tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:08
Seite 1
No. 13, 2008
In focus “Everything under control” Condition monitoring and diagnostic systems for troublefree system operation Handling and assembly “Strong arm” Spindle driven cantilever axis EGSA for powerful applications Handling and assembly “Well armed” Pneumatic and electric drives and axes in action Sensors “Improving conditions” Monitoring of flow rates and air consumption using flow sensors
www.festo.com
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:08
Seite 2
Automation cockpit Sunshine, sandy beaches and faroff countries. Every year millions of people fly to their holiday destinations. They place their faith in the experience and skills of the pilots controlling the complex aircraft. Despite the effortlessness of flying it has lost nothing of its fascination since the days of the aviation pioneers at the beginning of last century – neither for the passengers nor for the pilots. The seemingly easy journey through the clouds is made possible by intelligent technical solutions. Onboard electronics enable the pilot to monitor all the relevant data in the cockpit at a glance, and inform him immediately of any changes. He can then implement corrective measures promptly in the event of a critical situation. Festo’s diagnostic and condition monitoring systems provide you with the same effortlessness in the field of automation. Our objective is to increase system availability for system operators and at the same time reduce total cost of ownership. We support you, as machine or equipment manufacturer, with innovative solutions which will provide your customers with added value.
Festo creates transparency in automation regardless of whether the topic is compressed air consumption, cylinder positioning time, deviation from reference values for working pressure, counting cylinder strokes or valve switching cycles. The diagnostic and condition monitoring systems presented in this issue of trends in automation will help you to implement preventive measures, accurately pinpoint problem areas and react quickly to deviations and errors. And thus you will always know that “Everything’s under control.” Enjoy your reading!
Markus Ott Head of Sales Communication
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:09
Seite 3
In focus Everything under control Increased system availability, lower life-cycle costs: condition monitoring and diagnostic systems for trouble-free system operation. 4
Newsticker At a glance New products, events and news in brief.
8
Handling and assembly Well armed Leading by seconds: pneumatic and electric drives and axes in action during machine tool changeovers.
11
Strong arm Powerful, dynamic and accurate: the spindle driven cantilever axis EGSA is easily integrated into machines and systems. 14 Who’s the winner? Lightweight, small, low-maintenance: single stage vacuum generators score more points in comparison with their multi-stage counterparts. 16
Sensors Improving conditions Reduce air consumption by continuously monitoring flow rate and consumption with MS6-SFE and SFE1 sensors. 19 Pure function integration CMPX, CMAX and CMXX servo-pneumatic and electrical axis interfaces expand the CPX terminal. 22
Industry specific solutions Active ingredient: automation Laboratory automation: automated patch clamping machines equipped with piezo valves control the movement of fluid into ducts on test panels. 26 No risk, but fun! Virtual driving license: combining the SPC200 axis controller with the DNCI standard cylinder makes this possible. 28
Automation worldwide From the USA to Vietnam Applications from all over the world.
30
Infoservice
34
tia13_EN_Druck7:tia13_EN_Druck.qxd
4
29.04.2008
08:10
Seite 4
In focus Condition monitoring for industrial applications Key features Monitoring of actual values and comparison with setpoints Benefits • Increased system availability • Lower life-cycle costs
Everything under control
Where system downtime once resulted in costs of up to 10,000 euros per minute, condition monitoring and diagnostic systems are now ensuring almost trouble-free system operation. Using sensors and electrical units in valve terminals from Festo for diagnosing components and systems, OEMs and system operators are able to concentrate on their specialised areas of core competence. Examples are provided from the packaging industry, pharmaceuticals manufacturing, the optics industry and the production of pre-cast concrete blocks.
trends in automation No. 13, 2008
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:10
Seite 5
5
More and more machinery and equipment manufacturers are recognising how important it is to pay close attention to more than just procurement costs, and to carefully consider the system’s overall life-cycle costs. After all, procurement costs frequently amount to only a small portion of the costs of operating a system over its entire life-cycle. Total cost of ownership and life-cycle management are the “magic words” in this respect. Maintenance and repair A study conducted by Rockwell Automation revealed astonishing figures: Between 15 and 40 % of the indirect costs incurred by manufacturing operations result from maintenance and repair. However, roughly half of these costs can be avoided – if strategically oriented diagnostic and condition monitoring systems are utilised. Amounting to roughly 70 % of these expenses, repairs make up the largest part of indirect costs as unplanned consequential costs they even constitute between 10 and 28 % of a system’s total lifecycle costs. And according to information published by an economics journal, these consequential costs have to be multiplied by a factor of between 4 and 5! Why? Because machine downtime may also result in quality defects or inability to deliver on time, and may even impair the company’s corporate image. Commissioning costs are also high for product and lot changeovers.
Germany: Packaging industry Machine downtime in the packaging industry may thwart the high demands placed on short cycle times and high productivity. For this reason the VPP 250 tubular bag packaging machine from Wolf Verpackungsmaschinen GmbH with a cycle time of 100 bags per minute is equipped with a diagnostic system for its pneumatic components. The MS6-SFE flow sensor and the SDE1 pressure sensor monitor deviations from a reference value. Measured data and available valve control and limit switch signals are read into the CPX electrical terminal and processed by the FEC controller module. Process parameters such as sheetmaterial dependent contact pressure and belt wear are monitored by means of position measurements executed by the SMAT analogue sensor included in the pneumatic feed cylinder. Coolant air
Indirect costs for manufacturing operations
15 to 40 %
Maintenance/repair
ca. 50 %
Potential savings
Indirect costs Costs for maintenance/repair Potential savings through the use of diagnostics and condition monitoring
volume and pressure are also monitored as process and sheetmaterial dependent quantities in order to avoid unnecessary use of compressed air. Transverse sealing knife wear is monitored by measuring cylinder positioning time, and monitoring for premature wear during longitudinal sealing is accomplished by measuring cylinder travel time. Operation hours and time-to-replace are indicated by means of a cylinder
stroke counter and a switching cycle counter for valves. The CPX’s electrical peripherals monitor events such as short-circuits, broken wires, overvoltage and valve jamming. Global access Characteristic diagnostic values include, for example, air consumption and operating pressure for the detection of leaks, as well as positioning times. The diagnostics
Diagnostics system included: The MS6-SFE flow sensor and the SDE1 pressure sensor monitor deviations from a reference value for the VPP 250 tubular bag packaging machine from Wolf Verpackungsmaschinen GmbH.
trends in automation No. 13, 2008
tia13_EN_Druck7:tia13_EN_Druck.qxd
6
29.04.2008
08:11
Seite 6
In focus ... Everything under control
function detects malfunctions and pinpoints their locations. Functions such as counting the number of valve switching cycles and cylinder strokes support preventive maintenance. The FED touch-panel displays the results, which are also made available to the machine’s controller via fieldbus. The diagnostic solutions can be easily integrated into existing control concepts. The machine manufacturer’s servicing personnel, the machine operator’s maintenance personnel and external service providers are thus able to increase system availability and optimise maintenance processes. USA: diagnostics package Remote monitoring of systems via a PC and the elimination of malfunctions without protracted investigation is in great demand in the USA. Diagnostics package solutions available from Festo enable Roman Stone, a manufacturer of pre-cast concrete products in Long Island, New York, to keep an eye on what’s going on in the dusty production environment. Roman Stone manufactures specially shaped blocks used to enclose electrical cables. “Many
Roman Stone: specially shaped blocks used to enclose electrical cables. The CPX unit with a VTSA valve terminal replaced Roman Stone’s old pneumatic control systems. Moreover, with compressed air preparation from the MS series, the MS6-SFE flow sensor, the SDE1 pressure sensor and the FED front end display, the diagnostic system was up and ready to go.
