, a success. By the time he died in 1908, as many as 30 rural energy utility companies in Denmark were using wind energy generators. Today, this country is the world’s largest producer of wind energy generators, not least thanks to Poul La Cour.
Photographs: Poul la Cour Fonden, Denmark
1.2009 trends in automation Panorama 6 7 –
Drives
A powerful and precise swivel drive
A power package for handling and assembly applications: the twin-piston swivel drive DRQD-B.
The modular twin-piston swivel drive DRQD-B with modified piston material offers improved repetition accuracy for swivel motions from 0.05° to 0.03°, in other words an improvement of no less than 40 %. Moreover, compared with its predecessor the DRQD, its mass moment of inertia is 2.5 times better. These technical improvements in combination with a price reduction, dependent on the variant, of up to 23 % make the
DRQD-B-16 ‌ 32 an ideal automation solution when it comes to powerful rotary and swivel motions.
Valves
CPE: used as valve manifold The solenoid valve CPE can be used as an individual valve and now also on a sturdy aluminium manifold. Among its many advantages are a very long service life and optimum use of installation space. This valve has the highest flow rate in the world for its slim width and also impresses with its low power consumption. A further plus point is the use of the very common M8 round plug connectors, which ensure easy installation.
Sturdy: the solenoid valve CPE...-PRS-... mounted on a manifold rail.
1.2009 trends in automation New products 8 9 –
New brochure
Standard drives The 16-page brochure “Standard Drives” shows that “standard” and “innovation” need not be contradictory. This soon becomes clear when the reader considers innovations such as the 3K piston, self-adjusting pneumatic cushioning and the use of alternative materials such as technical polymer for ISO cylinders. The brochure also provides information on pneumatic drives, cylinder sensors and position transmitters.
Valve terminals
Integrated pressure sensor
Valve terminal MPA-F with integrated pressure sensor.
The pressure sensor integrated into the pneumatic interface CPX/MPA-F enables the working pressure in all parts of a valve terminal to be monitored, thus increasing process reliability. The measurable pressure range is 0 to 10 bar. A three-digit LED display shows the actual pressure. This pressure sensor is compatible with analogue CPX modules and enables communication with the valve terminal.
Valve terminals
Autonomous miniature controller The autonomous miniature controller CPX-SF34/35 can be used to expand the electrical terminal CPX by adding a front-end controller Phoenix Contact for the programming system PC Worx and enables pre-processing. It can thus be used to optimise stationary manual workstations as well as linked autonomous subsystems and to reduce installation and energy costs. Moreover, the facilities for networking and numerous diagnostic and visualisation functions ensure a high level of flexibility in practical applications.
The miniature controller facilitates: • A seamless control concept which is easy to work with • Lean solutions with low installation costs thanks to direct mounting on machines • Lower costs compared with conventional solutions with a miniature controller, parallel wiring and a control cabinet
The perfect choice for the automotive industry: Valve terminal type VTSA with PC Worx.
Valve terminals
Additional functions for valve terminals type MPA Sub-base valve
Diagnostic module D2
Sub-base
Pressure sensor
Function expansion with valve terminals type MPA: pressure sensor and diagnostic module D2.
Modular pressure sensor An optional pressure sensor is available for the valve terminal MPA; this can be ordered directly via the valve terminal order code and can also be integrated into the valve terminal at a later date. Up to eight sensors can be placed at any point on one valve terminal. The sensors enable immediate, on the spot measurement of external signals or internal pressures for an entire valve terminal. Settings relating to data, parameters, error or status messages are carried out using CPX-FMT software or via the hardware configurator S7. This eliminates the possibility of manual setting errors or tampering with settings. The sensor is compatible with a fieldbus and offers diagnostic facilities,
thus permitting flexible variation of pressure parameters. The switching status is displayed by LEDs on the module. Diagnostic module D2 The new diagnostic module D2 offers an even greater range of functions. With a serial connection within a valve terminal MPA, it expands the existing diagnostic facilities to include monitoring functions for undervoltage, open circuits, short circuits and switching cycles. Moreover, the module includes a higher performance chip with a greater storage capacity to offer still more reliability through condition monitoring.
Air preparation
New pressure booster variants New variants of the pressure booster DPA help reduce the costs of compressed air still further – directly within the application. A new polyurethane piston material increases product service life from 1,000 to 2,000 operating hours. And what is more: • The low-cost, compact variant DPA-D without regulator has an output pressure that is twice the supply pressure. DPA-63 and 100-…-A incorporate a magnetic piston and can be equipped with all types of size-8 proximity sensors.
• An interesting alternative is the complete solution DPA-...-CRVZS, which is available as of now with various sizes of reservoirs. • The special variant DPA-63-18-SA with a ratio of 1:3 can operate with a low primary pressure of up to 6 bar to generate a secondary pressure of up to 18 bar.
Pressure booster DPA-D
Pressure booster DPA-...-A
Pressure booster
DPA-...-CRVZS
1.2009 trends in automation New products 10 11 –
Air preparation
Balancer applications with the MS series
Valves
Miniaturised vacuum valve combination
Lightweight but powerful: the vacuum valve combination MH1.
Ideal for use in the automotive industry: the precision pressure regulator MS6-LRP-PO.
The new precision pressure regulator MS6-LRP-PO can from now on also be used in balancer applications in the automotive industry. The PO variant has the same technical features as the MS6-LRP but has an additional G1/8" connection for pilot air. The MS6-LRP-PO with a 12" connection for pneumatic pilot signals offers advantages such as:
MH1 valves are heavily miniaturised and are thus suitable for even the very smallest of installation spaces. Used in conjunction with a central vacuum supply, this valve combination helps switch from vacuum to ejector pulse. This is ideal for transporting very small workpieces, for example in the electronics and semiconductor industries. In order to generate vacuum quickly, the valve combination has almost twice the flow rate of standard valves, while its low weight of just 30.6 g means it can be installed very close to a vacuum generator. This means moving machine components are not loaded unnecessarily and tubing lengths between the valve and vacuum generator are kept to a minimum. The result is high energy efficiency and optimised process times. In addition, the valve’s low leakage rate guarantees that workpieces will continue to be held securely in the case of a sudden energy supply failure.
• Low hysteresis, enabling precision adjustment of drive force • High secondary exhaust rate for the fastest possible reaction times • Wide choice of variants for maximum flexibility
Software
Free Device-Type Manager software The CPX-DTM software makes it possible to integrate electrical CPX terminals into frame applications and provides fast and clear information on the status and I&M data of a CPX terminal and any module errors. The software also offers CPX error tracking. The Device-Type Manager is simple to use and easy to access. It is compatible with both current and future
versions of the CPX terminal, thus providing users with the assurance of reliable, long-term operation.
Interview
The “Sun King” of Bitterfeld Since its start-up ten years ago, Q-Cells SE in the German state of Sachsen-Anhalt has become the world’s largest producer of solar cells. This success story is inextricably linked to the name of Anton Milner. Born in Britain and the CEO of Q-Sells, Milner has again and again demonstrated his exceptional instinct for market opportunities and wise strategic decisions. In this interview, he describes his path to success.
trends in automation: Mr. Milner, within a few years Q-Cells has grown from a small start-up company to the biggest manufacturer of solar cells in the world. Can you tell us about some of the major steps which you took along the way? Anton Milner: Well, Q-Cells was founded in 1999 and I became a shareholder in the new company in 2000. Our first challenge was finance. We had a starting capital of 60,000 euros, but to begin series production of solar cells we needed 15 million euros. Obtaining this capital at a time when the dot-com bubble had burst and was troubling investors was the company’s first success. The second important step was when we first produced a solar cell with a viable degree of efficiency. The first ever cell we made had zero efficiency and the second would not produce any electricity either. The seventh cell achieved an efficiency of 14 percent, and from that time onwards we were sure that we would be able to produce cells of good quality on our production equipment. As our company grew rapidly, a further milestone was the moment our total sales reached the 100 million euro mark. This happened in 2004 and fitted perfectly in the growth strategy which we had adopted for the time up to our planned initial public offering.
