No. 12, 2008
In focus “Safety first” Minimising risk with safety-related pneumatics
Valves and valve terminals “3x the choice with ASi” Creating decentralised solutions with the new valve terminals
Control systems “On the safe side” Checking fuel injection sleeves with compact vision systems
Handling and assembly “Discover the possibilities” Positioning Drives software for electrical drive systems
www.festo.com
Trends in Automation Nr. 11, 2007
Safety rules
Yosemite National Park, October 2007: Two extreme climbers stand at the foot of the 1000-metre granite monolith El Capitan, one of the world’s most famous challenges for rock climbers. Their goal: to reach the top in record time. Each grip and step must be precisely executed and teamwork is key. An attempt such as this requires maximum safety – even the slightest lapse of attention or failure to consider a risk can quickly lead to dangerous situations. It’s the same in automation. The high dynamics that are often involved require coordinated system components. The interaction between man and machine must be harmonious, possible risks should be identified in advance and the pneumatic system designed in such a way that risks do not occur or are systematically avoided. Safety for man and machine is the top priority. Minimising risks with safety-oriented pneumatics means ensuring the safe operation of machines and systems at all times. “trends in automation” addresses this topic in the cover story “Safety first”. Festo covers the key relevant safety functions, whether the safe pressurising and exhausting of system components, manipulation protection or the stopping and blocking of movements, with pneumatic as well as servo-pneumatic products and solutions. Read more on page 4.
By the way, the two exceptional athletes Alexander and Thomas Huber completed their speedy ascent in 2:48.35 hours – 15 seconds faster than the previous record that had not been broken since 2002.
The “trends in automation” Editorial team
In focus Safety first Safety-related pneumatics: minimising risk with the valve MS6-SV and clamping units DNCKE-S.
4
Newsticker New products, events and newsflashes.
8
Handling and assembly Ideal gripper type The servopneumatic proportional gripper HGPPI in the assembly of A/C system controllers. 10 Discover the possibilities Fast and reliable: Positioning Drives software calculates electrical drive systems for every application. 12 On the sunny side Solar modules: spindle axis DGE-SP and servo drive MTR-DCI position the dispenser heads. 14
Valves and valve terminals 3x the choice with ASi Realising decentralised solutions with the valve terminals MPA, VTSA and CPV for AS-interface. 17 When space is tight The valve series VOVG is available as an individual valve, valve manifold and directly integrated. 20
Industry specific solutions Divine purity Clean water: decentrally installed CPX/FECs control 28 filtration tanks with shut-off valves. 22 On the safe side Compact vision system SBOI-Q check sleeves for vehicle fuel injection systems.
24
Reliable welding connections Pneumatics, logistics services and training courses are on board for the construction of ship blocks. 26
Services and products ATEX – now ready to install! Systems in areas of explosion risk: assembled and tested complete systems with full documentation. 28
Automation worldwide Applications – from Argentina to Indonesia.
30
Infoservice, Editorial
34
In focus
4
Greater safety: avoiding accidents with state-of-the-art safety technology In use Soft-start and exhaust valve MS6-SV, clamping units KEC-…-S and DNCKE-S Benefits • Reliable pressurising and exhausting with the MS6-SV • Braking with KEC-…-S and DNCKE-S
Safety first
Safety standards are becoming more and more important. The requirements span the entire control sequence – from compressed air preparation through drives and valves to controllers. Consequently, the industry’s declared objective is to make processes and systems as safe as possible.
5 Exhausting system parts
4 Pressurising system parts
3 Reducing pressure and force
Normal operation 6 Maintaining pressure
Initial position, standstill
2 Two-hand control
Setting and service operation
1 Force-free switching
7 Manipulation protection
Emergency operation
8 Reversing movements
9 Reducing speed 10 Pausing and blocking movements
10 Safety measures for 4 operating states
trends in automation No. 12, 2008
5
Klaus Gabriel, safety technology expert at Festo: “The safety functions for pneumatics can be summarised in approximately 10 functions. For these safety functions, we offer either individual products or complete solutions for realising safety functions in a system. Safety measures that can be integrated in a product offer our customers many advantages. As a result, elaborate calculations and certification of conformity with standards are no longer required, saving a lot of time and expert knowledge.”
Increased safety standards and the new machine directive coming into effect at the end of 2009 make safety technology a much discussed topic. Safety is a hot topic for Festo too, both in the process industry and in industrial automation and is relevant for all automation levels and products. Machines have to be constructed in such a way as to avoid physical damage. Certain safety measures can prevent hazards in all operating states of a machine. At the same time, the use of safety technology minimises the risk of liability.
Forewarned is forearmed The machine directive prescribes risk assessment and possibly risk reduction for machines. The risk assessment then serves as a basis for deriving and defining safety measures. The primary goal when designing a new system is to identify risks in advance and, if possible, to eliminate them through appropriate planning. Since risk can never be eliminated fully, this residual risk must be minimised or eliminated by means of technical safety measures, for example using safety-related pneumatics. These safety goals are achieved
using various safety functions. In this context, reliable operation of the machine in all modes and phases of the machine’s service life must be taken into consideration. For this reason, safety-related pneumatics offer solutions for commissioning through automatic and manual operation to emergency functions such as reliable stopping or exhausting. The three steps of risk analysis According to EN ISO 12100, a risk analysis essentially comprises three steps: first the machine’s limits are determined, next the
risk situations are identified and finally the risk assessment is carried out. Depending on the outcome of the risk assessment, either design-based safety measures or technical safety measures must be defined. This process is repeated over and over until the residual risk is reduced to an acceptable level. As a general rule, the simpler the safety technology used in the application, the more efficient it is. The complexity of the safety technology is typically determined by the range of risk possibilities
Key safety related standards at a glance Mechanical: • Forced control (contours, cams) • Pneumatics • Hydraulics
Electrical, electronic: • Sensors • Relays • Controllers (hard-wired logic)
Programmable, electronic: • Programmable mini control systems • Reliable bus systems • PLC safety
old: EN 954 new: EN ISO 13849-1 DIN EN IEC 61508 series Mechanical engineering DIN EN IEC 62061, process industry DIN EN IEC 61511
trends in automation No. 12, 2008
6
In focus ... Safety first
that require individual attention. Standardised implementation of safety technology is therefore very difficult. Two examples for greater safety: 1. Braking with KEC-…-S and DNCKE-S Whether in response to power failure, a requirement of the safety function, intermediate stops for service units, pressure failure or drop, the clamping unit KEC-…-S provides braking action within precisely defined tolerances by means of a clamping component acting on a rod by spring force. It provides this action over sustained periods, in applications involving varying loads, irrespective of fluctuations in the operating pressure and unaffected by system leaks.
Both the clamping unit DNCKE-S and the clamping unit KEC-…-S are approved as holding devices and as brakes for use in safety-relevant control systems. With appropriate additional measures, however, they can also be used for accident prevention in control systems of a higher category. The components are certified by the BGIA (Occupational Safety and Health Institute), affirming their particular suitability for safety requirements.
ic system according to the requirements of ISO 13849-1. This means that the pneumatic safety measure of reliable exhausting is ensured even if defects occur within the valve. But that’s not all – the safety check of the piston rod position is performed directly by the valve during the self test. This means less complicated wiring, which simplifies installation.
