trends in automation

The Festo Customer Magazine Issue 18


Floating perfection
Automated high-tech kites


No speed limit
Ready-to-install high-speed handling units


IDEAL model for Unilever
Festo Training and Consulting

In focus

Productivity tomorrow
Solutions that offer more productivity, efficiency and flexibility

Inspired by nature
With its “Bionic Handling Assistant” prototype, Festo as a learning organisation is transferring principles found in nature to biomechatronic applications.

trends in automation Editorial 1

The future of production
Dear reader, “The future is faster” and the quick will win against the slow rather than the big against the small. This well-known fact refers to all industrial processes. Speed is the keyword when it comes to machine design and the selection of the right components, the delivery of the equipment and finally, operation. This is even more true today when after an industrial crisis of formerly unknown proportions we are seeing a wave of recovery that has already reached many industries and has brought back a lot of companies to pre-crisis levels and beyond much faster than expected. Speed makes the difference. In the future, we will see much more competition regarding speed and flexibility than in the past. In this edition, we are focussing on the future of automation and how we can support you even better in the future. Your future challenge is “mass customisation” – balancing volume effects in production with the flexibility to address the individual needs of your customer. Our mission is to make you more successful, through efficient design tools, reduction of changeover times (page 26: ifc flexfeeder) and fast production equipment (page 14: High Speed Handling Units). Speed is also required when reaching international markets with your new machine designs. The competition is not sleeping, and your only protection is to run faster than they do. Festo as an international partner with 58 own companies all over the world is prepared to help you in this endeavour. We strongly believe in international networking and are prepared and ready to assist you. As an example, have a look at our operations in Brazil (page 28). Confront us with your international challenge and find out what we can do for you worldwide! We are looking forward to making use of the upcoming boom together to strengthen our partnership. Let’s move ahead together! Yours,

Ansgar Kriwet, Sales Director – Europe

Ansgar Kriwet

In focus “Productivity tomorrow”: Just as mechanical and electronic developments are leading to higher productivity today, automation technology will find solutions for tomorrow’s production processes, reflecting the demand for large numbers of variants, “one-off” production, stringent safety standards and rising energy prices. In this edition of trends in automation you will find information on the latest trends and expert opinions on this subject, together with many examples of progress in production and assembly operations.

trends in automation

Issue 18

Editorial 1 Panorama 4 Festo worldwide Soft Stop 37

A rising star: the CyberKite from Festo’s Bionic Learning Network.

Ingenious ideas take off Automated kite system with cybernetic control. Our designers used nature as a source of inspiration for its development. 24


“The discussion about the ecological footprint of production installations will intensify.”

In focus “I have a few questions on production technology.” Professor Reijo Tuokko of the University of Technology in Tampere, Finland, is a leading expert in matters relating to tomorrow’s production. We have been talking to him about sustainable production, the globalisation of machine building and harmony between people and machines. 6

elumatec GmbH utilises the advantages of VTSA valve terminals for its machines. 32 Impulse No speed limit! High-speed handling units can be used in all applications requiring fast.trends in automation Contents 2 3 – 26 14 Fast and precise positioning with high-speed handling units. 26 Is it party time again? In Brazil. 28 The professional profile The production of aluminium or plastic profiles demands speed and precision. 10 Relaxed around every corner The integral moulded seats of the Mercedes-Benz E-class adapt to fit any body shape – thanks to piezo technology. Synergies Unilever Festo Training and Consulting enabling Unilever’s apprentices to make a positive business impact. too. However. flexible and inexpensive positioning. dynamic seat modules add further realism to 3D film experience using fluidic muscles. things are starting to pick up again. even with a large number of workpiece variants. The Tripod enables dynamic handling and requires little space. the economic crisis has left its mark. 18 Audiences stirred by fluidic muscles Innovative. the ifc flexfeeder provides extremely short set-up times. 21 At the press of a button Thanks to a Tripod robot and a vision system. 14 .

even larger than the 1851 exhibition at Crystal Palace in London. Heinz company displayed the first industrially produced tomato ketchup. For the first time. . The response to the exhibition was equally gigantic: around ten million visitors over 180 days. the exhibition was also a dream of the future which the young US nation imagined for itself.864 manufacturers displayed their innovations over an area of 115. At the opening ceremony.J. exhibits were not displayed together in a single central hall but were spread over five halls with various themes. while the Remington company showed the first marketable typewriter and the H.000 m2. with an exhibition area of 81. US President Ulysses Grant and the Brazilian emperor Dom Pedro II set a giant Corliss steam engine in motion that was used to drive all the other machines in the Machine Hall. Apart from the impressive statistics. opens its doors in Philadelphia.Back to the future 10th May 1876: the Centennial International Exhibition.600 m2. Alexander Graham Bell presented a telephone. The USA was celebrating the 100th anniversary of its independence and presented a show of superlatives. the first international exhibition on American soil. The two largest exhibition buildings were the Machine Hall (photograph) and the Main Hall. A total of 30.

trends in automation Panorama 4 5 – Photograph: HistoCard – private www.histocard. Garmisch-Partenkirchen .

In your opinion. where the effects of production on the environment are zero and where highly trained and motivated workers operate in a safe and pleasant working environment and in complete harmony with the machines.In focus Interview “I have a few questions on production technology. though. but surely I am allowed my visions. We discussed sustainable processes. What will production lines look like in 2020? Tuokko: By 2020. as an expert observer of the industry: where is machine building heading? What are its development objectives? Prof. At the same time. while engineers concentrate on flexibility and miniaturisation and planners attach importance to new processes. which of these groups will set the tone in the future? And how will it be possible to find a common denominator for these different viewpoints? Tuokko: Of course I can’t give you a magic formula for the future. And ultimately they allow costs and the consumption of resources to be reduced. Reijo Tuokko: No matter in which direction production technology develops. the globalisation of machine building and harmony between people and machines.” What form will tomorrow’s production take? What will be the dominant trends in machine building in the coming years? Professor Reijo Tuokko is among the world’s leading experts in matters relating to the future of production technology. Having said that. mini-sized production systems are being studied at universities and research centres worldwide with regard to their environmental viability. It is a fact. the main emphasis will always be the same: on the harmonious interaction between people and machines. Micro and desktop factories are conceivable architectures for the on-demand manufacture of specific products such as medical implants or pocket-sized electronic entertainment devices. Mini production systems based on modular principles have a greater operational availability. dexterity and ability to adapt and interact are far from what would be required to achieve this harmony. they require an amalgam of new technologies. However. the more difficult it is to create this harmony. we should have reached a level of sustainability where both production equipment and the products made are fully recyclable. What is more. Production equipment must keep pace with the development of the products for which it is used throughout its life cycle. This is a bold forecast. a clear advantage when it comes to re-configuring a system. robots’ sensory capacity. I hope that by 2020 we will succeed in creating inexpensive and sustainable production methods. irrespective of individual viewpoints. so-called desktop factories. small batch sizes and a large number of product variants. aren’t I? . Managers are interested above all in the costs and profitability of machines. Even today. trends in automation: Let me begin by asking you. At the moment. despite all the efforts which have been made in research and development. These products are typically characterised by short life cycles. by 2020 there will be more and more mini-sized production lines in operation. while at the same time consuming as little of our resources as possible. that the discussion about the miniaturisation of production equipment and its ecological footprint will intensify. the higher the degree of automation and autonomy of machines.

Tuokko has also worked on development projects as a programme manager and programme coordinator for Tekes. Since 1996. Tuokko began his career with the automation division of Valmet Oy Machine Tool and Factory. Finland. since 1990 and is also Head of the Department of Production Technology. where he worked for eleven years as a research engineer and R&D manager. Tuokko has a great deal of experience in international joint research projects. As a member of the high-level group MANUFUTURE. he has been lecturing at the universities of Lappeenranta and Tampere. the European technology platform for production technologies of the future. and a member of the Board of Management of EFFRA. . Since his appointment as professor. the European Factories of the Future Research Association.trends in automation Inspiration 6 7 – Personal profile Professor Reijo Tuokko Reijo Tuokko has been Professor of Automation Technology at the University of Technology in Tampere. the Finnish Funding Agency for Technology and Innovation.