We then successfully went public with the company in 2005. This opened up further opportunities for the company, including opportunities relating to quality. You have demonstrated that you have a “good nose” in certain situations and are able to choose the right direction when it comes to important decisions. What were these? Anton Milner: Because of my professional background with a large business consultancy, I have the ability to prepare business decisions in a very analytical way. In a decision-making situation it is essential to identify clearly the opportunities as well as the risks. The aim of analysis is to be able to take a clear direction in terms of risk management and strategic objectives. One particularly important factor for our company, for example, was the decision to enter into long-term partnerships with our silicon suppliers. My guess was that this essential resource for the manufacture of solar cells would cause a bottleneck in production operations. Hence I came to the conclusion that it was important to secure supplies and not bet on falling prices. This strategic decision has subsequently proved to be correct. It was also right from today’s perspective to enter into further photovoltaic technologies. Subsidiary companies of Q-Cells are active in the field of thin-layer photovoltaics and we also
1.2009 trends in automation Inspiration 12 13 –
Personal details
Anton Milner With a degree in engineering and an MBA, Anton Milner, in his mid 40s, has been a member of the Board of Directors of Q-Cells SE since 2000. After completing his studies, Milner, born in the UK, first worked for Royal Dutch Shell in the areas of oil trading, risk management, gas trading and business analysis. In 1993 he moved to the business consultancy McKinsey & Co., initially as a Senior Consultant and then as a Senior Engagement Manager. As the CEO of Q-Cells SE today, he is responsible for strategy, business development and corporate communication and is also acting Head of Sales and Marketing.
Photo: Q-Cells SE
Anton Milner, CEO of Q-Cells SE, expects to see a significant expansion of production capacity for photovoltaic modules over the next several years. Photo: Archive of IMG Investitions- und Marketinggesellschaft Sachsen-Anhalt mbH
have our fingers on the pulse of research in other new developments. In short, Q-Cells will not miss any future developments in the photovoltaic industry. Who or what inspires you in your work? Anton Milner: I am inspired by the principle of trying to achieve the optimum every day. So I go home in the evening with a good feeling when I have been successful, but am irritated when it’s not worked out well. And, of course, my bond with the company is a great source of motivation. If you have known a company from its very beginnings, you can still feel something of the initial entrepreneurial spirit in its everyday work. You are a trained engineer and businessman and a Briton who lives and works in Germany. What are the advantages of this mix of experiences? Anton Milner: The mix gives me a different perspective and the ability to take a global view. I have tried to instil this at Q-Cells right from the start. Now, as we move towards further internationalisation of the company, this is more important than ever. On the other hand, I no longer consider it exceptional for an individual to have both technical and commercial skills. In many situations and discussions it is useful to be able to speak the “language” of the other partner.
The keyword is: the production of solar cells and thin-layer photovoltaic modules. What developments do you expect in the production equipment used in the photovoltaic industry? Anton Milner: We must first recognise that photovoltaics is still in its infancy. The objective remains the cost-effective production of electricity from sunlight. The greatest potential for rationalisation lies in the materials used. As regards production technology, we urgently need fully automated processes. Production technology must be continuously developed with this aim in mind. An increase in capacity and further reduction of production costs will be vital for the commercial success of photovoltaic (PV) technology. Festo offers above all handling systems and workpiece transport systems for the photovoltaic industry. How important are these subsystems for the production equipment used in the solar industry? Anton Milner: These systems are crucial for the survival of the industry. As I indicated earlier, the existing PV production capacity is just the beginning. Each year, we will need to increase production by a factor of X in order to meet the demand for photovoltaic systems. Handling and transport are central themes when it comes to expanding capacity in this way. For example,
1.2009 trends in automation Inspiration 14 – 15
“For me, it is important to identify clearly both the opportunities and risks associated with a given decisionmaking situation.” A. Milner
The company
Q-Cells
pneumatic drives and valves must ensure that sensitive raw wafers can be transported quickly and positioned correctly. Vacuum generators and corresponding suction cups must continue to hold the fragile wafers securely even as processes become ever faster. Founded in 1999, Q-Cells SE has around 2300 employees and is the world’s largest manufacturer of solar cells. In 2007, the company produced mono and multicrystalline solar cells with a total rating of 389 megawatts peak (MWp) and supplied these to producers of solar modules worldwide. More than 250 scientists and engineers at Q-Cells work on further technological development in order to achieve the central aim of the company: to reduce the costs of photovoltaics quickly and permanently and make the technology affordable and competitive. In addition to the core business activities of the parent company, a number of Q-Cells SE subsidiaries have since mid-2008 been producing photovoltaic modules on the basis of various thin-layer technologies. Q-Cells SE is building a production facility in Malaysia and has branches in Hong Kong, China and Japan. The company is quoted on the Frankfurter Stock Exchange and listed in the German technology index TecDAX. Photo: Q-Cells SE
Finally, a personal question, Mr. Milner. What do you enjoy doing in your free time; do you have any particular hobbies? Anton Milner: Generally, free time is something of which I have little. I live in Berlin and spend my weekends there, meet friends and relax. When I have the time, I follow the German football league; that is a kind of hobby for me.
Renewable energies on the rise
Endless energy and sheer vitality Sunshine not only creates a good mood but keeps us cosy and warm, even in winter. In the coming years, experts predict an even greater use of sunshine and other renewable energy sources. By 2020, plans are for these sources to generate 20 % of all electricity and heat in Europe – not least because the price of equipment to generate solar energy will continue to fall.
F
ossil energy sources will only be able to meet the rising energy demands for a limited period. One way out of the threatening energy shortage is represented by renewable energy sources – sources which grow back, such as wood, or those which
are virtually inexhaustible, such as wind and water. The most important source of renewable energy is the sun, whose radiation can be utilised with solar thermal and photovoltaic installations. Wood, biogas, biofuels and geothermal energy are making an increasingly large contribution
to long-term energy supplies and the reduction of climate-damaging emissions. The use of these energy sources is virtually CO2-neutral and also helps conserve existing stocks of raw materials.
1.2009 trends in automation Compass 16 17 –
The changeover is complete The use of renewable energy in Germany is increasing faster than predicted. The target set by the German government was for at least 12.5 percent of electricity to be generated from renewable sources by the year 2010; this was met as early as 2007. In total, renewable energy accounted for around 6.7 percent of overall electricity consumption in 2007. Within the rest of the European Union there
are also signs of change. Prompted by the EU Directive in 2007 governing renewable energy, the EU member states resolved to raise the target for the proportion of electricity generated from renewable sources within the EU to 20 percent by 2020. The proportion in 2005 was 8.5 percent.
Solar power plant in the province of AlmerĂa, Spain Photo: Q-Cells SE
Particularly important: economical production processes As the proportion of electricity and heat generated from renewable sources rises, so do the requirements for the cost-effective use of energy. Manufacturers therefore face the challenge of making the pro-
duction processes for energy generators as efficient as possible. Pneumatic and electrical automation technology is playing a central role in this process. Possible applications include the handling and transport of components with vacuum grippers or air bearing transport systems
and quality inspection with the aid of intelligent vision systems, as used, for example, by RENA GmbH (see page 36). It is also possible to use automation technology to simplify many processes which were previously carried out manually.
