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Festo – your world-wide partner in factory and process automation

Rio W. Kusumahadi
12/04/2016

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich
 Topics

Basic Pneumatic & Industrial Automation Overview

• Festo Introduction
• Automation Level and Hierarchy
• Drives and actuators
• Valves and actuation
• Compressed Air Preparation
• Sample of Application

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 2
 Exit
Our history - from woodworking to automation

1925
1955 1956 1965 1989 2000 2001
Invention and market
Festo recognizes the launch Bionic Learning
potential of pneumatics of valve terminals Network
for factory automation Didactic as a driving force
in automation
First business field:
Woodworking machines. Italy: first sales
World's largest
Today: Festool company outside
modular
Germany
mechatronics
system
4
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Festo in figures

30,000 1,000 2.28 7% 24 h

100 16,700 > 300,000
billion
10,000
Staff Delivery
service
Components Of turnover
spent on
R&D
Customer-specific
Industrial solutions
customers every year
Sales Engineers
worldwide Euros
Patents annually Festo Group
turnover
5
Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich
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Production, logistics, service – in 176 countries world-wide

Over 250 branch

Subsidiary offices
Authorized agencies in
companies a further 39 countries
in 61 countries

Sales Centres
11 Global Production
Centres
6 Regional Service Centres
28 National Service Centres
6
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Europe, Asia, America – all over the world. we're there when you need us
In 200 industries
Delivery 12 – 24h local presence world-
wide Worldwide flexibility
after receipt of order

Fast international
availability of Festo
staff and products

Local and regional

know-how

Global synchronization
Long-term stable with your value creation
supplier chain
partnerships Consistent quality of
products and services -
7
world-wide
Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich
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Clear commitment to Germany as a production location

Investments Training
• 11 commercial and
• 125 million euros in global
technical professions
development, production and logistics
• 7 courses at dual-
network
system technical
• 50% of this in locations in Esslingen,
8 college
Scharnhausen and St. Ingbert
Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich
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Our
expertise

Your
competitive
edge Technology mix: pneumatic, Industry-specific solutions Worldwide presence
servopneumatic and electrical

Engineering Tools

Energy efficiency@Festo Safety@Festo Individual solutions and

services
Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich
 Festo Introduction

• Contact Center :
0804-1-2-33786
• Fax :
0804-1-4-33786
•Email :
sales_id@id.festo.com
•Web :
http://www.festo.co.id

Representative Offices:
PT FESTO • Jakarta & Glodok
(Head Office) • Bandung (West Java)
Jl. Taman Tekno V, • Semarang (Central Java)
Blok A/1, Sektor XI • Surabaya (East Java)
Kawasan Industri BSD • Medan (Sumatera)
Serpong, Tangerang • Batam
Banten 15314 • Makasar
Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 10
Automation Level and Hierarchy

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 13
 Automation Level and Hierarchy

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 14
 Automation Level and Hierarchy
VALVE

CYLINDER

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 18
 DRIVES AND ACTUATORS

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 19
 Drive and Actuator

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 20
 SINGLE ACTING AIR
CYLINDER
• Spring Return Cylinder
LINEAR
MOTION • Membrane Cylinder
Bellow Cylinder

PNEUMATIC Muscle Cylinder

ACTUATOR DOUBLE ACTING AIR
CYLINDER
ROTARY AIR
CYLINDER
ROTARY
MOTION AIR MOTOR
Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 21
 Single acting cylinder

Normally extended

Normally retracted

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 22
 Single acting cylinder
How does it work?
The piston moves, because:
• Pressure air applies force on the piston
of the cylinder and pushes it.

• Pressure air is directed into the cylinder

from the outlet of a direction control
valve
• Pressure air comes from service unit to the
direction control valve inlet

• Pressure air comes to service unit from the

network which starts with a compressor.

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 23
 How to extend and retract a single acting cylinder

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 24
 Single acting cylinder

DSNU-XX-XXX-P/PPV-A ADN-XX-XXX-A-P/PPV-A

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 25
 Double acting cylinders

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 29
 How to extend and retract a double acting cylinder

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 30
 Cylinders and definitions DSBC-40-150

Piston
diameter

Stroke

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 32
 Cushioning DSBC-40-150-PPV

Front cushioning adjustment

Check valve

Front cushioning bar Front cushioning ring

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 33
 Positioning sensing DSBC-40-150-PPV-A

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 34
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 Bagaimana menentukan diameter piston
yang sesuai dengan kebutuhan ??