Machine builders should therefore increase their involvement in international joint ventures and look for business success across national borders. What is the position at international level? Is there a difference in standards between continents? Are there different machine philosophies? Tuokko: From each country’s individual point of view. we consider the machine building industry as subject to regional variations. ergonomics. that have a neutral specification. That is why there are not many machines that can be used in all regions or. in other words. In the course of globalisation. Even in the “No matter in which direction production technology develops.At present. suppliers of production machines still have different machine variants for different markets and regions. efficiency and sustainability vary from country to country and in accordance with the applicable standards.” Reijo Tuokko . The requirements for machine safety. as that is the only way in which it is possible to safe-guard jobs in the country concerned. even today. these requirements are moving ever closer together. the potential for improvement varies enormously from continent to continent. With regard to production efficiency. the primary objective must of course be a competitive national industry. To what extent will globalisation also result in uniform standards in this industry? Tuokko: We should note that. however. the main emphasis will always be the same: on the harmonious interaction between people and machines. This supports the case for producing regionally neutral machines.

de Intensive exchange: Prof. At the same time. whether at home or on trips together. Prof. These not only give me time to relax but also numerous opportunities to learn something new by exchanging ideas. which has also become my hobby. while the Fraunhofer Institute of Production Technology and Automation (IPA) Stuttgart is responsible for the technical management of the implementation of MANUFUTURE’s working programme. Dr. which are after all the catalysts for changes of this kind. Tuokko is always ready to discuss his visions for the future. Which are doing better: the countries that carry out development or those with production operations? Tuokko: The countries that develop technologies themselves are in a better position. The objective must be to increase added value and incorporate knowledge at all levels. I have been able to make many personal contacts and friends.manufuture. KG. they demand a new approach to production. Peter Post. The developed countries have the advantage over the developing countries in that they have more universities. the German Ministry of Economy and Technology (BMWA) and numerous industrial companies. a question about you personally: how do you relax after work? Where do you get the new energy to reflect on “tomorrow’s production”? Tuokko: I must admit I have a privileged and interesting job. The project is supported by the Ministry of Education and Research (BMBF) and the Project Management Agency Research Centre Karlsruhe (PTKA). from a use and discard economy to a sustainable economy. ¢ . They are better placed to develop and implement new concepts for the transition from a traditional economy to a knowledge-based economy. However. certain countries will take up the challenge to improve efficiency. the German Ministry of Education and Research (BMBF). Finally. Head of Research and Programme Strategy at Festo. Head of Research and Programme Strategy at Festo AG & Co. while others will relocate their production to countries with low wage costs or to countries which offer higher efficiency and performance. These new concepts will have a great influence on markets. highly developed countries this potential is well over 100%. society and technology. Reijo Tuokko. www. From left to right: Dr. institutes and research centres. Peter Post. Through my work in the international community. The industrial spokesman for MANUFUTURE Germany is Dr. the best way for me to relax and recharge my batteries is with my family. with partners from the high-level group Manufuture. Christoph Hanisch. such as the complete sustainability of products and production equipment. Head of Future Technology at Festo.trends in automation Synergies 8 9 – About the project MANUFUTURE Germany The MANUFUTURE Germany Platform was founded in September 2005 on the initiative of the German Engineering Federation (VDMA) together with other associations. The overall project is co-ordinated by the VDMA. This has heightened my awareness of regional differences and global trends and the effects of these trends on tomorrow’s production. As I see it.

In contrast. initially using their engineering.Unilever and Festo Festo Training & Consulting: enabling apprentices to make a positive business impact U nilever is one of the world's leading suppliers of fast-moving consumer goods. At this time. programme manager at Festo Training & Consulting who leads their partnership with Unilever.000 per annum and making improvements in site Overall Equipment Effectiveness (OEE) from 64% to 76%. it's about reducing factors such as downtime and increasing productivity. “Rather than offering managers a knowledge based training programme. offering over 400 brands globally and over 40 in the UK. home hygiene and personal care. in partnership with the Festo team. as well as improving skill and knowledge levels within the site workforce. the IDEAL approach focuses on giving Unilever employees the skill and understanding to identify problems within the business and find the best and most effective solutions. Festo Training & Consulting objectives at the forefront and by working through each stage of the IDEAL model enabled the team at Crumlin to review how a focused approach to identifying training needs. over the years. the business welcomed a fresh perspective to technical training and development in 2006.” he explains. manufacturing and training expertise to access a series of ‘off the shelf’ skill and product based solutions. tangible difference to the business. Unilever seized the opportunity to review the effectiveness of these ‘off the shelf’ solutions and question whether they were the most appropriate solutions for the operational and people development issues the business needed to address. “The IDEAL approach is not about increasing skills and knowledge levels within the business. To maintain its market position. An ideal approach to training Festo was keen to demonstrate to Unilever that a fresh approach to training could deliver a positive.” explains Gary Fuller. Unilever has invested in training and development for many years. The results were impressive and included. In April 2007 the Crumlin team and their Festo partners presented their experiences and significant financial savings to a meeting of Unilever Technical managers. Reproduced with kind permission of Unilever . alongside issues within the business. Whilst these training solutions have. Unilever has worked with Festo for over 15 years. enabled Unilever employees to secure and implement business-relevant knowledge of specific products and issues. The organisation has been serving the UK for more than a century with a mission to meet everyday standards for nutrition. financial savings of over £26. could offer significant return on investment. By keeping these Gary Fuller. Programme Manager. for example. By focusing on the Crumlin site in south Wales. Festo worked through a new training model – IDEAL – to outline how the business could secure tangible results for the business.