220 207 (977)
Solar energy Geothermal energy Biomass Wind power Water power
200 180 160 140
4.500
4.500
4.000
4.000
3.500
3.500
3.000
3.000
2.500
2.500
2.000
2.000
1.500
1.500
120 100 88 (443) 80
75 (190)
60
52 (152)
40 27 (34)
500
26 (121)
20
14 (31)
10 (45)
0 Global
Developing countries
EU-25
China
Germany
USA
Spain
India
500
7 (52) Japan
Available capacity for generating electricity from renewable resources globally, in developing countries, in the EU and in the six leading countries, 2006. Source: REN21 (33)
0
1997 1998 1999 2000 2001 2002 2003 2004 2005 2006* 2007*
0
Development of available capacity and electricity generated by photovoltaic plants in Germany, 1997–2007. Source: BMU based on Renewable-Energy Working Group statistics (AGEE-Stat)
This can reduce manufacturing costs considerably. One example is the automated test equipment for fuel cell components used by the manufacturer balticFuelCells (see page 34).
More is less The future presents good opportunities for the increased use of renewable energy. The turnover generated by the industry in 2007 was around 25 billion euros and
1.2009 trends in automation Compass 18 19 –
France 46 MW Belgium 48 MW Portugal 50 MW Czech Republic 51 MW Japan 230 MW Italy 258 MW South Korea 274 MW
Spain 2.511 MW USA 342 MW Germany 1.100 MW
Global market of photovoltaics in 2008 (top ten of new installations). Source: European Photovoltaic Industry Association
Oil 34,9 % Water power 0,5 % Wind power 1,0 % Biomass 5,3 % 2)
RE share 7,1 % 1)
Gas 22,2 %
Brown coal 11,1 % Black coal 13,1 %
Other RE 0,3 %
Nuclear energy 11,6 %
Percentage of primary consumption in Germany in 2008. Source: BMU (AGEE-Stat) based on data of Energy Balance Working Group AGEB (April 2009) 1) calculated by efficiency method 2) solid, liquid and gaseous biomass, biogenic share of waste, landfill and digester gas
35
RĂśdgen Solar Park, Sachsen-Anhalt, Germany. Photo: Q-Cells SE
30
30,9 %
25
23,3 %
20 15
12,2 %
10
6,7 %
6,2 %
5
5,9 %
3,7 %
3,5 %
3%
Italy
France
United Kingdom
2,6 %
1,9 %
Portugal
Canada
0 USA
China
Other countries
India
Germany
Spain
Newly installed wind power plants worldwide in 2008. Source: Global Wind Energy Council (GWEC), spring 2009
exports, for example by the wind power industry, have risen to around 70 percent. German products are world-leading in terms of technology, thanks to targeted government aid that has fostered the coordinated further development of renewable energy technology. There is
a particularly strong demand in the world market for wind energy, photovoltaic and biomass installations from Germany.
New interface concept at I/O level
Communicative sensors Sensors have traditionally been regarded as anything but “talkative”. They generally don’t convey more than just a “Yes” or “No”. With IO-Link, however, this is about to change. This new interface provides an easy means of transmitting digital data between controllers, sensors and actuators.
M IO-Link is a standard created by leading automation technology manufacturers to solve the problem of the “last metre” in industrial data communication.
any designers and developers would like data communication to reach all the way down to sensors and actuators. Up to now, however, this has been marred by economic reasons. Individual sensors could only be justifiably connected to the dominant form of industrial communication system, the fieldbus, in exceptional cases. The cost of integrating the bus interface right down to field level was simply too high. Against a background of increasing demand for diagnostic systems, pressure to adapt to predictive maintenance concepts and above all the lower costs resulting from simplified installation systems, the situation has now changed. The subject of the “last metre” in industrial data communication is once again the focus of attention in the automation business. The
technological leaders in the industry are just on the point of finding an answer to previously unfulfilled wishes for communication facilities. And the answer is called “IO-Link”. What is IO-Link? IO-Link is a new interface concept at I/O level. It facilitates the connection of sensors or actuators to the I/O modules of controllers. The interface is based on the existing standard connection systems M5, M8, M12 etc. It uses three or five-pin unscreened cables which provide pointto-point connections for serial data transmission in both directions. The key data of this concept identify IO-Link not as a bus system but as a lower-level connection concept at I/O level. An IO-Link system consists of an IO-Link master and one or more IO-Link devices
1.2009 trends in automation Compass 20 21 –
Project Industrial Ethernet Control level Profibus DP Field level AS-i Module level IO-Link I/O level
(sensors or actuators). The IO-Link master provides an interface to the higher-order controller (PLC) and controls communication with the connected IO-Link devices. An IO-Link device is an intelligent sensor or actuator. “Intelligent” with regard to IO-Link means that a device has, for example, a serial number or parametric data describing sensitivity, switching delay times or characteristic curves which can be read or written using the IO-Link protocol. Parameters can thus be modified to some extent via the PLC during operation. What’s new about IO-Link? Nowadays users of automation technology are confronted by numerous problems. Digital and analogue signals have to be transmitted and then processed in a controller. At the same time, the parameterisation of a number of different sensors involves a great deal of work, as these sensors often receive no diagnostic data from field devices. The IO-Link concept deals directly with these issues: The interface standardises the data connections between sensors and actuators. This means that only one type of interface is needed to transmit data serially regardless of the type of signal (analogue/digital) the sensors send out. A further new feature is the communication capability. With IO-Link, it is possible for the first time to download parameterisation data from a controller to a sensor and also transmit diagnostic data from a sensor to a controller. Consortium driving the innovation process forward The development of IO-Link is the responsibility of a consortium made up of leading suppliers of automation products.
The main advantages of IO-Link are: simplified installation, lower wiring costs and cost-effective transmission of parametric and diagnostic data from a low I/O level.
Their aim is to establish the new concept in all areas of sensor, actuator and control technology. The consortium is working to further develop the IO-Link in order to be able to offer users a large number of advantages, no matter what connection concept or fieldbus system they use. Festo is backing the new concept Festo is among the founding members of the consortium. It wishes to promote the new communication standard at I/O level in order to offer its customers major potential for improvements and savings. In addition to benefits such as improved data communication at lower cost, the concept is also expected to lead to the development of new intelligent mechatronic devices throughout the industry. Cylinder/valve combinations, signal lamps, vacuum generators and valve terminals using IO-Link communication are just a few examples. The new standard could become a general incentive for innovation, which will drive automation technology forward and initiate further changes.
Lower threshold value CH1 Upper threshold value CH1 Hysteresis CH1 Switching function CH1 Switching-component function CH1 Lower threshold value CH2 Upper threshold value CH2 Hysteresis CH2 Switching function CH2 Switching-component function CH2 Unit Lock … New communication capability IO-Link makes it possible for the first time both to download parametric data from a controller to a sensor (in this case the digital pressure sensor SDE1) and to upload diagnostic data from a sensor to a controller.
Handling Technology
Grippers for all occasions From gripping under tough conditions on a machine tool to “sensitive” handling in electronics production – Festo constantly expands its range of grippers so that it can offer the right type for virtually any industrial handling application. Dimensioning software available via the Internet makes it easier to select the optimum pneumatic drive system.
E
very gripper application is different and requires a different approach. Festo’s modular mechatronic system offers the right solution for every need, no matter what gripper functionality is necessary or what type of electric or pneumatic drive is required. However, the selection of the right type of gripper raises fundamental questions which need to be examined carefully before a choice is made: what is the shape, weight and surface texture of the workpiece? How much precision and force does the gripping operation require? What type of drive should be used? To make it easier for customers to take decisions, Festo constantly expands the range of applications of its grippers by introducing new products. The latest exam-
ples: the new electric gripper HGPLE and the two pneumatic grippers HGDT and HGRC/HGWC, which demonstrate their strengths in all kinds of working environments.
piece, thus reducing travel times to an absolute minimum. Even if the workpiece size requires the full gripper stroke, the HGPLE can deliver impressively short opening and closing times.