trends in automation No. 13, 2008
miles of electrical cable under the streets of Manhattan are laid in our pre-cast concrete blocks”, reports directing manager Thomas Montalbine, not without a hint of pride. The systems used to produce the pre-cast concrete blocks are pneumatically controlled, but they began to fail frequently due to age and adverse conditions of use. “We decided in favour of a complete package from Festo for modernisation – a system that encompasses diagnostic services in addition to fully equipped control cabinets, as well as sturdy and highly resistant DNC cylinders”, explains Montalbine. Remote monitoring in the USA Short cycle times and good machine availability are also success factors for Davis Vision, a manufacturer of lenses for glasses, and a supplier of optical systems for roughly 35 million people in North America. The use of remote monitoring and diagnostic systems for the production of optometric lenses by means of CNC machines with milling and polishing technologies ensure reliable processes
Short cycle times and good machine availability at Davis Vision: Pressure (SDE1) and flow rate (SFE1) sensors monitor the pneumatic gripping mechanism of a spindle, by means of which optometric lenses are milled into the desired shape.
for the company. Sensors for detecting pressure (SDE1) and flow (SFE1) monitor the pneumatic gripping mechanism for a spindle, by means of which the lenses are milled into the desired shape. Based on a pressure profile, testing is conducted daily on a PC and via the FED 100 front-end display in order to determine whether there are any leaks in the compressed air system. The flow sensor transmits analogue or digital signals to a standard controller. Thanks to the condition-oriented maintenance program, the company is capable of detecting irregular
increases in compressed air volume – genuine condition monitoring. “We’re thus able to replace defective components within the compressed air system between shifts before it’s too late”, explains William Barbaro, maintenance manager at Davis Vision in Plainview, New York. And the real showstopper: Festo USA provides Davis Vision with a service which is unavailable anywhere else to date, namely continuous fault monitoring for the company’s pneumatic processes conducted by Festo’s experts in New York.
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:11
Seite 7
Infoservice
is 1301 Partner to the food and packaging industries
is 1302 Partner to the biotechnology and pharmaceuticals industry
is 1303 Dr. Christian Boehm, manager of the Technical Engineering Center for Diagnostics at Festo Corporation in New York: “Customer service is not limited to just delivering replacement parts very quickly. Error diagnosis and condition monitoring systems create true added value that customers greatly appreciate, especially in the USA: In addition to the latest automation components, users who decide to take advantage of diagnostic solutions can monitor their systems and eliminate errors without protracted investigation. Festo USA offers a complete package including remote monitoring of a system and valuable assistance in fault diagnostics.”
CPX electrical terminal
is 1304 MS series service units
is 1305 Sensors, image processing systems, controllers
Saving money with flow sensors The use of flow sensors can achieve enormous savings. Overall costs of more than 2685 euros can be incurred as a result of undetected leaks during non-stop operation of a system over a period of 50 weeks per year. With costs of this magnitude, the use of sensors is amortised after just a few weeks. Finland: pharmaceuticals industry What’s good for machines and systems in discrete manufacturing can only be right for process automation in continuous operation. A consistent diagnostics concept reduces the cost of goods in the biotechnology and pharmaceuticals industry. Without a functioning concept of this sort, it’s almost impossible to meet current requirements specified by the United States Food and Drug Administration (FDA) for process analytical technology (PAT). For this reason, for example, multiple effect water distillation systems supplied by Steris Finn-Aqua for the production of ultra-pure water for producing medications are already integrating diagnostic systems with the CPX/MPA valve terminal. “In addition to extensive diagnostic options, we also save 30% of our installation costs using
the CPX/MPA”, explains Veli-Jukka Parkkamäki, engineering manager at Steris Finn-Aqua. Remote I/O valve terminal node The CPX/MPA modular valve concept referred to by Parkkamäki – a combination of a CPX remote I/O terminal and an MPA solenoid valve terminal - indicates the fault source and location, as well as corrective measures. This includes error detection and pinpointing in the form of module or channeloriented I/O diagnosis, valve diagnosis per channel, on-site display
in plain-text, data processing and transmission via fieldbus. Also included are expansion options via Ethernet interface, integrated IT solutions such as remote maintenance, e-mail or SMS alarm, and diagnosis tracking with error memory. And thus everything is kept under control.
Reducing the cost of goods in the biotechnology and pharmaceuticals industry: multiple effect water distillation systems supplied by Steris Finn-Aqua for the production of ultra-pure water for producing medications integrate diagnostic systems via the CPX/MPA valve terminal.
www.wolf-pack.de www.romanstoneco.com www.davisvision.com www.steris.com
trends in automation No. 13, 2008
7
tia13_EN_Druck7:tia13_EN_Druck.qxd
8
29.04.2008
08:11
Seite 8
+ + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + +
Electrical drives
Sensors
Logical supplement
Compact, versatile, inexpensive
After integrating the MTR-DCI motor unit into the HSP handling module, the HSW high-speed handling module is now joining forces with electric drives under its new designation: HSW-AE. The electrical variant for repositioning workpieces at a 90° angle is available in 10, 12 and 16 mm sizes. As is also the case with the HSP-AE, the module is programmed at the control panel of the MTR-DCI-..-HM, or by means of FCT software.
Low cost reliable functioning.With its versatile configuration and connection options, and thanks to its minimal size of just 30 x 30 mm, the SPAB pressure sensor can be used worldwide in all industry sectors. Switching point settings are highlighted by means of a switching status indicator, as well as by identifying the display value via a specific colour. Practical: After one device has been programmed, settings can be transferred to all other SPAB pressure sensors.
Advantages of the HSW-AE at a glance: • Freely selectable positioning • Freely selectable speed • Smooth motion sequences Ideal for use in insertion processes at various speeds, and for stacking thin workpieces that require different handling sequences.
Position transmitter
Small but impressive It’s the first position transmitter the size of a cylinder sensor – the SMAT-8M. Depending on the drive, the sensing range is a large as 40 mm; an analogue voltage signal is used for a feedback signal. It’s used directly on standard drives from Festo – without accessories – in particular on short-stroke cylinders and grippers. Ideal for all applications with space restrictions.
trends in automation No. 13, 2008
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:11
Seite 9
+ + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + +
Vision system
Valves and valve terminals
Parts in view
Analogue I/O module for thermocouples
Detection of position and rotational position sensing of parts, precision positioning of axes, 2D quality testing and type identification – tasks which are easily executed by the SBOx-Q compact vision system. Recently added to the family of intelligent surface based cameras: the price-optimised SBOx-Q-R3x-WB compact vision system with wide VGA sensor (resolution:750 x 480). For applications with minimal requirements for duration of analysis (in comparison with VGA variants), and for which CAN bus (intended for integration into a CPI network) is not necessary.
Mixing various electronic modules within a single system, for example digital and analogue I/Os, technology modules and pneumatics, make the CPX terminal highly modular and extremely flexible. Thanks to the CPX-4AE-TC, the CPX I/O range will now be expanded to include a 4-channel, analogue input module for temperature measurement via thermocoupler. The advantages: minimised installation width for the valve terminal, reduced per channel and system costs, and less downtime thanks to diagnostics – including individuality thanks to selectable connection technology depending on the operating environment.