2. Reliable pressurising and exhausting using MS6-SV The BGIA-certified soft-start and exhaust valve MS6-SV serves as a decentralised/centralised unit for supplying machines and systems with compressed air. It is a self-testing redundant mechatron-
Clamping unit KEC-…-S • Sizes: 16, 20, 25 mm • Static holding forces: 1,300; 3,200; 8,000 N • Assembly: Wide selection of mounting options Cylinder with clamping unit DNCKE-S • Function: Double-acting • Sensing • Dimensions: ISO 15552 and VDMA (apart from the length) • Piston diameter: 40, 63, 100 mm • Stroke length: 10 ... 2,000 mm • Static holding forces: 1,300; 3,200; 8,000 N • Cushioning: Adjustable pneumatic end-position cushioning • Assembly: Wide selection of mounting options
Soft-start and exhaust valve MS6-SV • Safety measure: Gradual pressurisation, adjustable (soft start), fast reliable exhausting • Size: MS6 • With/without safety silencer • With/without pressure gauge • With/without pressure sensor SDE1 • With indicator output (floating) • With LED status display
trends in automation No. 12, 2008
Infoservice
7
is 1201 Safety technology – pneumatic positioning
Attention: New machine directive! The new machine directive comes into force on 29.12.2009. There will be no transition period. EU countries are required to incorporate the machine directive into national law by the end of 2009. Among other things, it contains safety and health protection requirements for the design and construction of machines. The manufacturer is furthermore required to carry out a risk assessment. To this end, the manufacturer is required to determine the limits of the machine, to identify hazardous situations and to estimate and evaluate risks. The system manufacturer is obliged to implement suitable safety measures to reduce the risk to an acceptable level.
2006
2007
2008
2009
2010
2011
December 29, 2009
old machine directive
Europe
May 2006 EN ratification
Incorporation into national law
new machine directive
November 30, 2009
EN 954-1 May 8, 2007 Listing in the EU official journal
EN ISO 13849-1
Germany
February 2007 withdrawn by DIN
DIN EN 954-1 October 2, 2006 EN ratification
February 2007 DIN ratification
DIN EN ISO 13849-1
EN 954-1 initiates assumption of conformity with the machine directive 98/37/EC EN ISO 13849-1 initiates assumption of conformity with the machine directive 2006/42/EC and 98/37/EC
trends in automation No. 12, 2008
8
+ + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + +
Vacuum technology
Compressed air preparation
Secure gripping
A wealth of booster variants
The vacuum security valve ISV not only ensures absolutely secure gripping, it also prevents loss of vacuum if a suction cup has not gripped the workpiece. The ISV closes the vacuum line or supply in the case of a parallel arrangement of several suction cups if there is a leak or if the workpiece accidentally drops off at one or more suction cups. The integrated filter prevents dirt attracted by the vacuum suction cup from getting into the vacuum circuit. The vacuum security valve is harmonised with the comprehensive suction gripper range ESG. This facilitates selection of the perfect connection size – for cost-effective use.
Pneumatic pressure booster DPA: the broad range comprising three different diameters and two pressure ranges for each gets a boost. DPA-…-D: The control-free price-optimised variant of the DPA range ensures twice the operating pressure in all sizes. DPA-…-A: Thanks to the integration of a magnet on the new piston system, this booster offers sensing options for cycles or response times and thus information about the service life as well as oversizing and undersizing. DPA-…-CRVZS2: Pre-assembled and easy to order with reservoir, pressure regulator and all accessory parts such as pressure gauges and tubing.
www.festo.com/en/esg
Sensors
Valves and valve terminals
Short ...
Pure integration
... and sweet: this is precisely the advantage of the proximity sensor SMT-8G/10G. With its extremely short overall length in the direction of the slot length, it is the optimum sensing solution for grippers and all compact drives. Housing parts or cable outlets projecting beyond the slot length in the direction of the gripper jaws are thus a thing of the past. The sensor is equipped with a sturdy robot quality sensor cable and two LEDs. It is mounted quickly and easily using a standard 1.5 mm allen key.
Three valve sizes without adapters on one valve terminal – for up to 32 standard valves of widths of 18, 26 and 42 mm. These are not the only strengths of the valve terminal VTSA. Also worth mentioning is its standardisation and flexibility: 100 % ISO 15407-2 and ISO 5599-2 meet individual configuration options through to comprehensive function and system integration with up to 512 I/Os. But that’s not all: integration of all common fieldbus systems and Ethernet both in CPX-AIDA in metal design or CPX in standard design. Also included is error detection by means of the integrated diagnostic concept.
www.festo.com/en/smt-8g-10g
www.festo.com/en/vtsa
trends in automation No. 12, 2008
+ + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + +
Compressed air preparation
Valves
Filters at the start
Three new additions
Whether in terms of product range, functionality of components or services, the MS series from Festo offers a fully integrated concept. In addition to the sizes MS4, MS6 and MS9, the MS9 is now also available in a metal bowl design. Also included from the outset are fine (LFM-B), micro (LFM-A) and active carbon (LFX) filters. The size and rotational adapters AMV and RMV for adapting to the next size range up or down make compressed air preparation more efficient – thanks to mixed sizing.
These additions to the one-way flow control valves series are causing a sensation: the small, lightweight one-way flow control valve VFOC is the first choice when either money or space are tight. The optional tamper-proof cap ensures that the set flow rate can be securely maintained. The second new addition is the new VFOC series with push-in sleeve. Installation takes just seconds: insert in the cylinder via the integrated push-in sleeve, align and you’re ready to go. Completing the new trio is the valve GRSLA. The incorporated scale clearly shows the set flow rate and enables this to be reproduced at any time.
GRSLA VFOC VFOV
Brochures
Valves and valve terminals
Handing system overview
Impressive!
The 100 or so pages in this brochure are devoted entirely to the topic of automation using multi-axis and positioning systems such as pneumatic and electric handling modules, pick and place units, linear and three-dimensional gantries. A clear matrix offers the perfect decision-making aid. Also included is a CD-ROM with full system description in pdf format and numerous animations.
The maximum expandability of the valve terminal CPX/MPA surely sets a new world record: its internal serial communication and specific ASICs for valve actuation mean that up to 512 I/Os per fieldbus node are possible. 128 solenoid coils (e.g. for 3/2-way valves) and up to 8 additional power supply modules for pressure and voltage zones can be included. With the latest function integration, comprehensive diagnostics and integrated IT services. A true marvel for greater productivity and economy – in lengths of up to three metres!
is 1202 Handing system overview
trends in automation No. 12, 2008
9
10
Handling and assembly
www.festo.com/en/hgppi
Automotive supplier industry: Assembly of A/C system controllers In use Servop-neumatic proportional gripper HGPPI Benefits • High flexibility within a single system • Independent gripper jaw control, therefore no need to change grippers • No retooling times
Ideal gripper type For some time now the design and look of car models have been about more than just the body; even the controls inside the vehicle express the driver’s individuality and aspirations. So, for example, the controller for the A/C system in a sports car is different to the controller for the A/C system in a people carrier. Without flexible handling concepts, however, assembly systems are severely restricted. This makes the servo-pneumatic proportional gripper HGPPI with its independent gripper jaw movements the ideal type for custom solutions.