Electric gripper HGPLE Thanks to its programmable gripping force, the HGPLE is suitable for applications where particularly “sensitive” gripping is needed, for example involving fragile workpieces or those where visible gripper marks must be avoided. A further advantage of this gripper is its long stroke and programmable gripper jaws, which can be positioned flexibly and precisely in accordance with the workpiece size. The HGPLE features a “pre-holding position”, i.e. it parks its gripper fingers just a short distance away from the work-
Its long stroke and ability to deliver high gripping forces when required mean that the HGPLE can handle workpieces of different sizes and weights without difficulty. Its sturdy and precise kinematic mechanism, with a rack and pinion, enables precise central gripping. The robust T-slot guide transmits even high torque levels reliably and guarantees high accuracy.
HGPLE: a pinion synchronises the motion of the two gripper jaws.
1.2009 trends in automation Impulse 22 23 –
HGRC: three sizes, each with three different opening angles.
HGDT-F: double the gripping force and half the stroke.
Pneumatic radial and angle grippers HGRC/HGWC Palletising and transfer operations are among the main applications of the new radial grippers HGRC and angle grippers HGWC. Their main strengths come to the fore in applications involving low workpiece mass, low gripping forces and loads, modest requirements for repetition accuracy and relatively large assembly tolerances. Moreover, in many cases, the wide opening angle of the grippers means that there is no need for a short-stroke Z-axis.
Pneumatic three-point gripper HGDT-F Thanks to its robust design and high load capacity, the materials used and its functionality, the HGDT is ideal for applications requiring mechanical strength and precision, and those in which external factors such as dust, dirt, liquids or process forces prevent the use of standard grippers, for example on machine tools.
These economical gripper versions are available in three sizes, each with three different opening angles. Workpieces can be gripped both externally and internally. Integrated restrictors reduce the opening and closing times, making additional flow control valves unnecessary in 60 to 80 percent of all applications. And, what is more, integrated sensor slots enable stroke sensing by SMx sensors and avoid unnecessary interference edges, such as might be caused by externally mounted sensors.
Fewer components, simple design based on the half-shell principle.
This three-point gripper is available in five sizes. The additional letter F (Force) in the type code indicates double the gripping force and half the stroke compared with a conventional three-jaw T-slot gripper of the same size. This high power density results in significant savings of space and money. In addition, the robust and precise T-slot guide for the gripper jaws ensures precise gripping even under heavy torque load or with long gripper jaws. Once again, integrated sensor slots enable stroke sensing by SMx sensors while avoiding unnecessary interference edges.
Safe gripping thanks to gripping-force back-up.
“With the gripper software and a free practical test the perfect gripper for every application can be found quickly and reliably.�
Achim Mebert Product Management Handling Units
How to find the right gripper Gripper software Faced with the question “Which is the right gripper for my application?”, users can obtain a dependable answer from the gripper software available in Festo’s electronic catalogue. Once the key parameters have been entered, the program presents a selection of suitable grippers with the correct size. The desired gripper can be ordered directly at the press of a button.
piece is actually being gripped correctly and safely. Festo offers a test service, free of charge of course. All that users need to do is send the workpiece to be gripped to Festo together with a description of the application and a checklist. After Festo has completed a test, users are provided with a test report including still photographs, a video and a parts list of the components used as well as a quotation by e-mail without obligation.
Gripper test facility The final result of a gripping operation depends on a number of parameters. Only a practical test can reveal whether a work-
Is the gripper right for the application? The gripper test facility provides a clear answer.
Overview: The right gripper for every application Flexible grippers
For soft or highly sensitive workpieces: electric T-slot grippers/parallel grippers HGPLE
For handling applications with controllable gripping forces: servopneumatic proportional gripper HGPPI
Pneumatic grippers: parallel grippers
In heavy-duty machine construction for all gripper applications: T-slot grippers HGPT-…-B
For general machine construction: longstroke grippers HGPL
For standard applications in handling and assembly systems: parallel grippers HGP
For precise positioning and assembly: precision grippers HGPP
Cost-optimised for standard applications: parallel grippers HGPC
For gripping very small workpieces or in confined spaces: micro angle grippers HGWM
For standard applications in handling and assembly systems: radial grippers HGR
Pneumatic grippers: three-point, angle and radial grippers
For plant and machine construction: threepoint grippers HGDT
For standard applications with rotationally symmetrical workpieces: three-point grippers HGD
For standard applications in handling and assembly systems: angle grippers HGW
For gripping very small workpieces or in confined spaces: micro grippers HGPM
1.2009 trends in automation Impulse 24 25 –
Pneumatic Drives
Self-adjusting cushioning for pneumatic cylinders More economical: round cylinder DSNU with self-adjusting pneumatic cushioning PPS.
Potential savings with PPS cushioning. An installation for sorting packages consists of 60 stations, each with a round cylinder DSNU. The cushioning means that it takes up to five minutes less to install and set up each cylinder, which means a total saving of 300 minutes or five working hours.
S With self-adjusting cushioning PPS, longitudinal slots on the cushioning piston ensure the guided discharge of air. This means that the round cylinder DSNU approaches its end position in a dynamic but gentle way. There is no more need for manual adjustment.
elf-adjusting cushioning PPS makes commissioning easier and means an end to the constant toing and froing previously required to set the correct cushioning for a pneumatic cylinder. It also ensures a dynamic but gentle approach to the end position, with no more need for manual adjustment of the cylinder.
more, the automatic adjustment means optimum cushioning every time, even if parameters such as friction and pressure change. This reduces the acceleration forces acting on machine components and workpieces. Furthermore, this type of cushioning is cheaper than shock absorbers and provides a significantly longer service life.
Previously, users had to keep on adjusting the speed control valves until they believed the cushioning characteristics to be right. The full advantages of manually adjustable pneumatic cylinder cushioning were not exploited and a price was paid in terms of cycle times and noise levels.
This self-adjusting cushioning, unique to Festo, is now available with the popular round cylinder DSNU.
As the cushioning no longer needs to be adjusted manually, commissioning time is now considerably reduced. What is
Safety technology – Part 1
Are you sure you’re safe? By the end of the year production managers, designers and developers not only need to implement the new Machinery Directive, they will also be required to reduce the number of safety-related shut-downs to a minimum. Products, tailor-made engineering support, services and training seminars from Festo can help with the implementation of effective protective measures without impeding production operations.
5 le du Mo
4 le du Mo
3 le du o M
2 le du o M
1 le du Mo
This installation has been divided into five modules or working operations. This aim is to illustrate the principles of various different applications and provide ideas for possible solutions (technical protective measures).
According to current legislation, machines and production equipment must be designed in such a way that people, animals, objects and the environment are protected from injury or damage. All manufacturers of machines and production equipment are thus obliged to carry out risk assessments and, based on these, create the protective measures necessary for each individual machine.
1.2009 trends in automation Impulse 26 27 –
Start
Risk assessment
Determine machine limits
Identify hazardous situation
Design measures Machine safe?
No
Design measures, e.g. inherent safety
Yes Technical protective measures Machine safe?
No
Technical protective measures
Risk reduction
Risk assessment
Estimate risk
Yes Instructive protective measures fully utilised?