Temperature measurement from -270 to 1820° C
Online replacement parts catalogue
Quick assistance Sensors
Simply accurate! Highly accurate and simple to use: the new SOE4 fibre-optic units. Super fast operation with switching frequencies of up to 8000 Hz. Furthermore they can be quickly installed thanks to top-hat rail mounting. Ideal for detecting small parts, and available in three different variants: for teach-in, with display or with analogue output. The perfect system expansion for Festo’s range of sensors.
The new online replacement parts catalogue is now even more user friendly - with numerous improvements and new features. Just enter the part number and place your order online – direct from the bill of materials (furnished with installation instructions), or from the PDF file into the shopping basket. Replacement part drawings can be zoomed via mouse click, and can also be saved and printed out as PDF files. The extended search function indicates which components the part still applies to, and also the possibility of searching for certain types. It doesn’t get any more convenient than that.
www.festo.com/spareparts
trends in automation No. 13, 2008
9
tia13_EN_Druck7:tia13_EN_Druck.qxd
10
29.04.2008
08:12
Seite 10
+ + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + Newsticker + + + + + +
Brochures
Didactic
Safety at a glance
39th WorldSkills in Japan
Maximum safety at the workplace: The new “Safety technology guideline” offers competent answers to important questions regarding safety-oriented pneumatics – from risk analysis, sample circuit diagrams and protective measures, through to Festo’s entire product portfolio.
is 1306 Safety technology guideline
1000 apprentices from 50 countries representing 48 competing professions in front of 300,000 visitors – these are the figures which distinguished the 39th WorldSkills vocational world championships that took place at the end of 2007 in the Japanese city of Shizuoka at the foot of Mount Fuji.
Valves and valve terminals
Pure modularity Integration has high priority: VTSA – three valve sizes without adapter on a single valve terminal for up to 32 standard 18, 26 and 42 mm valves. Moreover, where modularity is concerned, integration is also making waves. Reason: individual M12 connection, whether the MP2 6-off M12 connection for controlling up to 12 single or 6 double solenoid valves, or the MP3 10-off M12 connection for controlling up to 20 single or 10 double solenoid valves is involved.
In the mobile robotics competition, the trainees had to prepare and program the mobile Festo robot Robotinoμ in such a way that it was able to carry out various tasks autonomously. With the help of control software, the Robotinosμ are transformed into an attractive experimental learning platform that covers the basics of sensor technology, electrically operated motor controls, image processing and, mobile robotics. The participants in the mechatronics competition were required to assemble industrial automation systems. Festo Modular Production Systems MPSμ were used for both the competition and general training.
A 5-pin M12 plug is used for electrical connection. This makes it easy to convert over existing applications which are equipped with robust, individual M12 connection technology to the VTSA valve terminal. Due to the fact that the modular system layout is fully retained, it’s also possible to convert to multi-pin plug connector or fieldbus technology with the CPX terminal.
is 1307 Robotinoμ
is 1308 Hybrid learning factory MPSμ
trends in automation No. 13, 2008
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:13
Seite 11
Handling and assembly
11
Changing over machine tools In use Linear drives, toothed-belt axis, gripper and rotary actuator for feeding tools and workpieces to a CNC machining centre Benefits • Concentration on core competence • Minimised changeover times • Shorter cycle times
Well armed One thing’s for sure: Whoever was able to reload his sixshooter fastest was the boss in the wild west. In the field of machine tool manufacturing, fast reloading – also known as retooling – is not at all easy, unless you’ve got good ideas, as well as handling units which not only move the tools quickly, but also the workpieces. In accordance with their maxim, “leading by seconds”, Chiron shows how major players are currently automating.
The planar surface gantry withdraws the required tool from the magazine, and feeds it to a mechanism which delivers it to the machining station.
Chiron manufactures stateof-the-art machining centres in Germany’s wild southwest, more precisely Tuttlingen – for example the FZ 08 CNC machining centre, a compact series produced machine with up to 5 axes for complete machining of small workpieces. As a standard feature, customers can use 12, 24 or 40 tools.
one part to another, we also have to change the tool set. Furthermore, if a large mix of parts is also being produced, we end up with immense changeover costs”, explains Matthias Giesler, production manager at Chiron. “Of course we want to avoid any machine downtime associated with this process.”
Long changeover times are a thing of the past A single set of tools is usually not enough to machine complicated workpieces or larger families of parts. “When we change over from
Background magazine increases productivity In order to minimise changeover time, Chiron has come up with a sort of “ammunition depot” for its customers. In cooperation
trends in automation No. 13, 2008
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:13
Seite 12
12 Handling and assembly ... Well armed
with Festo, a tool magazine with enough capacity for up to 400 tools was developed for the FZ 08. Not only did Festo supply the handling technology, but rather the entire background magazine with tool holders as well. The required parts are purchased in accordance with Chiron’s specifications from their suppliers, and the complete tool magazine is delivered to Chiron on rollers. Chiron only needs to connect the magazine pneumatically and electrically, and insert the tools. Tool handling: “You provide the planar surface gantry!” A planar surface gantry forms part of the background magazine which picks the tools and feeds them to the machine for the machining process. The gantry is equipped with a tandem solution in the horizontal plane which consists of two
DGE toothed-belt axes. The axes are coupled together by a shaft via a T- gearbox, in order to ensure ideal synchronous operation. Tools are withdrawn from the magazine in the vertical plane by means of a DGC pneumatic linear drive with intermediate position and gripper system. Tool transport: the loading unit is in charge The unmachined workpieces are clamped in a fixture. The fixture is located on a pallet which has been encoded with a chip, to which the machining data have been saved. In this way it’s possible to load the entire pallet conveyor system with many different workpieces. The chip is read and the data is transferred to the controller at the transfer station. The machine is thus capable of flexibly changing over to various workpieces
Dipl.-Ing. Matthias Giesler, product manager for small machines, CHIRON-WERKE GmbH & Co. KG: “The background magazine provides us with the ability to insert tools simultaneously. There’s no more lost time when we change over to a different part.”
autonomously without setup expenses. Plausibility checks ensure that the pallet has been inserted correctly, and that no collisions occur. After the system gives the OK, the gripper lowers the loader handling unit, grips the pallet with the workpiece and advances it into the machine. It picks up the pallet with a finished part if one is present, and sets down the pallet with the next blank to be machined. In order to reduce machine changeover time, the loader handling unit is equipped with a double gripper.
The gripper arm is retracted with the finished part. The manufacturing process continues, and the gripper arm sets the finished part onto the pallet conveyor system. The primary component of the loader handling unit is and HGPL parallel gripper attached to a DRQD semi-rotary actuator. The gripper’s large opening stroke enables it to travel over the workpiece and then to grip it from below. The loader handling unit is advanced in the horizontal axis by two DGC pneumatic linear
General view of the Chiron FZ 08 machining centre, to which tools and workpieces are fed by means of handling units. The double parallel gripper passes over the finished workpiece, and is advanced to a specified withdrawal position underneath the workpiece by the DGC linear drive.
trends in automation No. 13, 2008
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:14
Seite 13
Festo components at Chiron
drives. One of these functions as a drive, and the other as an additional guide. A DGC pneumatic linear drive lifts and lowers the vertical axis, and an external clamping unit prevents the axis from sinking in the event of a pressure drop.