apprentices complete specific projects – such as achieving energy saving. as required by Government.” Identifying the needs of Unilever apprentices To ensure the IDEAL model did offer the ‘right’ solution for Unilever apprentices. Investing in apprentices “Apprentices are a key component of our talent management strategy and we recognised the need to ‘up our game’ to ensure our programme could continue to deliver exactly what the business needs now and in the future. It’s all about demonstrating return on investment. apprentices were recruited to and managed under a centrally led programme. rather than attempting to apply a preconceived textbook solution. “I was very impressed with the work undertaken with Crumlin. the business took steps to review and refresh its apprentice programme in 2004. Once complete.” comments Hazel Elderkin. coaching and development needs of individuals. which means that following their formal training they must be able to apply their learning in a real business setting. The IDEAL model really took the theory of training evaluation and put it into a business context. Based on this research we were in a strong position to develop a solution that reflects the current and future needs of apprentices and the business. At Unilever. a five-day Pneumatics & Mechatronics module – based around the IDEAL model – that blends the theory delivered in the academic. Festo and Unilever developed the ‘Improvement Project’. continuously improving the solution by building confidence and experience. Following these site visits. for example. it is unlikely that any solution will prove to deliver. A… APPLY An effective review of the project provides feedback on project issues and can identify. E… ENGAGE The development stage will have tested the concepts.” explains Steve Fletcher. the development stage can begin. At this time Unilever began work to unify the organisation’s approach to its apprentices. The first year requires all apprentices to attend full time at West Cheshire College (Capenhurst Technology Campus) with subsequent years combining ‘hands on’ learning in the workplace. reducing production downtime and increasing productivity within the business – that are reviewed by all project stakeholders. Projects generally involve a wide range of people from inside and outside the organisation and if their needs and expectations are not properly evaluated and considered. L… LEAN This stage provides the opportunity to demonstrate how the new skills and knowledge are being applied and outlines the impact on the business. By installing a feedback loop the project can become self-sustaining in the long term. the full implementation can begin. “We took the opportunity to look at every production environment within the business to help us understand the world the typical Unilever apprentice lives and operates in.” explains Hazel Elderkin. interspersed with block release back at the College. receive regular feedback from College on their learning and technical capability. “Not only does this help us to ensure they’re happy and are enjoying the programme. I… IDENTIFY The first stage is to properly identify the needs of all stakeholders. but it’s their opportunity to comment on their experience and how they think they are performing to date. knowledge. but they have a quarterly line manager review to assess their development. rather than recruiting apprentices at a site or factory level. Alongside this was the opportunity to assess the needs of individual apprentices to confirm what they need to know. College-based programme with the practical skills. D… DEVELOP Once the identification process is complete. Unilever’s Engineering and Technology Director at Unilever Europe. the competency levels required and what should be included in any future apprentice offering. the business took the opportunity to clarify and understand the role apprentices were to play within the business now and in the future. and receive informal feedback from existing Unilever engineers at their host site as they develop and apply their skills back into the workplace. ensuring results are delivered and clients have the ability to repeat or multiply the success of projects without the need for ongoing consultancy intervention. Not only are regular reviews undertaken every twelve weeks. Unilever apprentices are reviewed throughout their four-year learning journey. when we take on a cohort of apprentices it can be difficult to predict exactly how the business will deploy them so we needed a flexible solution that can cope with any eventuality. Project Manager – Engineering Development at Unilever. However. assessed results and proven the potential impact of the project. processes and tools the project requires in partnership with the client.” says Hazel Elderkin. I could see immediately how the approach might apply to aspects of our existing apprentice programme because of its focus on implementation and offering apprentices a vital business context to their development. “We want our apprentices to be up and running quickly. .trends in automation Synergies 10 – 11 IDEAL provides a structured approach to projects. The apprenticeship resulting from this review was a four-year programme that offers apprentices ‘freedom within a framework’.” says Festo’s Gary Fuller. “We also proactively seek feedback from the apprentices themselves. The objective is to develop the core skills. To this end.

That is.knowledge and behaviours required by the business. Unilever Project Manager – Engineering Development . “The investment required by Unilever is also manageable. the results each apprentice can achieve – initially through the direct financial savings of their Improvement Project and later through their work on the shop floor – are much higher and represent a considerable return on investment for the business. Here they use the model to report and record the business issue they’re working on. This increases their engagement and confidence in their own ability and means that when they graduate from the programme they can observe issues and be confident they have the correct solution to address them.” comments Hazel Elderkin.” says Festo’s Gary Fuller. it makes sense to keep investing. training and development of this nature can be used to solve issues within the business that are costing money. “Throughout the module we use examples.” Hazel Elderkin. it’s only necessary for apprentices to undertake the Improvement Project Module once. If. in the case of Unilever. The module is undertaken in the final year of the formal apprentice programme and was delivered for the first time in September 2007. It helps everyone – especially the apprentice – to feel good and know exactly what they have accomplished. many organisations have wanted to reduce costs and have therefore cut training spend. Extending apprentices’ learning journey The ‘Improvement Project’ module ensures apprentices’ learning journey is not restricted to the classroom. this isn’t necessarily the answer. whether it’s regarded as a cost or a solution for the business. academic programme. Return on investment is a key factor in the Unilever apprentice programme. controlled environment.” comments Festo’s Gary Fuller. It enables individuals to continue their learning and development within the work environment and transfer their knowledge to tangible skills and impact for the business. For example. All participants need to know what was done and how it has made a difference to the business. Taking place over eight weeks following the formal.” says Hazel Elderkin. for example. application and exercises from the business to demonstrate what apprentices are likely to experience in their everyday work. In the recent downturn. “This approach enables apprentices to realise they can apply practical and manageable solutions for the business. All these examples are taken from Unilever sites and are real issues for the business. because of the significant investment over the four year period. “Although this is a significant cost to the business. we find a typical problem that causes a headache for the apprentice and work with them on the course to find a solution in this safe. “It is very important for all three parties – the individual apprentice. the project module encourages apprentices to make use of the IDEAL tool to extend their learning. The skills they learn and the confidence they have to transfer this learning to the “We have developed a partnership relationship in the truest sense and much of this is based on Festo’s understanding of our organisational and commercial needs.” he says. Delivering a measurable return on investment “The effectiveness of any training solution very much depends on how an employer or individual participant regards the intervention. The module concludes with a formal presentation to the Unilever and Festo teams to outline what the project has meant to them and the organisation. Unilever and Festo – to understand the return on investment of the project modules.” “However. outline the action they took and measure what this means for the business in financial and non-financial terms. diagnose potential solutions.

The face-to-face sessions are concluded with a competency-based interview.trends in automation Synergies 12 13 – Recruiting and placing Unilever apprentices “Unilever seeks to recruit the best possible candidates who are passionate about working with us and who can meet the future needs of the business. their creativity and their innovation.” observes Hazel . We recruit high calibre apprentices who offer the complete package.” says Hazel Elderkin. This has certainly changed for the better and I see no reason why this should change!” she concludes. Before making significant changes to the programme I think it’s fair to say that apprentices were regarded as the ‘help’ within the business rather than a proactive. as well as psychometric tests. The process for recruiting Unilever apprentices is consistent across all sites. which is due to their own heritage in manufacturing and engineering. Its mission is to meet everyday needs for nutrition. valuable resource that was capable of getting involved and making a difference. Candidates first experience a telephone interview and. Our mindset now is focused on recruiting to meet the needs of manufacturing in five or ten years’ time and. apprentices take responsibility to find a full-time role within the Unilever has been serving the UK for more than a century. “A full time position within Unilever isn’t an automatic rite of passage for apprentices. The future of apprenticeships at Unilever Unilever’s successful approach to recruiting and developing apprentices is largely down to the way in which the business has worked together to ensure it meets the current and future needs of all sites.” explains Hazel Elderkin. proceed to an assessment centre where they participate in team building exercises and practical tasks.” she enabling the organisation to recruit the best talent for the future. ¢ Unilever www. “Festo has demonstrated. including West Cheshire College (Unilever’s national college of choice). for example. look good and get more out of life. their ownership of their own development. Appointing the right training partner A key factor in the success of IDEAL’s implementation at Unilever is the partnership the business has developed with Festo. a strong work ethic and a positive attitude. rather than focusing on their priorities and objectives. as well as more intangible qualities such as their motivation and drive. All candidates are required to undertake the formal application and interview process and many apprentices are interviewed alongside external candidates.unilever. home hygiene and personal care with brands that help people feel good. including academic ability.” says Gary Fuller. “We need to be sure that our investment in these young people is a wise one and we have a high benchmark for success. by partnering with experts and sites across the business. “Consistently checking back to how we can deliver positive results for the business have driven our apprentice programme forward. The success of the engineering apprentice programme to date has had a positive effect on other areas of the business.” This strong partnership approach with ‘supplier’ organisations is a strong theme throughout the apprentice programme and is reflected in Unilever’s work with other organisations. “It’s a credit to the programme and our partners that our apprentices can quickly make a positive impact when they take on full-time roles. One only needs to look at the calibre of current and recent apprentices to see the quality and impact of their work. that they’re working towards achieving our agenda. we can be confident that we’re on the right track.” says Hazel. sites and situations within the organisation. time and time again. is infoservice 18-01 Training & Consulting brochure . Reproduced with kind permission of Unilever business is transferable and can be applied to most issues. Following graduation from the programme. “We have developed a partnership relationship in the truest sense and much of this is based on their understanding of our organisational and commercial needs. if successful.