No
User information on machine and in manual
Yes End
Schematic diagram for risk assessment
Module 1: Material feed Support and coating materials are unwound from two rolls and fed to the coating station. Module 2: Coating station The two strips are pressed together by a roller. Coating is carried out using, for example, the application of heat or adhesive. A further roller completes the bond. Module 3: Cutting station The bonded strips are cut into individual pieces and separated. Module 4: Shaping station The separated pieces of material are used to produce various shapes with cutter dies. It would also possible to print on the workpieces in this station. Module 5: Palletising and packing station A handling system stacks the finished workpieces. Once a stack is complete, it is pushed towards the packing station. Wrapping foil is placed on the stack by hand, and the stack is then wrapped automatically, triggered by the two-hand control unit.
Safety@Festo Festo safety pneumatics make it easy to reduce risks by offering a comprehensive range of goods and services relating to safety technology. This includes products, engineering, services, solutions and training seminars, all geared to make it easier for users to follow legal safety requirements and to increase the level of safety in the daily work environment. It is
thus possible, for example, to reliably avoid collisions, uncontrolled restarts after emergency stops and other safetyrelated problems in various operating modes. A web-based training programme from Festo Didactic provides the necessary know-how for the safe operation of production equipment and machines in ac-
cordance with the Machinery Directive 2006/42 EU and the EN ISO 13849-1 standard. Series of articles on a model installation In our series of articles we will use a model installation to provide information on effective protective measures and how to implement them. In the first article the model installation and some ideas for
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Crushing Impacting Pulling Cutting Burning Electrical hazard
Hazards associated with working operations on the model machine. (Note: The list of hazards is not claimed to be exhaustive but is simply intended to illustrate the system used to classify the different types of hazards).
Hazards on module 2
protective measures in module 2 of the installation are presented. The overall process is made up of five modules or work operations. The aim is to illustrate the principles of various installations and concepts for possible solutions (technical protective measures).
Pressurising
Maintaining pressure
Reducing pressure and force
Initial position, standstill
In a first step, a risk assessment is carried out using a defined method. The outcome of the risk analysis and assessment is protective measures to reduce risk.
Set-up and service operation
Normal operation
Two-hand control
Protective measures must be implemented and evaluated for each risk. Depending on the risk concerned, design-related, technical or instructional measures will then be carried out. Potential hazards are determined in accordance with EN ISO 12100-1 in order to define the limits and service life of the machine concerned. Each module contains a number of examples of hazards.
Exhausting
Emergency operation
Reducing speed
Switching to unpowered
Stopping, holding, blocking a movement
Preventing tampering and unexpected re-start
Reversing a movement
Illustration of pneumatic safety functions. The highlighted functions are the safety functions which are to be implemented in module 2.
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1.2009 trends in automation Impulse 28 29 –
Valve manifold (2-channel linkage) with individual connections or integrated into valve terminal VTSA
Pneumatic circuit diagram used to implement the two safety functions.
In the example shown, the overall machine is divided into five modules. For the purposes of safety measures, we will consider each module separately. The first article in our series is concerned with safety solutions for module 2. Module 2: Coating station An isolating safety device is installed for this area. There is, however, a need for a service door to allow access under certain circumstances which must be provided with certain safety functions. Solution with safety pneumatics When the protective door is opened, the thermal energy of the heater plate, among other things, must be switched off and roller 2 must be raised in its upper end position. The conveyor belt should come to a halt after a certain run-on phase. Safety functions for the pneumatics must be defined.
Safety pneumatics are selected as the means of providing the two safety functions for the pneumatic drives used to position the roller. Solution for “reversing a motion” A valve manifold with two VSVA plug-in valves and piston-position sensing using proximity sensors plays a key role in implementing the safety functions for module 2 of the model installation. Assessment of solution in accordance with DIN EN ISO 13849-1 (maximum achievable values): Category = Cat 3 (2-channel) MTTFd = High (assuming certain application data) DC = Low CCF ≥65 % PL = d
We must determine whether the technical protective measures adequately minimise the risk based on this data. The detailed procedure from risk analysis through to a risk assessment and protective measures can be followed step by step in a web-based training programme from Festo Didactic: www.festo-didactic.com In upcoming editions of tia, we will bring you further articles on this subject, describing the hazards and protective measures associated with modules 3 to 5.
The gateway to growth in South India: the entrance to the Peacock Temple in Chennai
1.2009 trends in automation Synergies 30 31 –
Automation technology in India
The Magnificent South “Despite the worldwide economic crisis, India will continue to be an attractive market for automation technology,” emphasises Rashmikant Joshi, General Manager of Festo India. Machine and plant builders in the southern states of Karnataka and Tamil Nadu are driving the dynamism of the subcontinent.
W
e generally think of China as the country that has gained most from globalisation. People often fail to notice that India, the subcontinent with the world’s second-largest population and a steady economic growth rate of 7 to 8 percent, is just as interesting. Festo has had a national company in India since 1986, located in Bangalore, the capital city of the southern Indian state of Karnataka.
“India has an inexhaustible supply of potential workers available at low wages, which is why there was no demand for automation technology for a long time,” explains the General Manager of Festo India. “In recent years, the market for automation has grown annually by 10 to 12 percent, faster than India’s economy as a whole.”
The business of the future – today India’s economy has changed fundamentally since 1986. Foreign trade grew strongly when India opened up to international markets at the start of the 1990s. Since then, there has been an enormous rise in demand for modern production technology and high-performance infrastructural systems; this demand is so high that it cannot be met by domestic suppliers alone. This means that the foundation of India’s future is being laid now and orders are being placed accordingly.
All sorts of interesting applications The most important client industries for automation are the automotive, food, packaging, paper, printing, textile and machine tool industries. The machine construction sector had growth of almost 14 percent in 2007, while the automotive sector grew by as much as 22 percent, thus offering considerable potential for automation technology. Not only this, but Festo products are also in demand for all sorts of interesting applications, for example fast-switching valves for sorting rice and corn and Fluidic Muscles for crushing spices and shelling cashew nuts.
As Indian consumers request high-quality products in ever greater quantities and ever faster, the demand for automation technology also rises. Furthermore, Indian consumers are more and more concerned with safety, hygiene and user-friendliness. Nevertheless, the Indian automation market is still in its infancy, underlines Joshi.
Japanese methods Quality circles, Japanese production concepts and continuous improvement processes – in order to be able to survive in world markets, India’s manufacturing industry is adopting the success models of the world’s leading industrial countries. This has resulted in a steep rise not
“The demand for automation technology continues to grow at an above-average rate,” explains Rashmikant Joshi, General Manager of Festo India.
only in production volumes but also in the technical requirements for production equipment. Moreover, the expansion of the country’s infrastructure also demands high-performance machines. The globalisation of its economy and the opening up of its domestic market have given India enormous opportunities to develop a
A feast of colour: fruit and flower sellers in Chennai.
strong domestic market. Around one third of the population now rates as middle class and can afford high-quality consumer goods. This benefits established Indian companies which have been able to create monopolistic positions for themselves in their own market. Conglomerates are setting the pace Indian industry is defined by a number of large conglomerates such as Tata or Larsen & Toubro (L&T). Tata intends to conquer first the Indian car market and then the world market with its cheapest ever micro car. L&T builds installations and executes infrastructural projects, from airports to refineries. L&T is participating in the construction of an underground railway system in the Indian capital Delhi. L&T has also made a name for itself as a plant supplier for the automotive component-supply industry. Tyre presses and vulcanisation machines are sent from Chennai, the capital of Tamil Nadu, to well-known tyre manufacturers throughout the world. They appreciate L&T’s great experience in plant construction, the high level of flexibility and quality of its products and their good price/performance ratio. Around half the company’s machines are exported to Europe and Latin America.
Like a Maharajah’s palace: the Karnataka Parliament Building in Bangalore.