Electric toothed belt axis DGE-ZR
Pneumatic linear drive DGC
Semi-rotary drive DRQD
After the tool magazine is delivered, it only needs to be pneumatically and electrically connected. Then it’s loaded with preselected tools via gates. Parallel gripper HGPL
CHIRON-WERKE GmbH & Co. KG Products
Contact
Vertical CNC machining centres 5-axis universal milling machines, long-bed machining centres Flexible manufacturing systems D-78532 Tuttlingen, Germany
The loader handling unit withdraws a blank from the pallet conveyor system, and advances it through a lift gate to the machining station.
trends in automation No. 13, 2008
13
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:14
Seite 14
Handling and assembly
14
Spindle driven cantilever axis EGSA Field of application Handling applications with short cycle times and strict precision requirements Key features • High dynamics • High positioning accuracy • Working loads of up to 6 kg • Drive and installation flexibility
Strong arm
Just as accurate as the time tested electro-mechanical mini-slides, but configured for longer strokes and greater loads: the new EGSA cantilever axes. Thanks to integrated “drive” and “guide” functions, as well as practical attachment options, they’re used to create multi-axis pick & place systems.
The powerful new cantilever axis EGSA can be easily integrated into machines and systems, and it's distinguished by outstanding positioning accuracy and also a large effective load capacity. Repetition accuracy is highly precise at ± 0.01 mm, but the axis nevertheless leaves virtually nothing to be desired (for the engineer) where speed and acceleration are concerned. With a maximum speed of 1.5 metres per second, the cantilever axis dynamically transports loads of up to 6 kg over the respective working area. Flexible drive Users are able to decide for themselves how the drive unit will be configured. Whether a space saving solution is used with the motor parallel with the axis, or with a conventional in-line layout, the overall drive package offers many possibilities. Festo also offers matching motors and controllers for the new linear axes: easy to put together using
trends in automation No. 13, 2008
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:15
Seite 15
Infoservice
is 1309 Spindle driven cantilever axis EGSA
Technical data • Sizes (drive width): 50 and 60 mm • Stroke lengths: 100, 200 and 300 mm • Repetition accuracy: ± 0.01 mm • Max. effective load: 6 kg
The EGSA fits seamlessly into the mechatronic multi-axis modular system without a hitch.
Parallel grippers
Festo’s “Positioning Drives” selection software, and simple to order thanks to well structured, clearly defined accessories. Furthermore, the adaptation of motors and controllers from other manufacturers to Festo’s belt driven reduction gear units and couplings is just as easy. Flexible connections The EGSA series will be launched with four types that differ with regard to size and nominal stroke. Whereas the EGSA-50-100 has a drive width of 50 mm and a nominal stroke of 100 mm, the 60 mm wide EGSA-60 variant is available with nominal strokes ranging from 100 to 300 mm. Maximum axial feed force of the EGSA-60 variant is 200 N. Adapter kits can be used to connect two EGSA axes, as well as for mounting grippers to the cantilever axis and attaching EGSA axes to profile constructions. The setup of complete pick & place systems is thus supported. Beyond this, a mounting kit is available which enables integra-
tion of EGSA cantilever axes into Festo’s mechatronic multi-axis modular system. Convenient integration of the axis into existing constructions, its long service life of roughly 20 million cycles and outstanding performance make the EGSA cantilever axis a component to which the motto “fit and forget” truly applies.
3-jaw grippers
Semi-rotary drives
Mini-slides
Linear modules
trends in automation No. 13, 2008
15
tia13_EN_Druck7:tia13_EN_Druck.qxd
16
29.04.2008
08:15
Seite 16
Handling and assembly Comparison of single and multi-stage vacuum generators Key features VN single-stage vacuum generators are entirely on par with multi-stage versions. Benefits VN single-stage vacuum generators are lightweight, small, low-maintenance and inexpensive.
Who’s the winner?
With their high suction rates, multi-stage vacuum generators are thought to deliver higher performance than single-stage vacuum generators. However, a direct product comparison offers a different picture.
Single or multi-stage – which vacuum generator is better? With the new VN single-stage generator, a rival that must be taken seriously has entered the arena along with the multi-stage products which are customary within the market. Six performance criteria under scrutiny: 1. Achievable partial vacuum (pu) in bar The degree of partial vacuum determines the suction gripper’s retention force. VN series vacuum generators reach a vacuum of -0.9 bar with a supply pressure of only
trends in automation No. 13, 2008
4 bar, and are second to none in relation to multi-stage vacuum generators. 2. Suction flow rate (l/min) Multi-stage vacuum generators often claim to have many times the suction flow rate of singlestage units. However, this statement makes reference to zero bar underpressure and is not meaningful, because this does not suffice to transport a workpiece. If we consider the suction flow rate over the entire underpressure range from -0.1 to -0.9 bar, both types of vacuum generators are comparable at -0.4 bar. Only with very
minimal underpressure down to – 0.4 bar do the multi-stage vacuum generators have a clear advantage (see graph). 3. Size and weight This point is clearly awarded to the single-stage VN generator: Thanks to its lightweight compact design, it can be mounted directly within the gripping area. Tubing with very short lengths can be used for direct, on-site installation which results in short evacuation times. 4. Maintenance-free The motto “fit and forget” is truly valid for VN vacuum generators.
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:16
Seite 17
17
1.200
Multi-stage vacuum generator VN 30 L vacuum generator VN 30 H vacuum generator
0,5
800
0,4
600
0,3
Evacuation time [s]
Suction flow rate [l/min]
1.000
0,6
400 200 0 0
-0,1 -0,2
-0,3
-0,4 -0,5
-0,6
-0,7
0,2 0,1
-0,8 -0,9
0 0
Vacuum [bar]
-0,1 -0,2
-0,3
-0,4 -0,5
-0,6
-0,7
-0,8
Vacuum [bar]
Suction flow rate in relation to underpressure.
Evacuation time in relation to underpressure.
Everyone who wants to double check things carefully ... ... is well advised to take advantage of Festo’s efficiency formula. It takes the relationship between air consumption (input) and evacuation time (output) into consideration. This enables an objective comparison of single and multi-stage vacuum generators.
η= VN single-stage vacuum generator.
1
η
tev,pu · qn 1+ v · 60
tev,pu qn v
Vacuum generator efficiency in relation to vacuum pressure Evacuation time [s] Vacuum generator air consumption [l/min] Volume to be evacuated [l] (standard volume: 1 l)
Single-stage vacuum generator This is ensured by the open silencer and the use of non-moving parts (basic version). This is not the case with multi-stage vacuum generators: These have several series chambers. Elastomer flaps are used to seal the chambers after the respective degree of underpressure has been reached. Depending on ambient conditions, they become contaminated more or less quickly and can no longer be fully closed – adequate underpressure can no longer be generated. The consequence is time consuming, costly maintenance at short intervals.
Compressed air
Silencer or ducted exhaust air
Vacuum
Multi-stage vacuum generator
Compressed air
Silencer or ducted exhaust air
Vacuum
Vacuum generators function in accordance with the venturi principle. The difference is the fact that singlestage vacuum generators (above) only have one receiver nozzle, and multi-stage vacuum generators (top) have two or more receiver nozzles.
trends in automation No. 13, 2008
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:16
Seite 18
18 Handling and assembly ... Who’s the winner?
Infoservice
is 1310 VN vacuum generator
5. Noise level [dB(A)] Connecting receiver nozzles in series on multi-stage vacuum generators reduces air exhaust velocity as well as sound level. This is a decisive advantage with regard to noise emission. Singlestage vacuum generators are not necessarily louder. The small sized units have a sound level of only approximately 55 dB(A). Vacuum generators with especially large diameters achieve acceptable sound levels of approximately 70 to 75 dB(A) in the vacuum operating mode thanks to the new open UOM silencer with expansion kit. 6. Costs The single-stage VN vacuum generator wins on costs as it is significantly less expensive than its multistage counterpart. And the winner is ... Single or multi-stag – which vacuum generator is better? With regard to size and weight, as well as maintenance and price, the single-stage VN vacuum generator takes the lead. Where achievable underpressure is concerned, the scores are level. In the case of suction flow rate, who wins the race depends on how much underpressure is required. Even if there’s no clear winner, the contest indicates that single-stage vacuum generators are a solution of entirely equal value in comparison with their multi-stage counterparts.