The custom engineering company axelius automation GmbH developed for Behr Hella Thermocontrol GmbH a flexible assembly system for electronic components for different variants of A/C system controllers. In this system, plugs are inserted into panels. In the next step, the panels are separated into individual circuit boards, tested on the ICT tester and packaged for final assembly of an A/C system controller. The servo-pneumatic proportional gripper HGPPI positions the plug over the circuit board; during the plugging operation it holds the plugs which are inserted into the panels with a force of 100 N per pin. “The proportional gripper can be adapted to different plug sizes flexibly and without costly conversion”, explains Bernd Büsser, project manager for systems engineering at axelius. “One signal from the system PLC via Profibus is all that’s
trends in automation No. 12, 2008
needed for adaptation to different plug dimensions.” Highly flexible The assembly step described is required since the plugs cannot be inserted in the reflow oven during manufacturing of the panels. This is where the HGPPI comes into its own as a flexible means of rationalisation. “Whereas before we could only insert a specific plug type on a specific panel type on a single assembly line, now we can produce a large number of variants with greater speed and flexibility”, says Peter Stillers, head of planning services at BehrHella Thermocontrol, delighted with the productivity growth generated by the new system. Independently adjustable jaws The servo-pneumatic gripper HGPPI combines mechatronics and microsystems technology in a single component, as it integrates
Infoservice
11
is 1203 Proportional gripper HGPPI
Producing large numbers of variants with greater speed and flexibility: with the servopneumatic proportional gripper HGPPI, costly conversion is no longer required.
gripper technology, electronics, a displacement encoder and valves. This mechatronic intelligence enables the small and lightweight gripper to move its jaws independently of one another and thus to grip a wide range of shapes, weights and workpiece surfaces. Without this, complicated gripper changes would be required. The gripper jaws are actuated via six piezo proportional valves in widths of 5 mm. The innovative piezo technology saves space and energy since energy is only supplied during the switching movement. Piezo ceramic bending actuators with propor-tional switching characteristics guarantee low energy consumption and fast cycle times. In the case of the servo-pneumatic proportional gripper, information about the displacement signal and the force is always available
to ensure controlled sequences thanks to the integrated electronics. The gripper fingers with their free and independent positioning offer maximum freedom of movement with an accuracy of Âą0.1 mm. Changing grippers or electric grippers calls for space, making the compact HGPPI the ideal type for assembly tasks of the future.
Station upstream of the ICT test: a robot transports the finished panels to the panel separator with the help of a gripper unit. The separator cuts the panels into the individual circuit boards that are later installed in the A/C system controllers. The gripper unit comprises a number of grippers of the type HGPT and uses gripping force retention to reduce the pressure. This enables the grippers to be set to an extremely gentle setting so as not to damage the circuit boards. The compact size of these T-slot grippers makes them almost customised for handling both delicate and small components.
Behr Hella Thermocontrol GmbH Products
Employees Contact
A/C system control panels, A/C system controllers, controllers for electric heaters, fan controllers, A/C system sensors 1,000 D-59557 Lippstadt www.bhtc.com
axelius automation GmbH Products Employees Contact
Assembly systems, testing technology, system construction 120 D-59555 Lippstadt www.axelius.de
trends in automation No. 12, 2008
12
Handling and assembly Positioning Drives: software tool for calculating electric drive systems Key features • Fast, reliable and convenient • Just a few application data need to be entered • Simple selection of the best possible solution
Discover the possibilities “Which is the right drive for my system? Is the selected drive accurately sized? Will the required speed be reached?” The “Positioning Drives” software provides the answer. It calculates the optimum electric drive system for each application quickly, reliably and conveniently.
Toothed belt drives, spindle drives or direct drives, servo motors, stepper motors or DC motors, ball bearing guides or plain-bearing guides – the abundance of alternatives poses a problem for the user: the correct drive must be calculated. To make the selection of the best possible solution as well as the associated components easier, there is now software to perform this calculation. Selecting the ideal combination from the wide and harmonised range of electric linear axes, motors, gearing, controllers and software becomes clear after a few application data have been entered. The tool can also calcu-
trends in automation No. 12, 2008
13
late the characteristic load values for the selected drive quickly and reliably through the specification of various project parameters. Switch on and go From start to finish, a calculation project involves a maximum of four steps. Step 1: Enter application parameters such as installation position, mass, stroke and precision. There is also an option for specifying the required travel time and of preselecting the drive technology. Step 2: Select the required solution package. These are sorted by motor and axis technology, component utilisation, cycle time or price to make selection easier. Step 3: The program then outputs detailed results such as motor characteristic, dynamic characteristic values, system data, product data and parts list; these are stored as a file and can be reused for ordering and preparation of machine documentation.
Looking for that little bit extra? As a supplier of complete solutions Festo has the ideal answer for every application, regardless of the requirements. The mechanical interfaces between pneumatic and electrical components are mostly identical, which enables a huge number of combinations. Plug and work makes commissioning easier, even without any specific previous knowledge. The components all come from a single source, with know-how and consulting included. “Positioning Drives” is not an offthe-shelf solution; it is precisely tailored to the customer’s task. Once the possibilities have been discovered, the customer makes the decision. You can find the latest version at www.festo.com/download.
The FCT is prepared for additions to the device family: each device type is supported by a separate software component or plug-in. Festo Configuration Tool FCT Simple commissioning of an electromechanical automation unit with just a few clicks of the mouse. The Festo Configuration Tool not only configures individual electromechanical drive systems, it also manages all electric drives within a system using one overall software project.
Further advantages: • Clear division of the screen into the navigator bar, workspace and online window for operating the drive • Guided sequences • The software rejects impermissible combinations • Directly supports selection of the mechanical drive • Sizing possible online and offline
trends in automation No. 12, 2008
14
Handling and assembly Bonding of solar cells In use Spindle axes DGE-SP with servo drive MTR-DCI for positioning adhesive dispenser heads Benefits • Accurate positioning of dispenser heads along the X-axis • Feed function along the Z-axis • Stop function for substrate plates
On the sunny side
The client list of ACI-ecotec, based in the Black Forest, reads like a who’s who of the solar energy industry. The company is achieving considerable market success with systems for the production of thin-layer solar modules. Electric linear drives, pneumatics and other automation components play central roles here.
Silicon, the most important constituent in solar cells, is the second most frequently occurring element on earth. However, turning it into the crystalline cell form previously required for photovoltaics takes a lot of work. Thinlayer solar modules are produced by applying photoactive semiconductors in thin layers to a low-cost substrate, usually glass. The lower material and energy consumption and the possibility of a high level of automation during production offer a considerable savings potential in comparison with crystalline silicon technology. The ecoContact system concept developed by ACI-ecotec for the production of thin-layer solar modules enables the construction of compact and customer-specific standardised production structures from 4x4 metre system mod-
trends in automation No. 12, 2008
ules. In principle, the system concept consists of a module for applying the conductive adhesive and modules for bonding in longitudinal and cross direction using tin-coated copper bands. Pneumatic and electrical components from Festo perform key functions in the individual modules. Precisely applied conductive adhesive Application of the bead of adhesive to the substrate plates is performed using CNC control in the conductive adhesive application module. This requires precision since applying too little conductive adhesive would not produce enough of a bond and too much conductive adhesive could result in short circuits. The two dispenser heads apply the adhesive at speeds of 70 to 100 millimetres per second. They are carried on
separate X-axes that work independently of each other. Integrated in the drive of the two electromechanical linear axes of the DGE are a motor, gearing and controller from Festo as well as power electronics with positioning control. This reduces the space required in the control cabinet and the need for extensive cabling. All that is needed to install the motor MTR-DCI is a cable for the power supply and a Profibus cable. The commissioning process can be performed directly on the MTRDCI via the LCD display or using the FCT (Festo Configuration Tool) on a PC. The two DGE linear axes along the Y-axes use toothed belts. They are connected using a cardan shaft and therefore require only one drive. Precision actuation of the axes enables the dispenser heads to apply adhesive beads
15
Dipl.-Ing. Karl-Heinz Menauer, Managing Director of ACIecotec GmbH & Co. KG: “Staff and management are equally enthusiastic about the principle of photovoltaics. Since we founded the company in 2004, our enthusiasm for innovation has been complemented by a strategy of driving new development, a strategy that has already been rewarded with some excellent results on the market. Among these successes are systems for the production of thin-layer solar modules, with components from Festo playing a central role. We attach great value to close and open partnerships with suppliers, such as we enjoy with Festo. It is very important for us to accept the challenges in this market of the future, for which Festo will become increasingly significant for us as a strategic partner.�
The application of the adhesive trail to the substrate plates calls for precision; this is achieved by means of CNC control in the conductive adhesive application module.