Identifying demand Festo has had its own national company in the thriving industrial zone of the southern Indian city of Bangalore for over 20 years. With 13 sales offices, Festo Controls Pvt. Ltd. has a presence close to all the Indian machine and plant builders in the country’s most important industrial regions. Offering a wide range of services, Festo India was soon able to become the market leader. At the same time as it began to sell automation technology, Festo also initiated the production of standard products for the local market. The Festo factory in Bangalore is a Global Production Centre for pneumatic cylinders, valves, fittings, tubing, service units and cylinder mountings. Today, the company manufactures around 2,000 different products and components and also supplies these to other Global Production Centres. Festo India imports a total of around 16,000 Festo products and maintains stocks of some 4,000 items in order to be able to meet urgent customer needs. Two freight flights a week between Frankfurt and Bangalore ensure that Indian customers do not have to wait very long for their goods from Germany. This is also how Festo supplies automation technology products to European and American companies who have production facilities on the Indian subcontinent. “The market offers considerable further development potential, particularly for sophisticated automation products,” explains Festo India General Manager Joshi. “This is why customer consulting is always accompanied by offers of training.” Hence the company has set up Training Centres in various cities and works closely with technical universities and training institutes.
1.2009 trends in automation Synergies 32 33 –
An astonishing development It is almost impossible to regard India as a single coherent economic area. The subcontinent is more fragmented than the European Union, with customs barriers between individual states and differences in business law, together with different scripts, languages and cultures which result in an unbelievable diversity. Bangalore has the reputation of being the world’s software house. In addition to electronics, the textile and automotive industries are also important in this metropolis of five million people. It is the capital of the Indian state of Karnataka (56 million inhabitants), is located on a high plateau which gives it a pleasant climate, and is an important centre for trade fairs and conferences.
50 % increase in turnover every year L&T’s unbelievable annual growth rate of 50 percent is due in large part to the booming Indian domestic market and to the fact that it has expanded its product range to cover tyres for mining and offroad vehicles. The company is the market leader in this product segment. Pneumatic automation technology is used to hold, clamp, pull and lift the tyre carcasses. “The pneumatic components must be robust and reliable,” says K. Subramaniam, Deputy General Manager of L&T in Chennai. Failures would be
India’s most southerly state, Tamil Nadu (65 million inhabitants), is one of the most important industrial centres in India. The capital city Chennai, formerly known as Madras, is home to 3.8 million people. Its important industries include not only textile but also automotive and chemicals. The Korean car manufacturer Hyundai builds vehicles on the tropical coast of the Indian Ocean in Tamil Nadu. India is the second most important market for the Finnish mobile telephone manufacturer Nokia, after China but ahead of the USA. Nokia has a factory in Chennai with 4,700 employees. The number of employees in the Nokia Industry Park is planned to rise to 30,000 in the near future.
pretty serious as most customers expect several decades of operation. L&T accordingly relies on Festo’s well-proven valves and drives, for example DNC cylinders and the ISO Tiger valves widely used in the automotive industry. Growing demand for complete solutions More and more of the pneumatic drives on L&T vulcanisation machines – including process valves to control water vapour and dirt particles – are now triggered by modern metal valve terminals VTSA. The modular design of the VTSA enables a high level of flexibility right from the plan-
ning stage and makes the valves easy to service after installation. The system consists of manifold sub-bases and valves. The sub-bases are bolted together and form a support system for the valves. “In addition to pneumatic components, L&T is asking more and more often for complete solutions,” explains Venkatamaran Ravi, the Festo Sales Engineer responsible for the L&T factory in Chennai. For example, Festo India supplies ready-toinstall control cabinets with all the necessary control equipment from its own assembly factory in Bangalore. The control cabinets are ready to operate and can be installed next to the appropriate machine. “This means that we can concentrate fully on our own machine layouts and do not need to worry overly much about pneumatic or electrical automation technology,” reports Subramaniam delightedly, referring to Festo’s services which are perfectly tailored to his company’s needs.
www.larsentoubro.com Vulcanisation machine built by Larsen & Toubro: 50 percent growth in sales each year.
Service included: high demand for ready-to-install control cabinets, both from Larsen & Toubro and other customers.
Quality assurance for fuel cells
Automatic testing Fuel cells have yet to make their great breakthrough. Less expensive components with better chemical stability may change this situation. That’s why balticFuelCells GmbH has developed a high-quality test device called “quickCONNECTfixture”.
R
eliable test tools are just as vital for the development of new fuel cell components as for quality assurance,” says Christian Graf, Sales Manager of balticFuelCells GmbH in Schwerin. He should know – his company has designed a test device, the “quickCONNECTfixture”, which uses a worldwide patented process to carry out functional and quality testing of fuel cell components. It enables targeted compression to be applied to the active surface of a membrane electrode assembly (MEA). “The most important internal components are measured using a defined contact pressure,” explains Christian Graf. This contact pressure can be endlessly va-
ried via a pneumatic short-stroke cylinder type ADN. This enables test conditions to be reproduced very precisely. Further advantages are the compact size of the short-stroke cylinder and its protection against torsion. Festo offers other products perfectly matched to the ADN, such as solenoid valves and silencers. Precise to 1 micron The compression measurement device (CMD) is a supplementary test device. It tests firstly how various contact pressures affect the thickness of the fuel cell components. Secondly, it makes it possible to determine how component thickness under a certain contact pressure varies
quickCONNECTfixture consists of two parts: a quickCONNECT pressure unit and a “cellFixture”. The cellFixture securely holds the components to be tested by means of metal clips.
as a function of time, or what influence operating conditions such as humidity and temperature have. “We can thus home in on effects such as the swelling behaviour of the membrane or the creepage of components,” says Christian Graf. “This in turn makes it considerably easier to select fuel cell components for series production.” The CMD can be connected directly to the quickCONNECTfixture and measures changes of thickness to an accuracy of 1 micron. For PC-supported measuring cycles, a proportional pressure regulator type VPPE is used in addition to the displacement sensor. The contact pressure generated by
1.2009 trends in automation Synergies 34 35 –
balticFuelCells GmbH Hagenower Str. 73 D-19061 Schwerin www.balticfuelcells.de Area of activity: Development and sale of highquality test equipment for the evaluation of internal PEM fuelcell components.
the short-stroke cylinder can be varied by the regulator via software, while the measured results can be evaluated on a PC. It is thus possible to carry out series of measurements fully automatically, even overnight.
The pneumatic compact cylinder ADN provides infinite regulation of the contact pressure.
Basic material for fuel cell components: graphite flow fields.
Quality assurance for solar cells
Spotlighting faults The photovoltaic industry is booming. Suppliers with the right products can earn themselves a place in the sun – like RENA GmbH. To automate its wet-chemistry process installations for solar cells, this machine constructor chose the compact vision system SBOC-Q.
S
The intelligent vision system SBOC-Q from Festo checks wafers for breakages around the edges.
ilicon wafers form the basis for the production of solar cells and are subject to extremely stringent quality requirements. For example, chips at the edge must not be larger than 2 mm. Damaged or dirty surfaces can also impair efficiency. This is where RENA GmbH comes in. As a specialist in wafer cleaning and pickling, this company’s process technology for wet–chemistry applications is regarded as world-leading. Up to now, this supplier has installed over 120 automatic semiconductor production lines worldwide and over 500 photovoltaic production lines.
testing, users select data for the desired wafer type which has previously been stored in the master controller; this then signals the desired type to the fieldbus node of a CPX terminal. The controller CPX-FEC selects the right test program in the vision system memory and sets an inspection area appropriate to the wafer size. The vision system then checks the wafer for cracked edges using a transmitted-light method. “The fact that the inspection field limits vary according to the test program was what made us choose the Festo compact vision system,” explains Christian Weber, Product Manager for RENA wafer-transfer systems.