VN vacuum generator with double ducted exhaust air in EKRA’s X4 Professional
Vacuum cleans printing stencils and prevents printing errors Space and money saving technology Where surface mounting technology is concerned (SMT), screen and stencil printers from EKRA ensure precision manufacturing of PCBs – for cell phones, computers and toys. In order to connect electronic components to the printed circuit board, solder paste is applied to the board with the help of EKRA
printing systems. Automatic insertion machines then place the components onto the printed solder deposits, after which soldering takes place in an oven. Faster and more reliable stencil printing With its compact “X4 Professional”, EKRA offers a printer which is capable of furnishing even the smallest SMD components with solder paste. And this makes it all the more important to avoid contamination which results in printing errors. Faulty contacts or short circuits would otherwise be the consequence. For this reason, cleaning cycles can be freely programmed for the X4, as is the case with all of EKRA’s printers. A liquid cleaning agent wets the mat and the stencil simultaneously. In order to vacuum remove the liquid again, underpressure with a correspondingly adequate volumetric flow rate is required. Festo’s VN vacuum generator is used to this end. As opposed to a vacuum pump, it not only saves a considerable amount of space, it’s also quicker to install and less expensive. Even explosion protection is ensured with the vacuum generator (the cleaning agent contains a solvent). www.ekra.de
trends in automation No. 13, 2008
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:17
Seite 19
Sensors
19
Air consumption Field of application Compressed air networks for machines and systems Key features Cost reductions by means of continuous monitoring of flow rates and air consumption using flow sensors
Improving conditions For marathon runners, insufficient energy leads to a quick withdrawal from the race. The same can be said for controllers in the field of automation. But help is never far away – because as a technology enterprise, Festo pays close attention to the efficiency of its components. Nevertheless, performance stands or falls on the condition of the entire production system. As an experienced coach, Festo can offer many tips. Today: war on leaks.
Maintenance costs
6%
Investment costs
15%
79% Costs for electrical energy
for generating compressed air
Figure 1: Costs of operating compressed air systems (source: ISI 2000)
Those who instigate an energy debate within their own company usually get things moving more quickly than national politics do. Environmental protection and cost reductions become feasible. The prerequisite, however, is a reasonable amortisation period for the required investments and careful consideration is required in this respect. After electricity, compressed air is the second most important industrial source of energy. There’s hardly a production system, not even in medical technology that can function without pneumatics. Within the framework of an internal energy discussion, companies should also scrutinise their compressed air systems. Festo offers a broad spectrum of services to this end. Compressed air is valuable As shown in figure 1, 15 % of the costs for compressed air systems are attributed to investment, and an additional 6 % to maintenance. But the lion’s share, namely 79 %,
is attributed to the electrical energy required for generating compressed air. It therefore makes good sense to ensure that valuable compressed air is not wasted. Above all air leaks are expensive, involving costs amounting to several thousand euros are incurred much more quickly than one might think, thus eating up the profits. What to do? A time tested solution is continuous monitoring of flow rates and air consumption. Hope is good but control is better! Let’s assume that the compressors, the compressed air distribution system and the pneumatic drives are all correctly sized. Are further measures still necessary in order to avoid leakage losses? Yes, because the one does not exclude the other! In fact, air loss is more frequently detected coincidentally than as the result of targeted searching. Previous methods of leak detection: A common procedure for the prevention of leaks involves searching
trends in automation No. 13, 2008
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:17
Seite 20
20 Sensors ... Improving conditions
for them at regularly scheduled intervals. To achieve this, a complete inspection of all air lines is required several times a year – with the disadvantage that despite all of the effort the quality of the results remains questionable. This is because the inspector might not hear or see smaller leaks in noisy industrial environments. Leak detection today: Continuous monitoring of compressed air consumption with the help of flow sensors is a much better solution. Increases in consumption, and thus in costs, are quickly detected. The sensors register deviations and indicate exceeded tolerances. If necessary, an alarm is triggered and thus undetected cost increases are ruled out.
Automated leak detection: how quickly are investments amortised? A practical example provides us with the answer: • System pressure: 6 bar • Several leaks which together amount to a hole with a diameter of 3 mm and a loss of 666 litres of air per minute • System operation: 24 hours a day, 7 days a week • Observation time period: 50 weeks This results in air consumption of 335,664 cubic metres. A figure that provides us with a clue regarding the considerable costs that result from wasted compressed air. Results: With compressed air costs of 8.00 euros per 1000 cubic
If compressed air consumption monitoring is envisaged when the system is first installed, costs for mounting and installation are minimal. The example below shows an MS series service unit (left) and a electrical CPX terminal with MPA valve terminal (right).
trends in automation No. 13, 2008
metres, total costs of 2685 euros are incurred. If we assume that leaks are detected and repaired without delay through the use of a flow sensor, the sensor is amortised in just a few weeks. Easy measurement of total air consumption! In addition to other values, SFE1 and MS6-SFE flow sensors also indicate total compressed air consumption. In this case, the flow sensor functions as a compressed air consumption meter. The sensors are also capable of monitoring with reference to a consumption value which is specified by system users themselves. Each time this value is exceeded a digital output signal is generated, after which consumption is measured and documented. This is
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:17
Seite 21
Infoservice
is 1311 MS6-SFE flow sensor
is 1312 SFE1 flow sensor
Udo Matheis, director of product management for sensors at Festo: “I’m frequently asked what can generally be done in order to prevent leaks on machines and systems. My advice is simple, and it applies in all cases: Use top quality pneumatic components and size them correctly. Again and again, when we perform comparative measurements on commercially available products, we discover that there are considerable differences in quality that influence service life, wear and leakage. But regardless of this, the use of flow sensors is advisable in order to monitor entire compressed air systems, or parts thereof. Basically it’s like a telephone bill where the list of individual calls exposes any erroneous entries and cost drivers.”
especially useful when the consumption of a given volume of air needs to be monitored over a certain period of time. From theory to practice: installing flow sensors Up until recently, there were no flow sensors available on the market which, on the one hand, functioned as stand-alone units like the SFE1 and, on the other hand, could be combined with service units like the MS6-SFE. Both flow sensors can be used: • In new systems • In existing systems • In parts of pneumatic systems • For temporary installation The operator doesn’t need to have any specific knowledge of aerodynamics in order to use Festo’s flow sensors, because they're designed such that no special installation conditions need to be fulfilled in order to receive reliable results.