The Bernoulli vacuum gripper is particularly suitable for transporting thin. Ever smaller batch sizes and rising numbers of product variants demand faster set-up times and cost-effective production. flexible and inexpensive positioning is required. highly sensitive and brittle workpieces such as solar cells and silicon wafers. i. Moreover. weighing from a few grams to three kilograms. T he requirements for automation solutions consisting of robots and handling systems are varied and complex. this means that solutions must be flexible. unit costs should be reduced by increased performance. And. that they can be expanded and condensed. They can be used wherever fast. intelligent adaptive systems. need to be transferred quickly and positioned . last but not least. The high-speed H and T-gantries have been designed for dynamic handling and assembly operations where handling small workpieces. Festo has developed two high-speed handling units as ready-to-install automation packages precisely in order to meet these demands. are used more and more often in installations for quality assurance purposes. such as vision systems. High-speed handling units No speed limit Ready-to-install high-speed handling units with an innovative belt drive facilitate highly dynamic assembly operations. Bernoulli vacuum grippers enable contactless gripping of fragile workpieces.e.

The linear/rotary module can accelerate at 20 m/s² to a speed of 1. precise and inexpensive: the high-speed H-gantry The H-gantry is a lower-cost alternative to robotic systems with delta kinematics. It is thus possible to adjust gantries to specific requirements and the ideal cycle time combined with maximised dynamics – and without a funnel-shaped feeding device at the edges or corners. making the module ideal for assembly applications. which incidentally also makes for a tidier layout of production lines. As a high-speed pick & place module. This allows the use of vacuum and mechanical grippers with workpieces weighing up to one kilogram. In comparison with other pick & place modules or picker solutions. the high-speed T-gantry requires considerably less installation space and can be scaled to any desired stroke. Linear and rotary motions in one unit The linear/rotary module expands the high-speed H-gantry by providing two additional degrees of freedom and permits linear and rotary motions within the same unit. together with an optimised classic energy supply concept. fast. The two axes of the module can move independently. The optimised acceleration and braking characteristics allow strokes in the X and Y directions from two metres to one metre with a repetition accuracy of 0. What is more.1 mm. These often require a combined linear/rotary motion in order to correct the orientation of components by means of a rotary motion as they leave a feeding device and before they can be assembled. This means that less installation space is required. the axes can be scaled to any desired stroke. it . the high-speed H-gantry combines the dynamics of a linear motor handling system with the relatively low costs of a toothed-belt handling solution – while being 30% faster than conventional handling units. The robotic controller included in the ready-to-install package combines mechanical components and electric drive and control technology to form a kinematic system solution. Low design. In contrast to delta kinematic systems. ensure maximum dynamics that no other Cartesian gantry can achieve. The compact design has a low centre of gravity with correspondingly compact frames of simple construction. The linear/rotary module consists of a sleeve with an integrated energy supply through-feed for the front-end module and forms a Z-axis onto which a gripper unit is fitted. flexibly.trends in automation Impulse 14 15 – The rigid construction consisting of the servo motors EMMS-AS and servo controller CMMS-AS. Compact and dynamic: the high-speed T-gantry The T-gantry is based on the same technology as the H-gantry.5 m/s.

1 mm. Clever design feature The two gantries achieve speeds of up to 5 m/s and an acceleration of up to 50 m/s² over their entire working area through a clever design feature: the two toothed-belt axes are connected to the cross arm by means of a single recirculating toothed belt round the drive shaft. in the Y direction of up to 1000 mm and in the Z direction of up to 300 mm with a repetition accuracy of 0.Motor 1 1000 rpm + 0 rpm • 1000 rpm - 1000 rpm Motor 2 + • x motion Diagonal y motion 0 rpm Diagonal • Diagonal Diagonal “The lower moving masses not only boost the performance of the overall installation but also allow energy-efficient operation. It combines mechanical components and electric drive and control technology to form a complete kinematic system solution and coordinates highly dynamic motions in three dimensions. with strokes in the X direction of up to 2000 mm. The CMXR also acts as an interface to These high-speed handling units are of particular interest for the following industries: • Electronics • Photovoltaics • Special machine building • Packaging feed functions • AMI suppliers . Kinematic system solution The basis of the high-speed H and T-gantries is the robotic controller CMXR. This toothed belt is driven by two parallel. These two factors (recirculating toothed belt and lower masses thanks to the two parallel. Performance can be boosted by overlapping motions.” Timo Kloker. fixed-position servo motors) enable fast dynamic motions to be achieved. The robotic controller CMXR interpolates and positions all axes which can follow contours on a centre line. allows more dynamic operation than conventional linear gantries and can also be scaled to any desired stroke. laser welding or water-jet cutting. fixed-position servo motors from Festo’s EMMS series. Solution Engineering Centre Handling. Motor 2 1000 rpm + 0 rpm • -1000 rpm - 1000 rpm Motor 1 + • y-axis Diagonal z-axis 0 rpm Diagonal • Diagonal Diagonal -1000 rpm - z-axis y-axis Mode of operation of T-gantry The two motors enable the high-speed T-gantry to be positioned freely in the y-z plane. such as is required with adhesive applications. The motion sequence can thus be optimised for the application in question. The T-gantry is very compact and offers impressively high acceleration in the Z direction. Festo 1000 rpm - y motion x motion Mode of operation of H-gantry The direction of rotation of the motors creates motion in the x/y plane. The positive side-effect of this is that there is no moving motor on the X/Y plane with its two degrees of freedom. The controller can set path switching points and thus precisely control process devices.

Using vision systems and various conveyor systems. And what is more. ¢ is infoservice 18-02 Handling System Overview brochure . vision systems. technological and economic terms. Festo wins Intersolar Award High-speed H-gantry wins over the experts Festo has won the Intersolar Award in the category “PV Production Technology” at Intersolar Europe in Munich. Vice President Technology at Schott Solar AG. Ingo Schwirtlich. The 2300 exhibitors at Intersolar were invited to submit their most innovative solutions to the Intersolar Awards competition in the categories photovoltaics. the world’s largest exhibition of photovoltaic and solar thermal products. solar thermal products and PV production technology. such as the Festo intelligent compact vision system SBOx. Ready-to-install system integration Both the H and T-gantries are available as ready-to-install subsystem solutions. The speaker at the prize-giving ceremony and jury member Dr.” higher order control systems on the one hand and to the motor controller of the servo axes and the valve terminals on the other. These solutions are fully tested and assembled and are delivered straight to the machine. can be easily incorporated. Festo. won this award with its high-speed H-gantry for the rapid transfer of solar modules. it is also possible to create applications for moving objects. together with all the necessary design documentation and circuit diagrams as well as a comprehensive functional and fixed-price guarantee. praised the high speed H-gantry as “a solution which represents progress in photovoltaics production technology in ecological. as a manufacturer in the field of automation technology.trends in automation Impulse 16 17 – The high-speed H-gantry offers the dynamic characteristics of a linear motor handling system for the price of a toothed belt handling solution.

Safe even at an extreme angle: thanks to piezo technology. the multi-function seat of the Mercedes E-class adapts to any driver and driving situation. .