Flexible and variable size of inspection field To ensure that solar wafers and cells meet the highest requirements, RENA relies on the intelligent compact vision system SBOC-Q from Festo. In order to carry out
Use with different systems RENA uses vision systems in its process technology in two different steps: “In the first part, the wafers are taken from stacks or holders – the so-called carriers – and fed to the vision system,” says Weber of
1.2009 trends in automation Synergies 36 37 –
RENA GmbH Ob der Eck 5 D-78148 Gütenbach www.rena.com Area of activity: Process technology for wetchemistry applications, e.g. for the photovoltaic and semiconductor industries.
The silicon wafers are removed from the carrier and fed to the vision system for quality inspection.
Three questions …
The conveyor system presents each solar module to the vision system installed above the station.
the first process. Depending on the results of the test, the wafers are then sorted or fed according to size onto one of up to ten tracks before being fed to a wet-chemistry machine. In the second part, the wafers emerge from this machine, are fed to the vision system and, after passing the test, are placed in accordance with users’ requirements. “It was above all the flexibility of the compact vision system that convinced us,” says Weber of the reasons for his choice.
Maximilian Schnackenburg Product Management Machine Vision and Control Systems
trends in automation: Festo is still considered primarily to be a pneumatics specialist. How did Festo decide to include its own vision solutions in its product portfolio? M. Schnackenburg: Festo’s roots are of course in pneumatics, but as a specialist in electric drive technology and a subsystem supplier for handling and assembly technology, it is necessary for Festo to offer vision systems too. These are a vital part of this range of applications.
What are the particular highlights of this machine vision solution? M. Schnackenburg: Festo’s compact vision systems are available in different variants: with VGA and high-resolution sensors, in monochrome and colour and with different optical sensors. The highlights of all systems include a compact industrial design, a wide choice of networking options and very fast vision sensors. How is a vision system integrated in an automation environment? M. Schnackenburg: Firstly, of course, via the integrated inputs and outputs. In addition, the systems can also be connected to all usual fieldbus systems via CAN and the Festo CPI installation system. Not only that, but we also provide an Ethernet interface on each system, which can be used to connect to industrial PCs, PLCs and Festo displays.
Worldwide further training Comprehensive range of seminars from Festo Didactic 40 years’ experience in training, 20 years in process optimisation, every year around 30,000 participants from more than 50 countries attending over 2,900 seminars in more than 50 countries – these figures speak for themselves.
Tickets for Calgary Festo wins vocational competition
This year, Festo is once again offering trainers modular and quality training materials. For an overview, have a look at the new seminar brochures “Products for Trainers 2009”, “Technological Products 2009” and “Development of value creation systems”.
Seminars from Festo Didactic: Modular and quality-assured training in over 39 languages.
www.festo-tac.com
Festo on the Mekong Delta 57th national company founded Ho Chi Minh City is the economic centre of Vietnam and has over 5 million inhabitants. It is here that Festo founded its 57th national company in February of this year. Festo Vietnam has 16 employees, with Johnny Ng as General Manager. Winners of the mechatronics vocational competition: Florian Haizmann and Jochen Spohrer from Festo
The 3rd SkillsGermany vocational competition was held this year at the Hanover Trade Fair in the disciplines of mechatronics, mobile robotics and electrical engineering. Apprentices from all over Germany competed for the German championship, and thus the title 2009 SkillsGermany National Champion. The Festo team won the mechatronics competition. The championship title is also the winners’ ticket to participate at the WorldSkills vocational world championships, which will be held in the Canadian city of Calgary in September 2009. Festo initiated competition in mechatronics 17 years ago, and took over sponsorship of WorldSkills Mechatronics. The company also supports SkillsGermany in the disciplines of mechatronics and mobile robotics. www.worldskills.com
Halong Bay in the north of Vietnam: With around 2,000 islands and an area of 1,500 km2, it is one of the most impressive landscapes on earth and was declared a World Natural Heritage Site by UNESCO in 1994.
1.2009 trends in automation Festo worldwide 38 39 –
Function, quality and innovation Design awards for Festo The prize-giving for the iF product design awards took place in March as part of CeBIT 09. All six products entered into the competition by Festo won one of the coveted awards.
Otto Bauer, General Manager of Festo Turkey (left) and General Consul Matthias von Kummer (right) at the presentation of the Order of Merit on ribbon.
Order of merit for Otto Bauer General Manager of Festo Turkey receives honour Otto Bauer (55), General Manager of Festo Turkey since 1989, has been awarded an Order of Merit on ribbon by the Federal German President; it was presented to him by General Consul Matthias von Kummer at the end of 2008 in Istanbul. He praised Bauer’s exceptional commitment to the promotion of German-Turkish relations, his contribution to the continuous improvement of technical training and his work associated with the training of disadvantaged children.
The international jury for the iF product design award 2009 awarded 802 prizes this year. A total of 2,808 products by 1,025 participants from 39 countries competed for the prestigious international awards. This year was the first time that competitors could register in 16 product categories. The products from Festo won awards in the Industry and Skilled Trades category. One of the products from the award-winning series is the SME/SMT-10M proximity sensor. Just 2.5 mm long, yet highly functional. Clearly arranged operating instructions on the product together with the product-specific design statement mean the product is essentially selfexplanatory. This increases the safety and accuracy of the product, while also making it easier to use and time-saving.
Despite his managerial responsibilities for Festo, Otto Bauer is engaged in various other business activities. He is, for example, a founding member of the Turkish-German Chamber of Commerce in Istanbul, advises the local machine construction industry and helps smaller companies to develop and expand.
Joint venture with LeekSeek Finding and fixing leaks – modernising industrial plant
LeekSeek finds leaks in production installations and documents them in a web-based software program.
www.leekseek.com
Festo and LeekSeek International Ltd., the specialist in leak management, have entered into a joint venture to combine their know-how about the efficient use of compressed air. Operators of pneumatic installations can thus access a comprehensive service package aimed at saving compressed air. The services help localise leaks and document these in a leak management software program. They also offer support in developing and implementing repair and modernisation concepts. Based on this leak management system, Festo offers its customers an on-site service to eliminate the leaks that have been detected.
iF product design award winner from Festo: the proximity sensor SME/SMT-10M.
Durability distinguished Busse Longlife Design Award for valve terminal CPV
High performance density in a small space: the valve terminal type CPV is the world’s best-selling valve terminal for use with pneumatic drives.
Joint venture in the training market Festo sells EPLAN Education training software
Products selected as winners of the Busse Longlife Design Award need to have special qualities: durability, sustainability and cost-effectiveness. The products must have been available on the market for at least eight years, at least 100,000 examples must have been sold and generated sales worth more than one million euros. None of this is a problem for the Festo pneumatic Compact Performance valve terminal CPV. Launched in 1996, it is the bestselling control device for pneumatic drives.
FIRST LEGO League Fun with technology at the Festo Technology Centre
International: available in 16 languages, the software can be used in every market worldwide.
Since the start of the PLC/IPC/Drives 2008 exhibition, Festo Didactic has been selling the industrial training software EPLAN Education, made by EPLAN Software & Service. Thanks to this joint venture, Festo has been able to expand its portfolio to include a leading international engineering solution. Conversely, EPLAN benefits from the worldwide presence of Festo Didactic. EPLAN Education features network-capable classroom licences for the current systems EPLAN Electric P8, EPLAN Fluid and EPLAN PPE. All these systems use the same database and communicate directly without interfaces. The software EPLAN Fluid has a link to the Festo xDKI product catalogue, thus making the planning of fluid engineering projects easier. The software is also suitable for international marketing as it is available in 16 languages and can be deployed in all markets.
FIRST LEGO League promotes fun with technology – a team of schoolchildren participating in a competition in the Technology Centre of Festo AG.