Technical data MS6-SFE flow sensor • Constituent of the MS6 range of service units • Measuring range: 200 to 5000 l/min. • Absolute flow rate values or overall consumption • Large LCD panel with background illumination • Compact and robust (IP 65 protection) • Digital outputs: two PNP or two NPN • Analogue outputs: 0 to 10 V or 4 to 20 mA • Range of applications: consumption monitoring of systems, documentation of consumption values, allocation of compressed air costs to cost centres and leakage monitoring in pneumatic systems
For example, the SFE1 flow sensor is equipped with a laminar flow inlet section which stabilises the flow of air. The MS6-SFE is used in combination with an inlet segment or a sieve arrangement which prevents erroneous measurement data. Conclusion: he who controls, saves! There’s no doubt about it. Technical data SFE1 flow sensor • Measuring range: 0.5 to 200 l/min. • Large format, illuminated LCD panel • Display can be rotated 270° • Absolute flow rate values or overall consumption • Threshold values and switching points can be adjusted via the display • Compact and robust (IP 65 protection) • Numerous installation options • Range of applications: leak detection in production, leak testing of finished goods, flow monitoring for parts feeding
trends in automation No. 13, 2008
21
Control technology
22
Consistent system concepts using the electronic CPX terminal Field of application Machinery and equipment manufacturing Key features • Soft-stop function and servo-pneumatic positioning with new characteristic quality • Multi-axis interface for electrical drives • Saves time and money by means of integrated functions
Pure function integration Fieldbus Ethernet
Interbus, DeviceNet, Profibus-DP, CANopen, CC-Link Modbus/TCP, Ethernet/IP, Profinet, EtherCat
CPX electrical terminal FED front-end display
Position
Compact
SBOX compact vision system
Proximity
Standard
Machine Vision Object detection Guided
Colour
Distance
Rotation/swivel
Pressure
Gripping
Temperature Vacuum/gripping
Digital/analogue sensors
trends in automation No. 13, 2008
Pneumatic cylinders/drives
Maximised modularity, flexibility and function integration: The CPX terminal enables simple connection of pneumatic and electrical control loops to an automation system. Depending on the respective configuration, it offers up to 512 I/Os throughout the entire system. The fieldbus interfaces are especially versatile. They’re not only possible using various fieldbus protocols such as Interbus, DeviceNet, Profibus-DP, CANopen and CC-Link, but also via industrial Ethernet as well, for example Modbus/TCP, Ethernet/IP, Profinet and EtherCat. Status and diagnosis of the CPX system and the connected
23
Holistic solutions and consistent system concepts are primary success factors in the field of automation technology. Where the electrical CPX terminal is concerned, CMPX, CMAX and CMXX servo-pneumatic and electric axis interfaces will constitute the next step towards comprehensive function integration.
CPX-CMXX Festo configuration tool FCT
Drivebus
CMAX
CMPX
Motor Controller SFC-LAC
Motor Controller SFC-DC
Servomotor Controller CMMP-AS
Stepper Motor controller CMMS-ST
Intelligent servo motor MTR-DCI
VPWP proportional valve
Proportional valve VPWP
Linear drive DGPL Linear drives with displacement encoder DGPI/L
Pneumatically controlled cylinders/drives
Cylinders/drives as positioning system
peripherals can be visualised according to modules and channels, and condition monitoring for the valves is integrated. Depending on performance of the connected Ethernet network, the CPX web server can be accessed from each PC – expensive service calls are thus avoided, and downtime is reduced in an enduring fashion. Integrated solutions ex-works The integration of functions into the CPX electrical periphery is a central success factor for the implementation of comprehensive automation tasks using an on-site valve terminal: Components and
Electric drives/axes
their functions no longer have to be selected, ordered, installed and configured separately; they’re provided by Festo as integrated solutions instead. Thanks to function integration, use of the valve terminal with CPX as a central unit reduces the price per channel by as much as 50 % – and reduced efforts required for ordering, setup, configuration and commissioning result in time savings of more than 60 % in some cases. CMPX soft-stop Thanks to the CMPX, soft-stop functionality is now available in the CPX environment. In addition
to fast, vibration-free travel between fixed limit stops, the system also offers the option of travel to one or two freely selectable intermediate positions. As compared with standard pneumatics, travel time is reduced by approximately 30 %. Applications demonstrate moving loads of 1 to 300 kg with a maximum stroke length of 2 metres. Depending on the selected fieldbus and other utilised modules, up to 10 modules can be installed on a CPX terminal.
servo-pneumatics is advantageous wherever moving loads are typically within a range of 1 to 300 kg, and accuracy to a few tenths of a millimetre is adequate. The CMAX servo-pneumatic positioning system is equipped with up to 64 configurable motion sets, and supports the FHPP protocol. Configuration and commissioning is executed via the central interface on the fieldbus node, via the fieldbus or via the CPX-FEC/CECX controller module.
CMAX servo-pneumatic positioning system Positioning technology using
Depending on the utilised drive, travel speeds of up to 3 m/s, acceleration values of approx. 30 m/s2
trends in automation No. 13, 2008
24 Control technology ... Pure function integration
Input/output modules
Digital Analogue Valve terminals MPA modular CMPX CMAX 1 axis CMAX 2 axes CMAX 1 axis group CMAX 2 axis groups
Inputs 4, 8, 16 2 x 16, 4 x 16 – – 48 64 2 x 64 128 256
Outputs 4, 8 2 x 16 8, 16, 24, 32 4, 8, 12 ... 128 48 64 2 x 64 128 256
Positioning of electric and pneumatic axes during manufacturing and packaging of ceramic tiles: a case for the new modules on CPX.
and accuracies down to 0.2 mm can be achieved. Standstill control, force control and monitoring in the target position are new features now included with the CMAX – no correction is required in the target position. Depending on the selected fieldbus and the other modules in the CPX terminal, up to eight pneumatic positioning axes can be installed. CMXX multi-axis interface for electric drives Planar surface and 3D gantries are the appropriate solution where workpieces need to be moved along several axes. Parameter configuration and control for this type of axis system with electric drives is no problem for the CPX-CMXX multi-axis interface. Simple parameter configuration using the Festo configuration tool (FCT) is a great advantage: Only the target positions need to be specified as input
trends in automation No. 13, 2008
quantities for the CMXX, which autonomously controls the individual axes via speed and position. The FHPP profile which has been expanded for multi-axis operation permits set selection operation, as well as direct operation with direct position specification by means of a PLC. The interface is suitable for single-axis applications and simple multi-axis applications in Cartesian systems. Pre-processing Simple, but efficient: In terms of control technology, the master PLC and the CPX terminal constitute a perfectly harmonised unit which, together with several CMXX or CMAX modules, comprises a PLC compatible interface. Cycle times are significantly shortened thanks to decentralised motion control at the CPX modules – and the master PLC’s workload is reduced at the same time. The servo-pneumatic
DGPL: fast travel with soft-stop: simple gantry design, with SLT and gripper at the front-end.
3 dimensional X-Y gantry with several DGE electric axes, Z-axis with HMPL pneumatic handling module and complex rotation/gripping. Can be completely implemented using the new CPX/MPA platform.