There is no clicking to disturb the driver as his or her high tech car glides smoothly over the asphalt.” Michael Hartmannsgruber. an elegant solution has been created which enhances seating comfort in cars. Ultra-fast. I ntegral moulded seats offer good lateral support but have only limited capacity to adapt to a specific body shape or driving situation. This was developed in collaboration with ATS Munich GmbH & Co. Head of Business Centre Mobile Pneumatics at Festo . ultra-light and quiet Each seat has seven valves with modern piezo-ceramics that generate the force used to fill and evacuate the air chambers in seconds. The Mercedes-Benz E-class demonstrates that even going around corners can be a relaxing experience. special valves are used to vary the volume of air in the seat backrest according to steering angle. This is innovation at the highest level through a combination of people and technology and points the way to the future. The use of the latest technologies increases the quality of the in-car environment. Mechatronics was the “Thanks to patented piezo technology. they are also light and quiet in operation. The piezo valves in the Mercedes multi-contour seat ensure that air cushions provide an ideal supportive shape. KG.trends in automation Synergies 18 19 – Piezo technology in automobiles Relaxed around every corner Car seats must provide support and comfort. lateral acceleration and travel speed. However. These valves are not only fast and precise. Festo met the seemingly opposing needs for perfect technology and precisely harmonised processes with a new piezo valve production line. In a joint project with ATS and Festo. since early 2009 the multi-contour seats fitted in the Mercedes E-class have been equipped with high-speed piezo valves to ensure optimum support.

com Area of activity: Suppliers of special machines for automated manufacturing. This makes it possible to prevent any mix-up. Large quantities. Hence all the batch data for the components and the entire process and test data are stored within an SAP production system. If even the smallest deviation occurs. Shorter cycle times and faster processes reduce costs. ¢ . This is achieved by affixing Datamatix codes to the products and through automatic sorting of the finished valves. inspiration for the design of the machines. high quality The fully automated production line turns out a piezo valve every 20 seconds. assembly and testing operations. On modern production lines. Mechatronics thus provides an elegant solution that leads to greater efficiency. Added value thanks to modern mechatronics On the new production line. Defective workpieces are rapidly detected and separated out. the developers took care to fulfil the high quality standards of the automotive industry in every way. Automation Tooling Systems Munich GmbH & Co. from manufacturing through to quality inspection. KG European Regional Headquarters Marsstraße 2 D-85551 Heimstetten www. including electronics and semiconductor production. it is more important than ever before to be able to trace workpieces throughout the process. When building this line. mechatronics as a multidisciplinary technology dominates all the steps in the production process. closed-loop corrective action can be taken.The ATS production line displays its strengths through the integration of all kinds of process steps – from manufacturing through to quality inspection. allowing real-time representation of the processes.atsmunich. The ATS Supertrak machine: the latest mechatronics was the inspiration for the design of this piezo valve production line. from delivery to final dispatch. Its strengths lie in the integration of all kinds of process steps into the same production line. More than 300 data items are available for each valve.

and many of the leading theme parks in Europe. Simworx has grown to become a world leader in the design. Its customer base also includes a considerable number of prestigious blue chip companies and organisations. manufacture and supply of fixed site and mobile 4D effects theatres and simulation attractions. Optional built-in effects include leg ticklers. and to complete the picture. incorporating all the motion control actuators in a shallow. Simworx has employed a variety of actuators from different manufacturers for its dynamic effects . synchronised to the film being shown. aeronautical and science museums in the UK and USA. left-right tilt and vertical drop functions to the list of effects. West Midlands. has chosen to base the innovative dynamic seat modules for its new Dimensions range of effects theatres on Festo fluidic muscles. The seats bring an unprecedented degree of experiential realism to 3D movies by subjecting occupants to a wide variety of movements. Never let it be said that today’s cinematic experience is merely visual! B ased in Kingswinford. the pedestal of each seat can be fitted with a pneumatically powered leg tickler. The headrest of each seat can optionally be equipped with fully integrated air blast and water spray capabilities. air-blast and water spray functions. The seats for Simworx’ latest Dimensions range of effects theatres are based on a modular design. while the Dimensions 5D models add forwards/backwards tilt. floor standing plinth that supports four individual seats. Over the years. Simworx Ltd.trends in automation Synergies 20 21 – Audiences stirred by fluidic muscles Innovative dynamic seat modules add further realism to 3D film experience. including a large number of space. The company has more than 600 installations worldwide. There are two basic models: the Dimensions 4D seats feature backwards drop and vibration functions. a specialist supplier of 4D effects theatres and simulation attractions.

“I first became aware of Festo’s fluidic muscles when I attended a technology showcase event at the company’s HQ in Northampton. as well as slow. We have just installed our new Dimensions seats in Manchester Science Museum and are currently putting the finishing touches to a system for an indoor theme park on Weston-Super-Mare’s Grand Pier. jolt free movement. I envisage we’ll be making increasing use of this technology in the future. The compressed air supply is generated . Fluidic muscles are tensile actuators which mimic their biological counterparts by contracting when fed with compressed air.” Simworx chose to use the most powerful. and have a much higher power density. They provide excellent dynamic performance. and can generate an initial force some ten times higher than a conventional pneumatic actuator of the same diameter.Dynamic seats bring an unprecedented degree of experiential realism to 3D movies. These muscles employ press fitted connections to minimise size and weight. Andy Roberts. designed specifically to provide a very easy and precise means of varying the flow rate to pneumatic actuators. Motion control actuators are incorporated in a shallow floor standing plinth that supports four individual seats. these are a unique form of pneumatic actuator resulting from Festo’s bionic concepts research programme. versions of Festo’s latest generation DMSP series fluidic muscles for the new Dimensions seats. and offers a much higher power density than electric actuators – making it easier to integrate into the body of the seat. Most of these have been pneumatic. They are capable of exceptionally fast and smooth operation. since this type of technology is cost-effective. seats. Simworx became aware of Festo’s fluidic muscles. The VPPMs use an innovative cascaded dual stage regulator. 40 mm diameter. During the development of its latest Dimensions series seats. and a control unit. Each four seat plinth module contains four DMSP fluidic muscles – one in each corner – together with four manifold mounted Festo VPPM proportional pressure regulators. which have now been commercialised and are available as standard industrial products. It was immediately apparent that the muscles are considerably better than conventional pneumatic actuators for simulator type applications like ours. inherently safe. According to Simworx’ Director.

In essence. Unlike 'standard' pneumatic cylinders the change in length is proportional to the pressure applied making them ideal for simple positioning tasks in both open or closed loop applications. The fluidic muscle has many applications in the worlds of entertainment. ‘Shaken not stirred’ has suddenly taken on a whole new meaning! ¢ Simworx www. Special event triggers contained within the film being shown instruct the central controller to issue appropriate signals to all the seat modules in the theatre simultaneously. is infoservice 18-03 Fluidic Muscle brochure . motion theatres. resulting in the entire audience experiencing exactly the same effect – be it pitch. and is distributed to each seat module via a ‘pneumatic ring main’. air-blast and water spray functions. they consist of a flexible tube with reinforcing Aramid fibres organised as a three-dimensional rhomboidal lattice. Optional built-in effects include legs ticklers. Fluidic muscles Festo DMSP fluidic muscles are very high power-to-weight pistonless pneumatic vibrate or sudden drop – at the same time. The tubes expand in diameter when filled with compressed air and simultaneously contract approximately 25-30% of their initial length depending upon the air pressure applied. the exhausted air is released Market leaders in 3D/4D effects theatres. via high-efficiency Festo silencers. animatronics and modern automation for clamping.trends in automation Synergies 22 23 – Wide variety of movements can be made with synchronisation to the film being shown.simworx. simulation attractions and the provision of 2D/3D film content. pressing and positioning. short move length applications – such as moving seats or driving a robot arm. Mimicking its natural counterpart the fluidic muscle generates force in one direction. The control unit in each Dimensions seat module employs fieldbus for communication with the system’s host control PC. outside the theatre to minimise noise interference. The movement is virtually without friction and stiction enabling exceptionally smooth movements without stick-slip and the very high initial forces enable inertia in the mounting system to be overcome. rock. ideal for highly dynamic.