Two dispenser heads apply the adhesive at speeds of 70 to 100 millimetres per second.
with an accuracy of 0.2 millimetres. The bead length, distance between beads, recipes, etc. can be freely programmed. All work programs can be stored and called up at any time.
support bridge for programcontrolled transport and positioning of the substrate plate is driven by two axes from Festo. They move along their four-metre path with programmable acceleration and deceleration ramps and speed profiles. The positions can be approached at up to 18 metres per minute and are programmed by means of teach-in.
Speed and precision during bonding Once the adhesive has been applied, longitudinal bonding and cross bonding are carried out in adjoining modules using contact bands and bus bars respectively, made from tin-coated copper bands. These bonding modules use Festo toothed belt axes of the type DGE with recirculating ball bearing guides. Throughout the bonding process, each processing step requires transportation of the workpieces within the system as well as exact positioning. So, for example, the
Within the movement system of the bonding module, cylinders ensure speed and precision during the feed movement, centring, swivelling and gentle stopping of the table. They operate scissors for cutting contact bands and insulating strips and also carry out a range of other functions. They are actuated by means of specially designed valve terminals. Compact service units prepare the compressed air from the network to
In principle, the system concept by ACI-ecotect for bonding of thin-layer solar cells consists of a module for applying the conductive adhesive and modules for bonding in longitudinal and cross direction using tin-coated copper bands. The picture shows two modules for bonding the thin-layer solar cells in longitudinal and cross direction using tin-coated copper bands. The workpieces coming from the conductive adhesive application module are assigned to the two modules by the module in the centre. The ecoContact system concept enables the construction of a customer-specific standardised production structure from variable system modules.
trends in automation No. 12, 2008
16 Handling and assembly ... On the sunny side
Festo components at ACI-ecotec
Spindle axis DGE-SP-KF
Servo motor MTR-DCI
Compact cylinder ADVUL
Compact cylinder ADN
supply the systems. The control characteristics of pressure profiles can be programmed using the integrated proportional pressure regulator VPPM. The user can also choose between three specific profiles by pressing a button. The pressure regulator can be actuated via fieldbus thanks to the connection to the CPX terminal. Close cooperation between specialists has resulted in an extremely progressive system concept.
Proportional pressure regulator VPPM
Valve terminal CPV The two adhesive dispenser heads are carried on separate X axes that work independently of each other and consist of a spindle axis DGE-SP and a motor unit MTR-DCI with integrated gear unit and positioning controller.
A standard cylinder ADN acts as a stop for the substrate plates.
ACI-ecotec GmbH & Co. KG Products
Contact
trends in automation No. 12, 2008
Automation technology for assembly of small and micro products; process techniques such as selective soldering technique, CO2 snow jet cleaning and dispensing, customerspecific production systems D-78112 St. Georgen www.aci-ecotec.de
Valves and valve terminals
17
AS-interface Field of application • Upstream machine and system functions as in feeding units for material, in conveyor sections or for opening/closing magazines • Downstream handling and packaging stations • Process industry Key features • Increased productivity combined with reduced costs for installation and power consumption • High flexibility • Simple structure
3x the choice with ASi Decentralised solutions are becoming increasingly popular – and with them actuator sensor interface (AS-i) technology. Fast, cost-effective and robust, AS-interface is suitable for binary and analogue actuators and sensors along with small valve terminals. Even though it will soon be 15 years on the market, AS-interface is far from obsolete. The latest area of application: the valve terminals MPA, VTSA and CPV (Spec. 3.0) for AS-interface.
Typical applications for AS-interface include conveyor sections, sorting systems with branches covering an extensive area and upstream machine functions.
The market for AS-interface is booming. In 1997, there were 100,000 slave applications worldwide; since then, this number has increased to over 10 million. When it comes to wiring at the lowest field level, the fast and cost-effective AS-interface always comes third worldwide after Profibus DP and DeviceNet. In order to meet the increasing requirements, more up-to-date ASi specifications with
enhanced functionality and performance are constantly being developed (these new specifications are always downwards compatible with earlier ASi versions). Fast, easy, cost-effective An AS-i slave is the ideal way of controlling a pneumatic control loop system made up of limit switches, valves and cylinders. If it is well designed, it will result in
trends in automation No. 12, 2008
18 Valves and valve terminals ... ASI to the power of 3
ASi specification 2.0
2.1
3.0
Inputs
4
4
4/8
Outputs
4
3
4/8
Max. bus cycle (ms)
5
10
20 *
Number of digital slaves
31
62
62
Number of analogue slaves
31
31
62
Total I/O
248
434
992
–
•
•
Peripheral faults
* All slaves to Spec. 3.0, profile 7.A.7
-30 % -40 % -50 %
reduction in cycle times *
reduction in installation costs **
reduction in air consumption *
* Example: Tubing length reduced from 3 m to 0.3 m thanks to decentralised installation at the AS-interface ** In comparison with conventional wiring
Decentralised, compact and modular machine structure - economically and flexibly networked using AS-interface.
low energy consumption and optimum pneumatic sequences. Decentralised AS-interface installations with short tubing lengths and an optimised pairing of valves and drives offer a straightforward way of completing a network and a robust method of data transmission. In addition, they also reduce cycle times in a system by up to 30 % and air consumption by up to as much as 50 %. The switchable power supply (yellow/black cable) ensures flexibility and reduces logistics. The open system to EN and IEC standards reduces conventional installation costs by up to 40 %. A further advantage for the user: AS-interface networks can be seamlessly integrated into all common Fieldbus and Ethernet environments. 3x the choice with ASi New additions to Festo’s product range: the new generation of valve terminals CPV, MPA and VTSA is now on the market – with integrat-
trends in automation No. 12, 2008
ed AS-interface connections. They offer three additional options providing ASi with a wide range of different applications. The latest version of the valve terminal CPV uses the 7.A.7 profile of the ASI Spec. 3.0, making it the first of its type. It enables A/B operation with 4 inputs and 4 outputs per slave and opens the way for many new functions, solutions and potential savings with ASinterface. Flow rates from 400 or 800 l/min as well as double slaves with 8I/Os are available for selection. Up to 62 slaves per master significantly reduce system costs. Cylinders and sensors are connected to just one slave, reducing the installation complexity. The cycle time per CPV slave is a few hundred µs. The maximum bus cycle of 20 ms is reached once the network is fully expanded with 7.A.7 profile slaves. Neither additional configuration nor specialised programming knowledge is needed to
Infoservice
Festo valve terminals with AS-interface
is 1204
is 1205
AS-interface
Standard valve terminal VTSA
is 1206
is 1207
Valve terminal MPA
Valve terminal CPV
Valve terminal VTSA, Spec. 2.1
450.000 400.000 350.000 300.000 250.000 200.000 150.000 100.000
Valve terminal MPA, Spec. 2.1
50.000 0 1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
AS-interface – a growth market
Valve terminal CPV, Spec. 3.0
use ASI Spec. 3.0. All the slaves need is an ASi master also running on Spec. 3.0 – everything else looks after itself. MPA and VTSA for AS-interface Modular sub-bases, compact sizes, integrated inputs and selectable electrical connection technology (M8, M12, CageClamp, Harax, Sub-D) make the valve terminal MPA-ASi extremly flexible. With the 4I/O slave, the power can be supplied by either the yellow or the black AS-i cable, halving the costs of logistics. Both 4I/Os as single slaves and 8I/Os as double slaves are available; the flow rate sizes MPA1 and MPA2 can be mixed. Flow rates of up to 700 l are possible on the 2…8 modular valve positions that can be equipped with pressure regulators, gauges and several pressure zones. The sturdy metal design of the subbase and valve also makes the MPA-ASI durable. The technical data:
• ASi Spec. 2.1 • 31 slaves • 4I/Os per master • Fault bit and fault LED for each slave • Bus and auxiliary power supply looped through via 2x M12 • Diagnostics of each slave • Watchdog
product variants within the valve terminal range, Festo offers users a range of economical and technically harmonised automation solutions. The ever increasing demand in the market proves it – the potential for AS-interface is nowhere near exhausted.