Infoservice
is 1303 CPX electrical terminal
CPX goes motion control – a selection tool CMPX
CMAX
Soft stop end-position controller
Servo-pneumatic positioning
CMXX Electrical multi-axis interface
system Pneumatic drive
Yes
Yes
–
Electric drive
–
–
Yes
Number of axes
10
8
8
Number of positions
2+2
As desired
As desired
Accuracy **
±2 mm
±0.2 mm
30 ... 200 μm
Load **
1 ... 300 kg
1 ... 300 kg
Up to 200 kg
Travel/stroke **
Up to 2
Up to 2
Up to 10 m
Coordinated drives
No
Yes *
No
Number of motion sets
1
64
1024
Direct control
Yes
Yes
Yes
Key features
• Sturdy, simple system • 30 % faster than standard pneumatics
• Integrated position and force control • Sturdy, space-saving positioning system
• Integrate dynamic calculation • Simple thanks to table assisted sequence description
* Only in combination with the CPX-FEC/CECX controller ** Depending on application and pneumatic drive or electric linear unit, controller, motor/gear unit
and electric drives are started and advanced to their positions by means of simple commands from the PLC program via a fieldbus. Additional reliability is provided by the preliminary test: FCT software is used to determine whether or not the motion sequences for the
multi-axis handling unit are OK. Package solutions for motion control and handling/assembly The electrical multi-axis interface and servo-pneumatic applications expand Festo’s modular mechanical axis system into a complete,
Definitions
consistent systematic package. In combination with the CPX-FEC/ CECX controller module, the CPX terminal is transformed into a complete automation system with motion control for electric and servo-pneumatic axes with direct connections to electrical I/Os and pneumatic functions such as rotation, swivel motion, gripping and vacuum.
Set selection operation Selection of positions saved on the CMAX/CMXX Direct operation Direct specification of positions via a PLC FHPP Festo handling and positioning profile for direct specification of positions from a PLC FCT Festo configuration tool for parameter configuration for drives, motion profiles etc. using a PC Cartesian system All axes are arranged at right angles
trends in automation No. 13, 2008
25
tia13_EN_Druck7:tia13_EN_Druck.qxd
26
29.04.2008
08:19
Seite 26
Industry specific solutions Laboratory automation Key features Handling solutions for specimen containers and liquids for laboratory procedures
Active ingredient: automation
Sanofi Aventis
Benefits Synergies between factory and process automation
When Alexander Fleming was busy discovering penicillin in 1928, most laboratory procedures were strictly manual. Much has changed during the following 80 years. Today, fully automated laboratory machines execute time consuming routine tasks and handle hazardous substances.
Health is extremely important; in times of increasing life expectancy, everyone wants to remain active and fit right up into old age. However, visits to the doctor are necessary, whether for preventive checkups or for treatment. Doctors don't place faith in a gut feeling, but rely on systematically ascertained values from the analysis of blood counts or from the preparation of tissue specimens. Testing and research processes in laboratories are currently running at full speed. In order to be able to complete routine procedures quickly, reliably and economically, laboratories are taking advantage of modern automation technology
trends in automation No. 13, 2008
to an ever greater extent. Grippers, drives and valves are ever-present. Laboratory automation – what’s involved? Laboratory automation is subdivided into three areas. In the specimen handling section, test tubes, other miniaturised liquid containers and specimen strips are removed from and placed into storage or fed to automatic analysis equipment. The area for fluids handling encompasses analysis procedures, usually involving the use of pipetting techniques. The third area includes hybrid systems, i.e. a combination of specimen and fluids handling, for example auto-
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:19
Seite 27
Infoservice
is 1302 Partner to the biotechnology and pharmaceuticals industry
Dipl.-Chem. Peter Jaschke from Festo’s medical technology and laboratory automation division: “We anticipate increasing degrees of automation in laboratory processes. The reasons for this include growing demands for the reproducibility of results and flexibility in analysis processes and specimen throughput, as well as results availability. Festo is preparing itself for this trend by expanding its range of miniaturised automation components and systems in a targeted fashion, and by means of more complex integrated solutions which take advantage of the most up-to-date technologies.”
matic analysis equipment with integrated specimen handling. Factory and laboratory automation ... ... go hand in hand. Many standard components which have proven their worth in the field of industrial automation are also used in laboratories. The emphasis is on compact, cost optimised components. This means that compact and miniature drives, as well as micro, high precision and vacuum grippers take centre stage. Door open – door closed This is the principle on which socalled patch clamping systems are based that involve automatic analysis equipment from the field of drug and active ingredient research in order to examine cell characteristics and ion currents. Cells must be introduced into a nutrient solution. Tiny “intake nozzles” then draw the cells in – always exactly one cell per nozzle. It’s important to ensure that the cell is only drawn up to a certain point within the nozzle, and that the cell membrane is slightly “perforated” in the process. The active ingredient to be examined can then be introduced into the solution, and the cell’s ion channels are measured. These “doors” in the cell membrane control the
flow of ions in and out of the cell. The measured values provide information which indicates how the cell assimilates or expels the active ingredient.
Concentrated valve power: seven Festo valve manifolds with 8 valves each ...
An extremely steady hand ... ... is required when drawing in the cells. That’s why Danish company Sofion Bioscience uses piezo valves from Festo for its automated patch clamping machines. The valves regulate the movement of fluid into the channels on the test panel within a pressure range of 500 to +500 mbar, and control the suction system for drawing in the cells accurately to ± 3 mbar at extremely small volumes. The benefits ... ... are clear, because the automated patch clamping system enables an increased specimen throughput: 48 cells are drawn in simultaneously during each cycle, and are tested on various substances. In comparison, systems without piezo valve technology are only capable of processing 16 cells per cycle. In addition, precision control of pressure ratios made possible by piezo technology results in considerably longer lifetimes for the highly sensitive cells. This, in turn, increases the success rates achieved for the individual tests.
... control the 56 intake nozzles in the patch clamp systems.
Rear view of the valve manifold.
trends in automation No. 13, 2008
27
tia13_EN_Druck7:tia13_EN_Druck.qxd
28
29.04.2008
08:20
Seite 28
Industry specific solutions “Genuine” travel in a virtual world with a driving simulator In use SPC200 axis controller combined with DNCI standard cylinder and FENG guide unit Benefits Constant distance from the laser to the spinning tyre
No risk, but fun!
Racing or cruising through the desert with one’s own car – and without any risk. Impossible? Not anymore since TAG Systems in Australia developed its simulator which makes these extraordinary driving experiences possible.
The car is mounted on a dynamometer and is thus perfectly safe for the driver.
trends in automation No. 13, 2008
The SPC200 axis controller, in combination with the DNCI standard cylinder and the FENG guide unit, ensure that the laser is not too close to the tyre.
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:20
Seite 29
Infoservice
is 1313 SPC200 axis controller
DRAG TAG – the racing simulator
The difference in comparison to conventional simulators is the pioneering technology. TAG Systems takes an actual car and transplants it into a virtual world. This is why TAG Systems calls its newest product the assimilator. A unique driving experience is created with the help of a specially produced dynamometer, laser controlled sensor technology and computer generated images. The car runs on dynamometer rollers while data regarding force, speed, torque and braking action is transmitted continuously to the TAG Systems computer in order to generate life-like, 3D motion sequences – synchronised with the running car. An image generator processes the data into images and projects them onto three large screens in front of the car. The screens are four meters high, have a range of 200° and thus encompass the driver’s peripheral vision as well –
Competing against one another is made possible with DRAG TAG. Any desired number of assimilators can be connected to each other, allowing drivers to compete simultaneously in a race. The drivers steer, accelerate and brake just like they would in the real world, and they can see each other and interact in the virtual world – and even crashes! A high scores table enables the drivers to compare themselves with each other. Well known international race tracks can be selected, as well as the desired card – from everyday passenger cars to race cars.
a perfect virtual driving experience! The screen in the middle also serves as an exit gate; it is lifted and held in place by a DNC-KP cylinder with clamping cartridge. Everything safe? Securely mounted on the dynamometer, the car is prevented from moving in an uncontrolled fashion so that the driver always has everything under control. Steering action is measured by means of a double laser which detects the distance from the front wheels to the laser and is connect-
ed to the image generator, so that actual steering action is transferred simultaneously to the virtual world. The SPC200 axis controller with DNCI standard cylinder and FENG guide unit ensures that the laser is kept at a constant distance from the revolving tyres, without mechanical contact. Undreamed of possibilities ... ... are made accessible by this system. From initial training to prepare drivers for real traffic conditions, to international driving instructions which, for example,
The idea One of the first demands placed on the system was that it would have to function with normal cars. In order to make TAG Systems commercially viable, cars would have to be connected to and disconnected from the system very quickly, thus avoiding extended idle time and protracted changeovers. This type of driving simulation, which includes a DRAG TAG operating mode, was intentionally developed in order to counter illegal motor racing, and thus to ensure greater road safety.
provide drivers with the opportunity of practising driving on the “wrong” side of the road. Testing newly planned roads is also conceivable, as is training for advanced drivers who want to test their skills in precarious traffic situations in a risk-free environment.