T he wind is unpredictable and it is always a challenge to get it under control. it is also a sustainable model that shows how companies can make intelligent use of natural energy resources. The result is impressive: CyberKite is a wing in bionic form of up to 24 m² in size. it not only demonstrates the high performance of Festo electric drives and controllers. an automated kite system with a cybernetic control system that represents a high quality. working with experts from the Aeroíx company. But this was the task which Festo engineers. Take for example CyberKite. .Bionic Learning Network Ingenious ideas take off Learning from nature is the central principle of bionics. Particularly when we try to make something as lightweight as a high-tech kite fly in a controlled manner. set themselves within the context of the Bionic Learning Network. Nature shows the way forward towards energy efficient motion sequences in tomorrow’s production and provides the impetus for new and amazing practical applications. With stand alone open and closed-loop control and energy supply systems. biomechatronic concept with great promise for the future.

and its servo motors are able to reclaim energy from control actions. It remains in the air even in the total absence of wind due to the uplift created by the gas. This means that the hybrid wing system is able to deal even with major wind fluctuations. It is controlled on the ground by a Festo mechatronic actuator unit. come rain or sunshine With the CyberKite. Under appropriate wind conditions the CyberKite can thus be operated self-sufficiently with regard to energy. The CyberKite is an excellent example of intelligent interaction between people and technology. These react rapidly to every new situation and keep the system stable. The self sufficient kite The central focus of the technological development of the CyberKite was to provide it with intelligent behaviour and make it sustainable. thus reducing net energy consumption.trends in automation Compass 24 25 – The servo motors act via cables which are unwound by the lifting force of the kite and can also operate optionally as generators. To ensure controlled winding and unwinding of the cables. Its energy efficient drives make use of wind power. It clearly demonstrates how machine building can provide sustainable solutions in conjunction with overarching technologies such as mechatronics and measures to increase energy efficiency. while the sophisticated automation solution has shown itself well able to deal with the unpredictabilities of a natural environment. each cable winch is equipped with a winding positioning axis consisting of an electric linear drive. ¢ . the wing system makes use of excess wind power from the flexible cable drives. In battery operation. The intelligent wing system has proven its value in practical operation. The passive adaptive cable gearbox system is able to efficiently reduce the effect of wind force when necessary. The endurance champion at high altitudes The CyberKite wing combines a high volumetric capacity for aerostatic buoyant gas with a good lift/drag ratio and high intrinsic stability. Festo and Aeroíx have developed a highly modern technology platform which provides dependable control of complex applications. The engineers of the Bionic Learning Network have even been able to dispense with any additional stabilising control surfaces. The electrical energy obtained is stored by the system in batteries. This makes the CyberKite an elegant flyer that stays up for a long time under any wind condition. Dependable control. The high cable forces which are created under strong and gusty wind conditions are handled by Festo electric drives and a Festo controller.

A feed system upstream of the handling unit separates the plastic covers and feeds them to the ifc flexfeeder via a conveyor belt with integrated lighting. sequences and settings via the Festo FED An alternative to bowl feeders: correctly oriented workpieces are picked up from the inspection belt by the Tripod robotic system from Festo using vacuum grippers and placed in the centring station. adds Halling. A feed system upstream of the handling unit separates the plastic covers and feeds them to the ifc flexfeeder. this system is open to new variants. as on some days the system set-up needs to be changed at least five times to accommodate different workpieces.Saving set-up time in automotive electronics production At the press of a button Large number of workpiece variants and short set-up times – these two market demands appear at first glance to be contradictory – and would be if not for the ifc flexfeeder.” Almost zero set-up times Tyco saves even more when its plant is running. tomorrow 200 examples of control unit B and the next day 500 examples of control unit C – the different sensors used with a wide range of vehicle and motor variants call for flexibility with small batch sizes. “We only need to enter positions. Setting up machines can be laborious and costly. We can change variant at the press of a button”. we would have had set-up times of up to five hours due to the need for mechanical adaptation and adjustments for each plastic cover variant.-Q from Festo determines the position and orientation of the workpieces. Saving the need for bowl feeders The ifc flexfeeder feeds at least six different plastic covers for control units flexibly and correctly to the next assembly station. T oday 500 examples of control unit A. Not only this. For Heinrich Halling.. This flexible feed system with an integrated Festo Tripod robot and vision system squeezes set-up times down to zero. What is more. The vision system SBO. With the ifc flexfeeder. New variants can be parameterised and configured very easily. produced by the special machine builder ifc intelligent feeding components GmbH for Tyco Electronics. . set-up time is 10 minutes. The assembly station laser welds the covers to the control unit housing. The control system concept is equally simple. which would have cost far more than the complete ifc flexfeeder system. An answer to the conflicting demands of large numbers of variants and short set-up times is provided by the ifc flexfeeder. the ifc flexfeeder solution was just the right one: “For the six different types of plastic covers. “With a conventional bowl feeder solution. Head of Equipment Design at the Speyer location of Tyco Electronics. we would have required at least four bowl feeders. This feed system permits changes of workpiece types at the press of a button. but with this solution there are no interchangeable bowl feeders and other parts to take up storage space unnecessarily.

The position of the axis and servo motors is fixed. ¢ ifc intelligent feeding components GmbH Neuenstadter Straße 12 D-74229 Oedheim info@ifc-online. Correctly oriented Area of activity: 50.. Integrated vision system A further important element of the feed system is the vision system SBO. on the other hand. is infoservice 18-04 Bionic Tripod brochure . The Tripod kinematic mechanism offers designers of assembly cells and system integrators such as ifc a fast and efficient alternative to conventional Cartesian gantry solutions or SCARA robots. This company anticipates that the machine will amortise itself within six to twelve months. “Position detection with the vision system SBO. What is more. the ifc flexfeeder is the ideal choice for Tyco Electronics.trends in automation Synergies 26 27 – Workpiece type changeover at the press of a button: no problem with ifc flexfeeder.000 products for automotive Area of activity: Solutions for feeding systems Tyco Electronics www. A slide unit moves the centring gripper out of the Tripod handling area.-Q in conjunction with the Tripod robotic handling unit as a ready-to-install solution provides the necessary degrees of freedom for fast. The Tripod makes use of standard components from Festo’s modular system.. explains ifc General Manager Andreas Schirmer. Three double rods ensure that the flange plate is horizontal at all times.-Q from Festo. electronic household appliances. this robotic handling unit is dynamic. while its pyramid-shaped enclosed design makes it very rigid. explains Schirmer. the flexible feed system. communications systems. Because of its design.tycoelectronics. are picked up from the inspection belt by the Tripod robotic system from Festo using vacuum grippers and placed in the centring station. front end display”. This determines the position and orientation of workpieces and transmits this data to the robotic controller CMXR. This handling unit is the ideal choice for the ifc flexfeeder – and in turn. Any incorrectly oriented covers are immediately separated out via a chute and fed back into the spiral conveyor. The laser welding station picks up the precisely positioned plastic covers and places them accurately on the plastic control unit housing ready for the subsequent welding www. Ready-to-install Tripod robot Thanks to its low moving mass. it is easier to set up using teach-in and is competitive in price compared with all other robotic systems. the Tripod is more easily accessible in the working area than Cartesian or SCARA robots. medical technology and other industries. reliable and accurate transfer of the plastic covers”.

However. Following the crisis. after a recessionary period of only six months. . analysts are already talking about growth again.Automation technology in Brazil Is it party time again? Caipirinha. the party at the Copacabana is just getting back into full swing: the Brazilian machine and plant building industry must find a way to position itself between the high technology available from Europe and the mass produced goods from Asia. Growth prospects are particularly good in the field of process automation. carnival – With its exotic atmosphere. Copacabana. Brazil is the epitome of Latin-American exuberance. Exuberant was also the mood in the Brazilian economy until the Sugarloaf Mountain country was overtaken by the effects of the world economic crisis.