The powerful VTSA valve terminal will be available with AS-interface from autumn 2007. It has a flow rate of up to 1800 l/min and modularity from 1 ... 8 valves – standardised to ISO 15407-2 and 5599-2. Its electrical data are the same as that of the MPA-ASI, however it also offers a shut-off plate for the hot-swap function that enables valves to be replaced under pressure. This makes it particularly well suited to controlling continuous processes where downtimes must be avoided. With over 30 products that support AS-interface and over 1 million
trends in automation No. 12, 2008
19
20
Valves and valve terminals
www.festo.com/en/vg
Valve series VOVG Field of application Standard pneumatics, handling systems, electronics/light assembly industry, process automation Key features • High flow rate with compact dimensions • Individual valve, valve manifold, direct integration
When space is tight What do you do if a shoe pinches when you try it on? The general advice is to go up a size. If, however, a mechanical engineer were to follow this advice, it might not go down so well with the customer. The rule here is the smaller, the better – and the more suitable! The new valve series VOVG is the ideal solution for the narrowest of spaces. Compact with an extremely high flow rate, the VOVG helps to keep machine dimensions compact.
Technical data • Flow rate: 200 l/min (100, 400 l/min) • Width: 10 or 12 mm (depending on the design) • Operating pressure range: -0.9 … 8 bar • Temperature range: -5 … 50 °C • Operating voltage: 5 V DC, 12 V DC, 24 V DC • Switching times (on/off ): 12/10 ms • Manual override: Pushing, pushing/detenting • Protection class: IP40
Where is the VOVG used? Wherever compact assembly is required, for example in compact handling systems in the field of standard pneumatics or in the electronics or light assembly industry. It can also be used in the process industry as a pilot valve for valves and drives coming into contact with other media. What are the advantages for the user? The narrow width of 10 mm or more does not mean having to sacrifice flow rate – using either an individual valve or a valve manifold. A flow rate of 200 l/min, for example, with the 10 mm width
VOVG as an individual valve ...
trends in automation No. 12, 2008
... on a PRS manifold
results in correspondingly high cylinder speeds. Furthermore, the VOVG can be mounted on-site. The response characteristics are now better at reduced minimum operating pressure. Higher performance, however, does not mean shorter service life. Quite the contrary; the durability has been proven at over 50 million switching cycles. Furthermore, the VOVG exhibits minimum leakage thanks to the reliable cartridge sealing system with piston spool, which in turn facilitates cost-effective operation. And on the subject of cost-effectiveness, the price/performance ratio is also impressive.
... as a customer-specific direct integration solution
Infoservice
21
is 1208 Valve series VOVG
VOVG supports process automation Two typical applications in process automation underscore the versatility of the new solenoid valves VOVG. Example: Valve control actuator Valve control actuators are used in process automation for actuating disk or double poppet valves. They comprise a displacement encoder, a fieldbus interface and up to 4 control valves VOVG.
How is the immense performance density achieved? Manifold rails can be used where an individual valve is not sufficient. For example, 8-fold valve manifolds with 200 l/min per valve and QS fitting. The next steps towards even greater individualisation is customer-specific valve manifolds. In this case, the key term for even greater performance density is direct integration. This is an extremely easy way of realising customer-specific interfaces and installation requirements. This increases the component density even further and simplifies handling.
Example: Controlled linear drive unit with slide Demanding environmental influences together with increased mechanical stress prompted customers to ask for a compact, sturdy and intelligent linear valve actuator. Festo responded to these requests with the type DLP-I that is used on sliding and gate valves. It comprises a displacement encoder, closed-loop control and four control valves VOVG and the proven linear actuator DLP – all hermetically protected. The required opening of the process valve is controlled through continuous comparison of setpoint and actual values.
trends in automation No. 12, 2008
22
Industry specific solutions
www.festo.com/processautomation
Water treatment for 300,000 inhabitants in the greater Paris area In use Decentrally installed CPX/FECs control 28 filtration tanks using Copac linear valve actuators for shut-off valves Benefits Sturdy and reliable solution with IP67 protection
Divine purity The river Seine was once protected by the Celtic goddess Sequana, after whom it is named. Her protection, however, did not extend to the industrial age, when cities such as Paris began pumping their sewage straight into the river. These days, however, the sewage treatment plant Les Grésillons is once again making sure that the Seine is clean – using automation technology from Festo.
Les Grésillons is presently treating 100,000 m³ of water from the Seine every day. This corresponds to a catchment area of 300,000 inhabitants. This figure will have tripled by the time expansion of the system is complete in 2015; it will purify the sewage produced by 1 million people in the greater Paris area and return it to France’s third largest river. Special filter technology Les Grésillons differs from conventional sewage plants with biological purification stages in that it uses special filter technology, not bacterial activation tanks. After the
trends in automation No. 12, 2008
mechanical purification stage using sand filters and screening units, the pre-treated sewage passes through three levels containing biofilters, specifically socalled Biolest technologies, where the nitrogen is removed from the sewage. The supply to the 28 biofilters as well as the backwashing process is controlled by process gates such as shut-off or butterfly valves using automated pneumatic actuators. Festo developed a special Copac linear actuator DLP with through piston rod for the 28 Fontaine shut-off valves without
Infoservice
is 1209 Partner to the process industry
Clean water in the Seine: thanks to biofilter systems in Les GrĂŠsillons. Fast detection of malfunctions via the diagnostic functions of the CPX/MPA.