Planning, building and programming: the FIRST LEGO League promotes fun with technology with a robot competition which can lead to a world championship. The first competition in the FIRST LEGO League took place 10 years ago. “Stand by your modular systems – ready, steady, go!” was the motto at the regional competition in November in the Festo Technology Centre. In this building, usually occupied by adults discussing, developing and planning work, schoolchildren aged 12 to 16 were able to demonstrate their enthusiasm and creativity in finding solutions to tricky tasks. This was also fun for the numerous spectators to whom Festo opened its doors.
www.eplan.de
1.2009 trends in automation Festo worldwide 40 41 –
Hanover Fair 2009 Chancellor Angela Merkel visits the Festo Stand
About this magazine trends in automation 1.2009 – July
Left to right: Han Seung Soo, Prime Minister of South Korea; Christian Wulff, Premier of Lower Saxony; Chancellor Angela Merkel; Dr. Ekkehard Gericke, Director of Product Supply, Festo AG; Dr. Wilfried Stoll, Chairman of the Festo AG Supervisory Board (photo: Festo)
During her visit to the Hanover Fair on April 20, 2009, German Chancellor Angela Merkel was given a tour of the stands and got to witness the innovative ability of Festo first hand. The Chancellor was particularly interested in bionic solutions designed to facilitate efficient production in the future. She tried out the prototype for a bionic gripper, a breakthrough in automation that can securely grip and deposit even fragile or irregularly shaped objects such as a light bulb, for example.
Publisher Festo AG & Co. KG Ruiter Straße 82 D-73734 Esslingen Project Management Silke Gartenmeier, Customer Magazine Phone + 49 711 347-3902 gtm@de.festo.com Responsible for content Dirk Ebertz, Head of Marketing Instruments dbrt@de.festo.com Ralf Sohn, Head of Direct Marketing rso@de.festo.com Copyright 2009 Festo AG & Co. KG All rights reserved. All images, graphics and texts are covered by copyright or other laws to protect intellectual property. Copying or modification of contents or their use in other printed or electronic publications is permissible only with the express approval of Festo AG & Co. KG.
1.2009 trends in automation Soft Stop 42
Why are you so interested in speed, Dr. Gericke? As Director of Product Supply for Festo AG, I am, as my title suggests, responsible for a fast and reliable supply of products. This means first of all the step from the initial product idea to the product being ready for marketing; and secondly, the route from a customer order to the moment customers receive their goods. If Festo wishes to be the performance leader, we must be faster and more reliable than our competitors. Every year, we launch 100 new products so our product range is constantly expanding. We also need to make sure that the goods reach our customers quickly and reliably. 96 percent of our sales in Western Europe are supplied as direct deliveries. This means that the goods are supplied from our Customer Service Centre (CSC) directly to customers throughout Europe. That enables our national Festo companies to concentrate on customer service and order processing. The advantage for our customers is that we do not waste time in the national companies transferring goods into and out of store and that we can deliver quickly and on time. As direct delivery is so successful, we have extended the model to other areas in the form of Regional Service Centres. In addition to fast on-time delivery of our standard product range, we offer a unique delivery service in Europe for configurable products. No more than 24 hours after placing an order, our customers have the products they need in their loading bay – anywhere in Europe. In the field of System Solutions, which is the assembly and delivery of complete ready-to-install subsystems, we are also better and faster than our competitors. We assemble a certain proportion of the systems “close to the warehouse shelf”, i.e. directly in our CSC in St. Ingbert-Rohrbach. The result is that customers receive fully-assembled, ready-to-install modules within a very short time, tested and documented by us. Customers occasionally need special solutions that require technical modifications to our products. After receiving a suggested design solution, customers usually like to see a prototype quite quickly. This year we launched the “Festo Fast Factory” project, a high-speed production concept with which we intend to speed up the production of prototypes. After a discussion and product definition phase, a working prototype finds its way onto the customer’s desk within a few days. That has made us even faster than before. After all, at Festo we sell not only pneumatics but speed as well!”
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Australia Head Office Festo Pty. Ltd. Melbourne 179 –187 Browns Road Noble Park Nth VIC 3174 Call Toll Free: 1300 88 96 96 Call Toll Fax: 1300 88 95 95
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Branch Offices Busan Tel: +82-(0)51-205 4921 Changwon Tel: +82-(0)55-288 7797 Cheonan Tel: +82-(0)41-533 4871
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Branch Offices Bandung Tel: +62-22-732 1329, 732 1330, 732 0753
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Batam Tel: +62-816 50 23 10 Cikarang Tel: +62-21-893 67 49 Glodok Tel: + 62-21-659 97 69-70 Makassar Tel: +62-813 42 05 52 00 Medan Tel: +62-61-453 89 35, 452 00 11 Semarang Tel: +62-24-355 66 53, 355 48 24 Surabaya Tel: +62-31-849 10 44, 841 05 12 Iran Festo Pneumatic S.K. #2, 6th street, 16th avenue, Km 8, Special Karaj Road, P.O.Box 15815/1485 Tehran 1389793761 Iran Tel: +98-(0)21-4452 2409 Fax: +98-(0)21-4452 2408 Branch Offices Esfahan Tel: +98-(0)31-1235 7148 Tabriz Tel: +98-(0)41-1524 1809 Japan Head Office Festo K.K. 1-26-10 Hayabuchi Tsuzuki-ku, Yokohama 224-0025 Tel: +81-(0)45-593-56 10/-5611 Fax: +81-(0)45-593-5678 Branch Office Osaka Tel: +81-(0)6-6320-3427 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
Daejeon Tel: +82-(0)42-861 7797 Gwangiu Tel: +82-(0)62-955 4168
Ulsan Tel: +82-(0)52-292 4215 Malaysia Head Office Festo Sdn Berhad 10 Persiaran Industri Bandar Sri Damansara 52200 Kuala Lumpur Tel: +(60 3) 62 86 80 00 Fax: +(60 3) 62 75 64 11 Branch Offices Penang Tel: +(60 4) 643 0918
Cebu Tel: +63 (32) 345-1120 Cagayan de Oro Tel/Fax: +63 (88) 857-4904 Davao Tel/Fax: +63 (82) 299-4275 General Santos City Tel: + 63 (83) 382-0005 Iligan Tel/Fax: +63 (63) 221-1966 Tarlac/Pampanga Mobile Phone: +63 (0928-5028288) Zamboanga City Tel: +63 (62) 991-0489 Singapore Festo Pte Ltd. 6 Kian Teck Way Singapore 628754 Tel: +65-62640152 Fax: +65-62611026/62659276 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
Ipoh Tel: +(60 5) 548 1002
Branch Offices Hsinchu Tel: +886-3-658-8318, 658-8307
Johor Bahru Tel: +(60 7) 352 3719
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Malacca Tel: +(60 6) 335 1018
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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 Christchurch Tel: +64-(0)-33488796
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Hamilton Tel: 64-(0)-78466080
Northern Branch/Lamphun Tel: +66 (0) 53 58 13 37-9
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
Saraburi Tel: +66 (0) 36 31 54 10
Branch Offices Bacolod and Iloilo Tel/Fax: +63 (34) 434 3341 Baguio Tel: +63 (74) 447-0394 Batangas Tel: +63 (919) 275-5857
Vietnam Head Office Festo Co. Ltd 206 Tran Nao Street, Binh An Ward, District 2 Ho Chi Minh City Vietnam Tel: +84 (8) 37406909 Fax: +84 (8) 37406910 Hanoi Sales Office 3rd Floor, New Center Building 27/41 Tran Duy Hung Street Cau Giay, Hanoi Tel: +844 35561509 Fax: +844 35561510 Da Nang Tel: +84 (511) 3759324