Even in the period of hyperinflation in the 1970s and 1980s Brazilian companies found ways and means to generate and re-invest profits. . This will generate fresh demand for assembly lines and production machinery for plastic and rubber products. there are increasing signs that the Brazilian economy has found its way back to growth. The Volkswagen Group is investing more than 2 billion euros in expanding its factories and developing new products. In order to limit the inflow of short term capital. with plans to increase VW sales to one million units by 2014. A Industry immune to crises In contrast to many banks in the rest of the world. Brazilian credit institutions had relatively little exposure to toxic debts and Brazilian industry itself proved to be virtually immune to crises. which had resulted in an increase in the value of the national currency. In the middle of the crisis. this industry – with massive state support – set a record in June 2009. the government re-introduced a financial transaction tax in October 2009.trends in automation Synergies 28 29 – ccording to Deutsche Bank Research. The Brazilian government has done its homework and created comprehensive tax breaks to encourage economic recovery. The German business newspaper Handelsblatt reported on 30 November 2009 that Volkswagen do Brasil planned to go on the attack against the market leader Fiat. The good prospects in Brazil are increasingly attracting the attention of international companies. Record sales of cars The greatest hopes for an economic recovery lie with the automotive industry. The growth target for 2010 is around 5%. the real.

which now has 450 employees in its Customer Service Centre assembling customer specific products and six sales offices ensuring a dependable supply of Festo’s high quality automation technology. pharmaceuticals. manufactures or imports machines and installations has been able since 1968 to rely on Festo for high performance pneumatic and electrical automation technology. sugar. alcohol and special machine building. food and packaging. explains Carlos Daniel Raymundo. electronics. paper.Festo in Brazil Everyone in Brazil who operates. petrochemicals. mining. The food and packaging sector alone accounts for one fifth of the total sales of Festo Brazil. of which the most important are car manufacturing. This division handles many projects in cooperation with manufacturing companies. sugar. poultry. This should come as no surprise. technical training colleges and universities. as Brazil is the world’s biggest exporter of coffee. However. That is when Festo set up a national Brazilian company based in São Paulo. In spite of the crisis: the continually high demand for consumer goods ensures that plastic packaging manufacturers still receive plenty of business. . Festo supports around 30 different industries. Sales Manager of Festo Brazil. Users can attend intensive training sessions in Festo’s own Training Centre. In the Customer Service Centre of Festo Brazil: customer-specific solutions for the fifth-biggest country in the world. plastics. beef and orange juice. it is in oil and gas that Raymundo sees the biggest opportunities for growth. Festo supplies more than just hardware to its Brazilian customers. “We develop projects adapted to the Brazilian market using the products and technologies available from Germany”. Equally important is the skills training provided by Festo Didactic.

A dangerous cocktail of low investment. comparatively low import duties for foreign competitors’ products (6 to 7%) and an unfavourable currency exchange rate is. we can expect to see the launch of many new products. Sales Manager of Festo Brazil Demand for consumer goods The food industry and the cosmetics and personal hygiene sectors were also virtually unaffected by the crisis. Nowadays production can be bought in. with innovations in form. Semi-finished products such as stainless steel profiles and sheet aluminium are significantly more expensive than in Europe. threatening the existence of many machine builders. The state company Petrobras alone will spend around 43 billion Brazilian reals (approx. particularly in machine and plant building. Latin America as the locomotive of growth Brazil is once again being the locomotive of growth in Latin America.” Carlos Daniel Raymundo. Machines and installations for extracting and processing oil and gas are becoming one of the most important areas for process automation. Pharmaceutical products. too.. The Brazilian industry association Abimaq (Associacão Brasileira da Industria de Maquinas e Equipamentos) announced a drop in overall industry sales of 14%. Machine building is lagging behind The situation described above in no way applied to the machine and plant building industry in the summer of 2009. The future with process automation In the energy sector. particularly of generic products. Many people’s verdict here is: “the party’s over”. £15 billion) in the period up to 2014 on equipment for exploiting new offshore wells and for transporting and processing crude oil and natural gas. according to the “Germany Trade and Invest” information service. The arm span of the statue is 28 metres. Large parts of Brazil’s population of almost 200 million have little or no access to medication or consumer goods and thus represent an enormous potential for automation technology. Vietnam or China. Brazilian employers still need to pay their workers an hourly rate ten times higher than that in India. there are plans for the construction of many gas.. In the future. high taxation. highly developed industry and production technology and large domestic market with great potential are the factors that will help the country to flourish economically. ¢ “Cristo Redentor” attracts up to one million visitors each year from all over the world. since in the next decade the sports mad Brazilians will host the football World Cup in 2014 and the Summer Olympic Games in 2016 in Rio de Janeiro.trends in automation Synergies 30 31 – “We develop projects adapted to the Brazilian market using the products and technologies available from Germany. It is no longer essential to invest in machine tools. The Brazilian machine and plant building industry therefore needs to find its own way between high technology from Europe and mass-produced goods from Asia. Its well-trained workforce. A difficult past The world economic crisis revealed the weaknesses of Brazil as a developing country. This industry will also generate demand for offshore and shipbuilding technology. hydro-electric and biomass power stations. and the country often needs to import high-tech electronic components. Investment in infrastructure will play a part in this. . This statue of Christ the Redeemer impresses with its sheer size and offers a spectacular view across Rio de Janeiro. fragrance and flavour as well as packaging. offer good sales prospects. These events will certainly get the party going . Despite the fact that labour costs are only around half those in Germany.

The modular profile machining centre only applies full clamping force to the clamping rollers during actual machining. machining operations are an everyday occurrence. . are actuated by standard cylinders type DNCB. These enable operation which is virtually stick-slip free. we exploit the options for creating pressure zones and for fitting vertical stacking modules which the valve terminal VTSA offers us”. which in itself is not a problem. An ingenious clamping system elumatec. A very great deal is asked of the machines used to produce aluminium and plastic profiles. elumatec offers an efficient automation solution for machining plastic and aluminium profiles tailored to individual needs. however. This is achieved by switching pressures or by switching off a counter-pressure. uses a dual-pressure clamping system for particularly sensitive steps in the process. explains Andreas Hettler. become a problem if the chips which it generates enter the profile guides and cause damage to the painted profiles. Individual activation “In order to be able to activate the cylinders with different pressures. This also applies to the production of aluminium and plastic profiles for window-making. I n the metalworking and plastics industries. a manufacturer of profile cutting machines. However. But when the results need to look good. The clamping components. With the modular SBZ 600 profile machining centres. it is possible to prevent this damage by using very low clamping pressures. there can be no compromises. And it is precisely here that the valve terminal VTSA can display its strengths with a combination of pressure zones and vertical stacking modules. Machining does. which hold the profiles in place and straighten these if they are bent.Machining profiles for windows and building facades The professional profile They need to be fast and precise as well as gentle. as with windows. The machine transports the profiles in an almost floating state between the individual machining stations.

Pressure zones are used in order to activate a number of clamps with the same pressure.trends in automation Synergies 32 33 – “For our customer. elumatec uses vertical stacking modules. VTSA valve terminals give us that extra speed and thus a decisive competitive advantage. says Andreas Hettler. the exhaust air is fed back directly. If it is necessary to apply control pulses to individual clamps.” Andreas Hettler. less expensive Reversible pressure regulators allow higher speed and reduce costs. With these pressure regulators. Project Manager for profile machining centres at elumatec Project Manager for profile machining centres at elumatec. . Every cylinder that is not travelling at The travelling tool magazines ensure fast tool changeover and thus optimum machining cycles. Smaller. The cylinder thus exhausts faster and a higher speed can be obtained with smaller valves. the top priority in machining PVC profiles is speed. the most important criteria for our customers is speed and the associated high productivity”. not via the regulator. “With the machines for processing PVC profiles. These enable a pressure regulator plate to be fitted under each valve in order to use different pressure for the advance and return strokes of a cylinder. faster.