Specially designed Copac linear valve actuator DLP with through piston rod: reliability for the non-housed shut-off valves of the filtration tanks.
housing to facilitate the use of a handwheel in emergencies. Each shut-off valve is equipped with two proximity sensors SME-8 for sensing the mechanical end stops and transmitting them to the controller. CPX for reliability 28 decentrally installed electrical terminals in conjunction with the valve terminal MPA actuate the drives and record all data relating to the 28 filtration tanks. Each tank has an interface with the centralised Allen Bradley controller via a DeviceNet fieldbus that is connected to the valve terminals. The CPX also integrates the Front End Controller FEC for managing the control circuits locally and ensuring safety positions. Its diagnostic functionality enable the CPX
to quickly detect any faults in the plant. IP67 protection permitted the open installation of the electrical wiring and pneumatic tubing without a protective guard. The CPX concept as well as the high protection class reduced the electrical and pneumatic installation costs to a minimum. Apart from reliable automation technology, the plant operator SIAAP, the supplier of the filtration tanks Stereau as well as the manufacturer of the shut-off valves Fontaine were also able to rely on Festo’s services for training and commissioning, thus saving valuable time. The inhabitants of the Seine valley no longer need to rely on the services of the Celtic goddess Sequana; a further 70 filter systems are to be installed in Les GrÊsillons by 2012. w2.siaap.fr www.stereau.fr www.hfontaine.com
trends in automation No. 12, 2008
23
24
Industry specific solutions
www.festo.com/en/sboc
www.festo.com/en/chb
Inspection of sleeves for vehicle fuel injection systems In use Checkbox Compact PLC and intelligent compact vision system SBOI-Q Key features • 100 % quality inspection • Reliable detection and rejection of faulty parts • Smooth material feed
On the safe side Faulty components in the production process are every industrial firm’s nightmare. Valuable time, tight budgets and reputation are at stake. System manufacturers therefore need to get to grips with their customers’ increasing quality requirements. Inspection systems such as intelligent compact vision systems or the Checkbox from Festo ensure these nightmares never see materialise.
Quality assurance is a central issue at Technik-Zentrum-Esslingen GmbH (TZE), particularly when it comes to the production of sleeves for fuel injection systems. With a part throughput rate of approx. 100 inspection parts per minute, the previous manual and visual final inspection was no longer adequate. A visual inspection system was needed.
Complete solution comprising feed unit and visual unit: the Checkbox Compact PLC and compact vision system SBOI-Q inspect drawing sleeves for vehicle injection systems.
A two-fold inspection system The problem called for a complete package of feed and visual unit. It was expected to feed the drawing sleeves in the correct orientation and at the same time to check the cross-sectional diameter of the part cross sections. Against this background, TZE opted for the com-pany ifc intelligent feeding com-ponents in Oedheim. As a supplier of flexible feed systems for type and orientation checking and quality inspection, ifc primarily uses vision systems and components from Festo. In the case of the sleeves, a Checkbox Compact PLC in com-bination with the new surface-based vision system SBOI-Q was felt to be the ideal solution. 100 % quality process The sleeves are inspected at two stations; the first one checks the cross section and the second the diameter. The “multifunctional” Checkbox Compact PLC is the first station. It controls the flow of the sleeves and at the same time checks their cross section as they
trends in automation No. 12, 2008
Infoservice
25
is 1210 Checkbox Compact PLC
is 1211 Compact vision system SBO..-Q
Intelligent compact vision system SBO..-Q
pass the optical duct. It performs a comparison against the dimensions of a good part learned beforehand and sends a signal to the ejector in the case of a faulty part. If the cross section of the inspected part is acceptable, a message is forwarded to the downstream integrated compact vision system SBOI-Q. As per the second station, it checks the part diameter and ensures that only perfect parts reach the production process. The interaction of the two systems guarantees 100 % quality inspection. Deformed or damaged parts are reliably detected and rejected.
The intelligent camera delivers reliable inspection results for a broad range of applications. The system can be used to check regularly and irregularly moving or static parts. Left: SBOI-Q with integrated lens; right: SBOC-Q with threaded connection for different lenses.
Checkbox Compact PLC User-friendly The Checkbox Compact features a teach-in function that enables it to learn inspection parts automatically and without the need for complicated programming. The CheckOpti software facilitates fine tuning during the recording and monitoring of the most minute contour deviations or quality-related measured variables. Following the presentation of sample parts, the user defines various inspection characteristics with the aid of the software, including length, height, surface, centre of gravity or angle, and loads the inspection program onto the Checkbox. Flexible Its compact design and clear interface definition mean that the Checkbox Compact can be integrated even into existing systems with limited space. All of the components required are incorporated into its housing, including the entire imaging sensor system (lens, lighting, camera). The optical duct underneath the Checkbox Compact faces downwards and is thus easy to integrate in the material flow. Intelligent The multifunctionality of the Checkbox Compact means it can control the entire feed process. It features I/O for communicating with a master PLC as well as an option for encoder linking. An additional PLC is therefore not necessary.
trends in automation No. 12, 2008
26
Industry specific solutions Automated welding systems in shipbuilding In use Valve terminals CPX/MPA, standard cylinder DNCB, MS series service units Benefits • Reduced installation and wiring complexity with CPX/MPA • Total solution package from products and training courses to logistical services
Reliable welding connections “With the installation of a PEMA flat panel line for the automated construction of ship blocks at Britoil Offshore Services Pte. Ltd. in Singapore, we’ve taken a major step in expanding our Asian business”, says Pekka Heikonen, President of the Finnish Pemamek Group. In this particular case, pneumatic components ensure sturdy welded joints for connections in shipbuilding.
Thus the delivery of the huge welding systems to Britoil is part of a series of globally successful, turnkey and customer-specific solutions from Pemamek. The impressive export figures accounting for 80 % of total sales speak volumes. “Due to a lack of specialists in this area, Asian shipyards currently have a huge need for automated systems of this type”, explains Mr. Heikonen. “And the automated welding systems result in a 25-fold increase in productivity”, adds Jyri Passila, engineering manager at Pemamek.
Welding on a huge scale: welding systems for shipbuilding are up to 150 metres in length.
Huge systems The welding systems are simply huge, measuring 150 metres in length and, depending on the station, 4 to 22 metres in width. Once sheets measuring 12 metres by 12 metres have been clamped, a robotic welding station attaches reinforcing plates. The number of reinforcing plates welded for a cruise liner, for example, can be anything up to 180,000, easily using 50,000 tons of steel. Pemamek considers the vision systems used to program the robotic welding systems to be a strategic competitive advantage. Equipped with these systems, the
trends in automation No. 12, 2008
Festo components at Pemamek
Standard cylinder DNCB
customised welding systems enable precision production of individual items. “Also associated with this, is our systems’ ability to construct different ship types on one and the same system”, stresses Mr. Passila. Minimum installation complexity Pneumatic automation technology is used above all for clamping and pressing as well as for small, precise movements of the welding torch. “We rely on the sturdy and modular valve terminals CPX/MPA with Profibus connection as they reduce installation and wiring complexity and are very cost effective”, says Mr. Passila.
help us in the automation of our systems, even though they suit our needs perfectly”, explains Mr. Passila, “it’s the complete package offered by Festo: comprehensive technical support and training, logistical services as well as reliability of both the products and the services.” This means that shipbuilders worldwide can rely on secure welding connections.
MS series service units
Valve terminal CPX/MPA
Apart from the valve terminals that are hidden away almost invisibly in recesses in the robot’s arms, the classic drives DNC and DNCB ensure reliable clamping and pressing of the panels while service units from the modular MS4 and MS6 series prepare the compressed air. “But it’s not just the pneumatic components that
Clamping and pressing using pneumatics: in use in the welding torches. Sturdy and modular: CPX/MPA with Profibus connection.
Pemamek Oy Automations-Systeme GmbH Products
Contact
Workpiece handling, welding systems, automation for shipyards, wind systems or power plants FIN-32201 Loimaa www.pemamek.fi
trends in automation No. 12, 2008
27
28
Services and products ATEX in ready-to-install solutions In use In areas of explosion risk in accordance with directive 94/9/EC Benefits • Assembled and tested complete systems with full documentation • Saves time and money during planning and assembly • Universal explosion protection conformity
ATEX – now ready to install! At Festo, ready-to-install solutions are a central theme in all areas. Whether as a pneumatic control system, solenoid valve cabinet, cylinder/valve combination or control block. Costs, time and safety are reasons that convince users and increasingly enable them to follow a philosophy of a reducing total cost of ownership. Festo now also offers more than just components in the ATEX world. The trend is moving towards the ready-to-install solution.