TAG Systems Australia Products Contact
Development and implementation of innovative driving simulators AU Victoria 3061 info@tagsystems.com.au
trends in automation No. 13, 2008
29
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
30
08:20
Seite 30
automation worldwide
automation worldwide
USA
USA Packaged passion
30
Singapore Dosing chemicals
31
Finland Clever automation
32
Canada Pneumatics help prevent RSI
32
Vietnam Powders, pellets and pneumatics
33
Packaged passion Who has never experienced the passion for nuts, cashews and pistachios? Setton International Foods in Commack on Long Island, New York, has turned this passion into a commercial business. Setton has the entire value creation chain for pistachio production under control – from pistachio cultivation in its own fields in California,
through to packaging in containers for retail sale. A typical American success story: With its passion for nuts, the company has become the second largest pistachio and cashew processor in the United States! Automation of the packaging sequence is becoming more and more important in order to be able to meet continuous demand for the company’s snack products: The plastic containers are now transferred from a feeder to a conveyor belt, on which they are filled with nuts via a pick and place system designed by Festo. “We weren’t just supplied with reliable automation products, we also received extensive consultation and support for setup and commissioning of the system”, explains Shawn Noren, automation manager at Setton International. www.settonfarms.com
trends in automation No. 13, 2008
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:21
Seite 31
automation worldwide
31
Singapore
Dosing chemicals The CWRP project in Singapore (Changi Water Reclamation Plant) – the first phase of a massive wastewater and sewer system project known as the “Deep Tunnel Sewage System” – is a construction project of superlatives. The wastewater treatment plant has been initially designed to process 800,000 cubic metres of wastewater every day, but can be expanded to a capacity of 2,400,000 cubic metres per day. Numerous international companies are involved in this enormous project, for example Festo who is providing solutions for dosing chemicals. United Engineers Singapore (UES), specialists in the fields of drinking water and wastewater treatment, have specified requirements in this area with regard to ambient conditions (Ex zone 2) and actuation of the process valves via Profibus and remote I/O stations. Ball valves
with V orifice in combination with DAPS quarter-turn actuators are being used in order to ensure linearity of flow control. Festo also supplied the solution for the interfaces and the overall control system.
DAPS quarter-turn actuator
trends in automation No. 13, 2008
tia13_EN_Druck7:tia13_EN_Druck.qxd
32
29.04.2008
08:21
Seite 32
automation worldwide
Finland
Clever automation
Average growth in turnover of 15 % per year – this is only possible with clever automation solutions. Finnish family enterprise Orfer secures growth rates of this magnitude using combination packaging and palletising lines which are individually customised. The systems integrate robots and gripper solutions that are configured according to available space at the customers’ facilities comprising food processing, printing, packaging and pharmaceuticals industries, as well as in the fields of plastics processing, woodworking, metalworking and paint manufacturing. Special gripper systems, matched to the various types of products, are at the heart of these automation solutions which are designed in-house by Orfer. A complex vacuum gripper, equipped with a compact CPV valve terminal, opens up new perspectives for handling parquet and plywood in the woodworking industry. www.orfer.fi
trends in automation No. 13, 2008
automation worldwide
Canada
Pneumatics help prevent RSI For quite some time now, repetitive strain injury (RSI syndrome) has been a familiar problem in many companies. Monotonous movements over long periods of time result in damage to the musculoskeletal system. Nobel Metal Processing Canada Inc., manufacturers of customised blanks for the automotive industry, has also been affected by this issue. Hundreds of laser welded steel parts with weights ranging from 13.5 to 22.5 kg had to be manually inspected on a daily basis for defects. This resulted in employees having symptoms of fatigue and stress in the joints. A solution was sought and found in cooperation with Edwards Pro-Tech Ltd. Thanks to the development of a vertically arranged rotary table platform, RSI is now a thing of the past. The use of vacuum grippers in combination with cylinders, for example the DGPL linear drive, makes it possible for the employees to inspect the welding seams without any great physical exertion.
DRQD semi-rotary drive
VTSA valve terminal
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:22
Seite 33
automation worldwide
33
Vietnam
Powders, pellets and pneumatics The production of medication such as tablets, powders, capsules and pellets, is a complex procedure for which each step is precisely planned and strictly controlled. For Tien Tuan Pharmaceutical Machinery Ltd, specialised in the production of processing and packaging machines for pharmaceuticals manufacturing companies, adherence to applicable international standards is a top priority. For years now, the company has placed its faith in Festo’s quality and performance in this respect.
The rotary table moves on a DRQD semi-rotary drive. CPV and VTSA valve terminals are used to control the system.
Festo components are utilised in the company’s latest systems for fluid bed drying and granulation. The standard cylinder DNC for example, with a stroke length of 2500 mm for shaking and pressing the powder through a filtration
unit. In order to facilitate stopping at different stroke lengths, it's connected to a rodless DGPL drive. Control is handled by means of a VTSA valve terminal. In combination with the cylinders, the efficiency of the machine was significantly improved as compared with previous models. www.tientuan.com.vn
www.nobleintl.com
DGPL linear drive
trends in automation No. 13, 2008
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:22
Seite 34
Fax-reply To From
is 1300
infoservice “trends in automation” 13
Take advantage of your personal info service! Convenient – fast – direct – free of charge – without obligation.
1301 Partner to the food and packaging industries 1302 Partner to the biotechnology and pharmaceuticals industry 1303 CPX electrical terminal 1304 MS series service units 1305 Sensors, image processing systems, controllers 1306 Safety technology guidelines 1307 Robotinoμ 1308 Hybrid learning factory MPSμ 1309 Spindle driven cantilever axis EGSA 1310 VN vacuum generator 1311 MS6-SFE flow sensor 1312 SFE1 flow sensor 1313 SPC200 axis controller
trends in automation 13 May 2008 Published by: Festo AG & Co. KG Ruiter Straße 82 D-73734 Esslingen Chief editor: 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 13, May 2008“
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:22
Seite 35
Pneumatic? Electrical! Your application is the decisive factor. Whether pneumatic, servo-pneumatic, electrical drives or a combination is involved, Festo guarantees a systematic and highly economical solution – including service.
www.festo.com/en/edrives
tia13_EN_Druck7:tia13_EN_Druck.qxd
29.04.2008
08:22
Seite 36
Festo AG & Co. KG P.O. Box D-73726 Esslingen Phone +49 711 347-0 Fax +49 711 347-21 44 service_international@festo.com www.festo.com