hydrogen chloride speed is slowing down production. For example. the valves on the VTSA are considerably more compact and easier to replace. The central pneumatic module and associated I/O terminals of the elumatec SBZ 609 machining centre.elumatec. Easily expanded at any time “The tough design of the VTSA is. “The VTSA also offers us the option of changing over at any time from the current multi-pin connection to a fieldbus connection. In comparison with earlier models. which combines with the moisture in the air to form liquid hydrochloric acid. it would be possible to use the CPX terminal to activate pneumatic servo axes without changing the valve terminal configuration. This machining centre can be integrated into automatic production lines for the reinforcement and machining of cut PVC profiles for windows and doors. At the top of the picture: the swivelling reinforcement screw driver system on its 3-axis support. They have to withstand chips.” The fieldbus connection reduces the amount of wiring work required Area of activity: Manufacturer of machine tools for aluminium and plastic profile production is infoservice 18-05 VTSA brochure The central pneumatic module with switch box for the elumatec KSA 605 automatic notch-cutting machine. as the mechanical interfaces remain unchanged. . Reliable operation of the VTSA valve terminal – despite such harsh conditions – is ensured by the high degree of protection provided by the electrical sealing. however. Each cylinder size is allocated an optimum valve. The components used must be able to take punishment. opens up new possible applications. explains Andreas Hettler. with plastic profiles. aggressive spraying agents in the case of aluminium profiles and. There is no need to remove pneumatic connections or electrical wiring in order to replace valves. not the only reason why we chose this valve terminal”. however. ¢ elumatec GmbH Pinacher Straße 61 D-75417 Mühlacker www. This is why elumatec uses different valve sizes to optimise flow rates. This can be integrated into various lines for the fully automatic production of PVC profiles for windows and doors. which was based on well proven and heavy duty ISO valve terminals. together with the heavy duty valve bodies. Users benefit from the development history of the VTSA. in conjunction with the modular electrical terminal CPX. The valve terminal VTSA allows up to four valve sizes to be combined. Machining profiles is a tough business.

Festo Turkey replaced the old control desks with modern control panels. Istanbul (then known as Constantinople) was supplied with water by the longest Roman aqueduct built up until that time. Step by step. drives and position controllers at the filter tanks were replaced. The water quality is measurably better. In order to tackle the increased level of contamination present in river and rain water and the growing shortage of drinking water. covering a distance of 242 kilometres. ISKI has since benefited from numerous advantages. ISKI has thus not only taken a major step towards securing a high quality water supply for the metropolis on the Bosporus in the long term but has also carried on a long tradition. Back in 330 AD. At the same time. The Turkish metropolis has around 14 million inhabitants who all need to be supplied with drinking water. . flow and filling level sensors were installed. The operation and maintenance of the plants today is much simpler and costs significantly less. Festo Turkey modernised the automation systems of the filtration installations at four locations: shut-off valves.trends in automation Festo worldwide 34 35 – Turkey Water for Istanbul Festo Turkey supports the modernisation of the drinking water supply An impressive panorama: the Blue Mosque with a view of the Bosporus. a manual control interface and CPX modules. The major partner in this project was Festo Turkey. Everything at a glance: the automation system of the filtration installations is controlled by new panels with a Festo FED touch screen. it implemented a new automation structure and modernised the air preparation system. Moreover. and the utility company is confident of being able to react quickly in an emergency. the plants now have an automation structure that can be expanded flexibly at any time. Water is a valuable commodity in Istanbul. ISKI decided in 2003 to modernise its water treatment plants. The Istanbul utility company ISKI (Istanbul Su ve Kanalizasyon Idaresi) accordingly operates five plants which together treat more than two million cubic metres of river and rain water every day. and modern closed-loop control systems.

fibre control rods and rigid geometrical structures. The modular nature of the vehicle means we can bring the products into your conference room or into a corner of your factory. the Southbank Centre and the Royal Society came together to explore science and our human impulse to understand the world we live in. . field buses and Industrial Ethernet networks. our full pneumatic valve and cylinder ranges as well as process control valves and sensor boxes. is once again touring the country. providing you with a chance to see. suppliers and partners. These bionic concepts have been developed to learn from nature. To celebrate the occasion. In addition we have our new safety valve. Festo flying penguins: entertaining in the Royal Festival Hall.Great Britain Festo mobile showcase Festo showcase without you leaving your premises Festo brings the latest automation products to our customers’ doorsteps. the creatures demonstrate some of the latest concepts . The vehicle can make up to two visits a day at customers’ and dealers’ premises – around 80 visits are planned during the current tour. Please contact your Festo Consultant if you’d like the mobile showcase to visit your company. intended to stimulate dialogue with customers. Static displays include our full range of mechanical axis for electric drives. Great Britain Royal Society 350th Anniversary Following in the footsteps of Darwin Festo's flying penguins. with a minimum of time and effort. touch and discuss the latest innovative automation solutions with your Festo Consultant. jellyfish and ray performed during the Royal Society's 350th anniversary celebrations. packed full of technology and product demonstration kits. Included in the vehicle are working models of our CPX integrated automation platform including motion control. but are proof of research ideas and demonstrations of design concepts. which is an alliance of educational establishments and specialist companies tasked with exploring bionic solutions for automation applications of the future. See Further Festival of Science + Arts at Southbank Centre. Using helium-filled balloons. a novel air bearing and sensors.they are not saleable products. exploring biological principles in the form of beautiful and mesmerising creatures. The Air Penguins are creations of Festo's Bionic Learning Network. proportional control and interfaces to PLCs. Festo's Air Penguins flew above the exhibition and for performances in the amazing auditorium of the Royal Festival Hall. The Festo Showcase vehicle. A key element of the celebration was the ten-day.

around the clock and seven days a week. To complement this we have the Virtual Academy. the Festo Academy team and I as its leader are not concerned with grades or any kind of selection process. data-processing and technology training. This focuses on product. The advantage is that they can use these training facilities when it is most convenient for them. We use a whole range of training tools that are suitable for different applications and that complement one another perfectly when used in combination. with and for colleagues. is “learning on the job”. which is crucial if participants are to make effective long-term use of what they have learned. every participant can concentrate on the material that is most important to him or her. Our most important and most frequently used form of learning. . Mr. but also uses the most modern methods. in other words informal “unorganised” learning in the workplace. We place particular emphasis on the period after the seminar.trends in automation Soft Stop 36 37 – Do you sometimes keep students in after school. In contrast to normal schools. The Academy cannot and does not wish to intervene directly in this form of learning. a web-based learning platform offering so called e-learning. workshops and training courses. which we have been rolling out since 2009 as a training programme for management personnel. as e-learning is available worldwide. of course we don’t punish students by keeping them in after school. What we can do. Among our methods is the classic classroom based training in the form of seminars. In terms of content. Instead of teachers or lecturers we have trainers or moderators. Our objective is to help Festo staff develop professionally so that they can expand their skills and perform their duties even better and more efficiently than before. In order to ensure successful learning. however. It is precisely for this reason that learning on the job is such an important complement to our “Festo Leadership Initiative”. while lectures are replaced by discussions in which the focus is on the concerns of the participants. however. Festo staff can learn foreign languages via our intranet and also acquire organisational skills. the Academy not only offers a bright and friendly learning atmosphere and the latest equipment. is to make Festo management aware of the subject of learning on the job and show them how they can create an environment and a climate in their departments that encourages learning from. Höschle? No.

Great Britain: Festo Ltd Applied Automation Centre Caswell Road Brackmills Trading Estate Northampton NN4 7PY Phone 01252 775059 Fax 01252 775015 E-mail: Internet: Internet: form will tomorrow’s production take? The spanner as a symbol of mechanical engineering. Extra added value in the shape of services. a circuit board to represent . form mechatronic solutions that represent quantum leaps in Ireland: Festo Ltd Unit 5 Sandyford Park Sandyford Industrial Estate Dublin 18 Phone +353 (0) 1 2954955 Fax +353 (0) 1 2955680 E-mail: sales_ie@festo. know how transfer and social and knowledge networks ensures sustainable global success. batch sizes of as little as one.festo. fast reactions to individual customer wishes and high energy prices will be just some of the factors involved. But what form will tomorrow’s production processes take? Large number of product variants. Innovative automation suppliers improve the productivity. efficiency and flexibility of their international customers. together with suitable software. These two.

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