To recap: since 2003, any equipment and protective systems for use in areas of explosion risk must be approved in accordance with directive 94/9/EC. Over 3,700 Festo products are already certified in accordance with explosion protection categories. This is the ideal basis for applying the savings produced by ready-to-install solutions to the “ATEX world”. A good example: ATEX-compliant control system In the process industry, where the distance between the controller and system is frequently greater than with production, handling and assembly machines, bus systems are being used more and more frequently instead of electrical multi-pin cables for signal transmission. The coupling point,
trends in automation No. 12, 2008
a remote I/O system, is located centrally among the valve terminals directly in the explosion area. This system converts the bus – often an intrinsically safe “Profibus DP” – into output signals that are carried to the individual assemblies via fixed wiring. The feedback signals from the drives are also detected using this system, as are analogue input and output signals.
An example of an ATEX-compliant control system is the combination of a valve terminal CPV10 EEx i and a remote I/O system from the companies R. Stahl and ABB for zone 1/category 2G. Further remote I/O systems are available. What advantage does this solution concept offer for control cabinets?
www.festo.com/en/ex
Infoservice
is 1212 Pneumatics and explosion protection
Explosion protection with ready-to-install solutions: electropneumatic control system in the control cabinet, MS series service units and ball valve drive units (zone 1/category 2GD).
Ready-to-install solutions: advantages in detail
Apart from valve terminals, other pneumatic components can also be integrated into the control cabinets. For example the air distribution system, the sensor for system pressure, further control elements and large power valves.
Procurement • 1 contact partner = 1 supplier • 1 order number = delivery of one item • 1 date • Fixed price guarantee • Warranty for the entire module Logistics • No warehousing costs for individual parts and no combination thereof • Just one supplier means reduced costs Design • Relieves pressure on deadlines • No design costs • Circuit diagram is created by Festo • Reduces the costs for documentation
Electropneumatic control system for the explosive area II 2G EEx e ib IIC T4: valve terminals and pressure switches with ignition protection type EEx ib, remote I/O system by Stahl with Profibus interface and input/output modules.
Installation and commissioning • Combined assembly for direct installation • Reduces the assembly time • Tested complete module
trends in automation No. 12, 2008
29
30
automation worldwide
automation worldwide
Argentina
Argentina Pneumatic mix
30
South Africa Absolutely safe
31
Taiwan Cost-effective capacitors
32
Netherlands Systematic palletising
32
Indonesia Dosing made easy
33
Pneumatic mix Systems for the manufacturing and packaging of beverages are the speciality of FRUSSO Mรกquinas Embotelladoras, in particular complete solutions in the area of small and medium-sized production systems. Just one example: the processing and filling of transparent PET cans with flavoured tequila with added carbon dioxide for a Mexican company.
Once the system has been loaded, standard cylinders DNC lift the cans while compact cylinders ADVU fit the lids. Quarter turn actuators DRD then seal the cans. Sensors also play as indispensable role in the system, whether inductive sensors of the type SIEN/SIEF, the pressure sensor SDE1 or the opto-electronic sensor SOEG-RSG. The
programmable logic controller FEC-FC600 and the multi-pin valve terminal CPV-14 round off the list of components. A strong mix! www.frusso.com
Quarter turn actuator DRD
trends in automation No. 12, 2008
automation worldwide
31
South Africa
Absolutely safe
180 million preservatives are produced each year in the condom factory of Kohrs Medical Supplies in South Africa – using machinery supplied by Richter Hi-Tech of Hanover. A machine dips a glass tube into liquid latex, which is then vulcanised by heat, and the result is a condom. Before packing, these products are tested by being stretched over a metal tube carrying high voltage. If the latex skin of the preservative is too thin, sparks will fly and the condom in question is rejected.
into foil two at a time. Throughput the production process, it is essential to maintain a hygienic environment - which naturally includes the compressed air used in the process. An MS6 combination with a branching module, a lubricator and a filter regulator keeps any dirt at bay which could impair quality. This is how perfect condoms are made – fully tested and absolutely safe! www.rrtmedcon.com www.richterhi-tech.com
Condoms which pass the test 100 % are rolled up and passed to a packing machine. Here, two CPV valve terminals control the actuators which pack the condoms
trends in automation No. 12, 2008
32
automation worldwide
automation worldwide
Taiwan
Netherlands
Cost-effective capacitors
Systematic palletising
Electronic components have to be manufactured as cost-effectively as possible, something that can only be achieved with highly automated production machines. For RODER Electronics Machinery Co. Ltd., the largest supplier of machines for capacitor production in Taiwan, Festo Taiwan has significantly increased the level of automation of the serial AC/DC capacitor winding machines.
Package and pallet conveying systems, layer and robot palletisers, automatic truck loading, systems for layer-order picking – the product range at CSi industries B.V. is immense. Many tasks – individual solutions: CSi developed a compact and sturdy handling system for palletising cans with different dimensions and volumes.
A combination of valve terminals of the type VTUB, DB series compressed air preparation modules , vacuum generators VN and tubing PUN-E optimises the production speed of the machines and at the same time saves installation space. The pre-fitted valve terminals VTUB in particular mean the solution covers various pressure requirements and depending on the machine design, is compatible with internal and external pilot controls. www.roderco.com
The gripping system on the robot flange comprises sturdy guided drives DFM that can be flexibly adjusted to the can dimensions
thanks to the electric piston rod cylinder DNCE. This is driven and actuated by a servo motor MTRDCI with integrated positioning controller. The servo motor is connected directly to the robot controller via the CANopen interface of the CPX platform. www.csiweb.nl
Valve terminal VTUB
trends in automation No. 12, 2008
automation worldwide
33
Indonesia
Dosing made easy Festo has supplied a complete support system for controlling a chemical dosing and mixing system to PT Henkel in Bogor, West Java. The system comprises four main process stations: rolling oil delivery, rolling oil process, solvent-based process and three mixing systems for the MPT process. The system is controlled by an IPC PS1 controller with integrated Profibus/Ethernet as a master controller as well as five electrical terminals CPX-FEC with Profibus module as slaves. Dosing of the raw materials into the mixing tanks is performed based on weight specifications. The mixing processes are executed according to a predefined sequence and schedule stored in the PLC. Process valves and actuators from Festo, for example ball valve drive units of the type VZPR, play an important role in transporting the materials. Parameters such as formulae, process sequences and process timings are input using a Festo text panel of the type FED-90.
Electric piston rod cylinder DNCE with servo motor MTR-DCI
Ball valve drive VZPR
Guided drive DFM-B
Front End Display FED
trends in automation No. 12, 2008
Fax-reply To From
is 1200
infoservice „trends in automation“ 12
Take advantage of your personal info service! Convenient – fast – direct – free of charge – without obligation.
1201 1202 1203 1204 1205 1206 1207 1208 1209 1210 1211 1212
Safety engineering – pneumatic positioning Handing system overview Proportional gripper HGPPI AS-interface Standard valve terminal VTSA Valve terminal MPA Valve terminal CPV Valve series VOVG Partner to the process industry Checkbox Compact PLC Compact vision system SBO..-Q Pneumatics and explosion protection
Editorial trends in automation 12 January 2008 Published by: Festo AG & Co. KG Ruiter Straße 82 D-73734 Esslingen Chief editor: Ralf Sohn, Marketing Service rso@de.festo.com Markus Ott, Sales Communication mott@de.festo.com
Please do not send me “trends in automation” in future.