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 46
 Piston Diameter

Load m
Contoh :
m = 100 kg.
P = 6 bar.
A
Stroke = 500 mm

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 47
 Gaya gravitasi F = m . g = 100 kg . 10 m/dtk2 = 1000 N.
Tekanan udara kompresi p = 6 bar = 600.000 Pascal = 600.000 N/m2
Friksi / gesekan R = +/- 10 % = 10 % . 1000 N = 100 N.
Effective force F = ( p . A ) - R = ( p . /4 . d2 ) - R

Effective force F = ( p . 0,786 . d2 ) - R


F + R 1000 N + 100 N
d2 = = = 0,00233 m2
p . 0,786 600.000 N/ m2 . 0,786

 d = 0,00233 m2 = 0,048 m = 48,3 mm

Piston diameter = 48,3 mm ?

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 48
 p = 6 bar

d = 50 mm F = 1060 N

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 51
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Decreasing the speed of cylinders

One way flow control

valve

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 63
Decreasing the speed of cylinders

Speed control of a double acting

cylinder

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 64
 Increasing the speed of the cylinders

1. Tubing as short as possible (valve on the cylinder)

2. Quick exhaust valve

3. Optimum pressure (high pressure may cause more friction of the

seals)

4. Shock absorber (to absorb vibration)

5. Larger tubing diameter

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 67
VALVES AND
ACTUATION

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 71
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 O A

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Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 79
 The main parts of a valve
1 – Valve Body
2 – Seals
3 – Spool
4 2
4 – Controls

14 12

5 1 3
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 Valve 2/2
2

2 (A)

1 (P)
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 Valve 3/2

3 (R)

2 (A)

1 (P)
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 4 2
14
Air Pilot/Spring Return
5 1 3

4 2

14 12 Air Pilot both Sides

5 1 3

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 83
Pneumatic valve / spring return

4 2
14 12

5 3

1
Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 84
 Pneumatic valve / double pilot (memory valve)

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 85
 How to extend and retract a single acting cylinder

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 87
 How to extend and retract a double acting cylinder

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 88
 2/2-Way Single Solenoid Valve

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 89
 3/2-Way Single Solenoid Valve

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 90
 3/2-Way Single Solenoid Valve with Pilot Control

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 91
 Compressed Air Preparation
Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 98
 Compressed air preparation

1 m3 of air contains

- up to 180 million dust particles

- up to 50 g of water (at 50o C)
- up to 0,03 mg oil
- various chemicals such as lead, cadmium etc.

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 99
 Compressed air preparation

The compressed air is most efficient when conditions below are

realised:

The right pressure Less condensate

Less particles The right oil

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 100
 The wrong adjustment of pressure may result More particles in the system may result in
in:
• early wearing of equipment
• early wearing of equipment • pressure drops
• vibration of machine and poor product • blocked lines
quality • malfunction of system
• more air leakages
• high operation cost

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 101
 More condensate in the system may result Wrong adjustment or type of oil may result
in: in:

• corrosion • early wearing of equipment

• lower velocity • washing out the special oil
• sludge blocking lines • swelling of seals
• staining the product

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 102
 Poor air preparation results in:

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 103
 Compressed air generation and preparation

1 Compressor
2 Cooler
3 Condansate separator
4 Receiver
5 Condensate drain
6 Pre-filter
7 Dryer
8 Electronic purgier
9/10/11 Class filters
12 Water and oil seperator

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 104
 New Service unit MS Series

Lubricator

Branching module
On-off
Filter-regulator
valve
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Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 117
 Air Clasification Standard

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MS(N)9/12 –LWS
Water separator

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SAMPLE OF APPLICATION

1. Packaging
2. Vision Sorting & Check box sorting
3. Color sorting
4. High cycle pneumatics
5. Dynamic pick & place system
6. Energy Efficiency

Created by Rio Wicaksono Basic Pneumatic 5. April 2011 geändert: 7. April 2011, LPK Entwurf Vertraulich 131