Reproduction of excerpts is permissible, provided that the source is acknowledged as “trends in automation 12, January 2008
Pick and place modules: speed & accuracy! Electric Drive Automation
Optics
Miniature assembly
High speed electronics
Micro assembly
Higher speeds and increased flexibility in a single pick and place module (HSP-AE) In a highly competitive market, time is of the essence. Whether it is the time to design, select compatible components and assemble your own pick and place system or the cycle time of the final solution. Why take a risk when guaranteed performance is available off the shelf – with the flexibility to suit your applications at a highly competitive price?
Festo Asia Pacific
Australia Head Office Festo Pty. Ltd. Melbourne 179-187 Browns Road Noble Park Nth VIC 3174 Tel: 1300 88 96 96 Fax: 1300 88 95 95
Wuxi Tel: +86-510-275 53 88
Nashik Fax: +91-253-2316044
Johor Bahru Tel: +(60 7) 352 3719
Daegu Tel: +82-(0)53-604 4365
Xiamen Tel: +86-592-239 61 23
New Delhi Tel: +91-11-26313558/26313923/ 26313924/26316838
Malacca Tel: +(60 6) 335 1018
Suwon Tel: +82-(0)31-217 5163 Ulsan Tel: +82-(0)52-292 4215
Branch Offices Adelaide Tel: 1300 88 96 96
Zhengzhou Tel: +86-371-79 44 928
New Zealand Head Office Festo Limited 20 Fisher Cres MT. WELLINGTON Auckland Tel: +64-(09)-574-10 94 Fax: +64-(09)-574 10 99 Branch Offices Christchurch Tel: +64-(03)-348 87 96
Changwon Tel: +82-(0)55-288 7797
Brisbane Tel: 1300 88 96 96 Perth Tel: 1300 88 96 96 Sydney Tel: 1300 88 96 96 China Head Office Festo (China)LTD 1156 Yun Qiao Road Jinqiao Export Processing Zone 201206 Pudong, Shanghai, P.R. China Tel: +86-21-585 4 90 01 Fax: +86-21-585 4 03 00 Branch Offices Beijing Tel: +86-10-65 15 50 96 Changchun Tel: +86-431-8 96 90 30 Changsha Tel: +86-731-256 42 72 Chengdu Tel: +86-28-86 19 98 70 Chongquing Tel: +86-23-63 63 68 66
Xi’an Tel: +86-29-88 31 12 90
Hong Kong Head Office Festo Ltd Unit C&D 7/F Leroy Plaza 15 Cheung Shun Street Cheung Sha Wan Kowloon Hong Kong Tel: +852-27 43-8379 Fax: +852-27 86-2173 Branch Offices Guangdong Province Guangzhou Tel: +86-20-8732 1613 Guangzhou Tianhe Tel: +86-20-8600 3032 Shenzhen Tel: +86-755-2650 5798 Dongguan Tel: +86-769-2236 7890 India Head Office Festo Controls Pvt. Ltd. 237-B, Bommasandra Industrial area, Bangalore Hosur Highway, Bangalore 560 099 Tel: +91-80-22894100 Fax: +91-80-27832058/ 27833362
Dalian Tel: +86-411-83 60 63 56
Branch Offices Ahmedabad Tel: +91-79-26565836
Hangzhou Tel: +86-571-87 22 37 97
Aurangabad Tel: +91-240-2337961
Jinan Tel: +86-531-811 39 10
Bangalore Tel: +91-80-22240994/ 22277582/22243518
Kunming Tel: +86-871-537 16 75 Lanzhou Tel: +86-931-260 44 19 Ningbo Tel: +86-574-87 28 92 18 Nanjing Tel: +86-25-86 81 91 18 Qingdao Tel: +86-532-579 83 26 Shenyang Tel: +86-24-23 25 00 92 Suzhou Tel: +86-512-68 28 11 19 Tianjin Tel: +86-22-26 26 40 76 Wuhan Tel: +86-27-87 36 62 37
Pune Tel: +91-20-25521401/ 25512227 Indonesia Head Office PT Festo Jl. Sultan Iskandar Muda no.68 Arteri Pondok Indah Jakarta 12240, Indonesia Tel: +62-21-27 50 79 00 Fax: +62-21-27 50 79 98 Branch Offices Bandung Tel: +62-22-732 1329, 732 1330, 732 0753 Batam Tel: +62-0816 50 23 10 Cikarang Tel: +62-21-893 67 49 Glodok Tel: + 62-21-659 97 69-70 Makassar Tel: +62-0813 42 05 52 00
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
Semarang Tel: +62-24-355 66 53, 355 48 24
Baguio Tel: +63 (74) 447-0394
Taichung Tel: +886-4-2475-7278
Surabaya Tel: +62-31-849 10 44, 841 05 12
Cagayan de Oro Tel/Fax: +63 (88) 857-4904
Tainan Tel: +886-6-202-3083 to 4
Iran Festo Pneumatic S.K. Kh. Ramsar, Ko. Behbahan No.1 P.O. Box 15815/1485 15 Teheran Tel: +98-(0)21-8882 9225 Fax: +98-(0)21-8882 2162
Davao Tel/Fax: +63 (82) 299-4275
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 Nagoya Tel: +81-(0)52-937-39 10
Coimbatore Tel: +91-422-2499975
Osaka Tel: +81-(0)6-6320-34 27
Hyderabed Tel: +91-40-27847286
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
Mumbai Tel: +91-22-26673133/ 26673134/26673113/ 26673181
Gumi Tel: +82-(0) 54-458 2235
Kaohsiung Tel: +886-7-384-2856
Chennai Tel: +91-44-28554491/ 28517143
Ludhiana Tel: +91-161-2407742
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
Cheonan Tel: +82-(0)41-533 4871
Branch Offices Cebu Tel: +63 (32) 345-1120
Baroda Tel: +91-265-2321749
Kolkata Tel: +91-33-22821276
Hamilton Tel: 64-(07)-846 60 80
Gwangiu Tel: +82-(0)62-955 4168
Medan Tel: +62-61-453 89 35, 452 00 11
Japan Head Office 1-26-10 Hayabuchi Tsuzuki-ku, Yokohama 224-0025 Tel: +81-(0)45-593-56 10/-56 11 Fax: +81-(0)45-593-56 78
Kolhapur Tel: +91-231-2660479
Wellington Tel: 0800 433 78
Daejeon Tel: +82-(0)42-861 7797
Branch Offices Penang Tel: +(60 4) 643 0918 Ipoh Tel: +(60 5) 548 1002
Bacolod City Mobile Phone: +63 (0917-8807050) Iligan Tel/Fax: +63 (63) 221-1966 General Santos City Tel: + 63 (83) 382-0005 Zamboanga City Tel: +63 (62) 991-0489 Tarlac/Pampanga Mobile Phone: +63 (0928-5028288) Singapore Festo Pte Ltd. 6 Kian Teck Way SGP - Singapore 628754 Tel: +65-62640152 Fax: +65-62611026/62659276 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 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 8th Floor, #801, Miss Ao Dai Building, 21 Nguyen Trung Ngan St, Ben Nghe Ward, Dist. 1 Ho Chi Minh City Tel: +84 8 910 12 13 Fax: +84 8 910 12 93 Hanoi Tel: +84 4 974 68 33