Next-generation pneumatic valves.

Greater range with new flow rates, configurations, functionality, certifications and more.

The latest stage of Emerson's next-generation AVENTICS™ Series XV pneumatic valve systems with new flow rates, configurations, accessories, UL certifications and more. These updates give original equipment manufacturers (OEMs) greater design flexibility and scalability to precisely configure valves when engineering handling systems and automation solutions.

After successfully launching the AVENTICS Series XV03 in most world regions in July, Emerson has now released the popular XV03 valve for U.S. markets, as well as globally released the larger Series XV05 and a bottom-ported version of the XV03. The XV03 provides flow volumes up to 350 liters per minute in normal conditions (NL/min), and the XV05 provides up to 1000 NL/min.

In addition to new flow rates and configurations, Series XV valves are also available with UL certifications and more accessories. Both the XV03 and XV05 are designed for compliance with UL429 and UL61010 for quality and safety. New and existing accessories provide greater functionality and include separators, blank stations, pressure supply plates, sandwich pressure supply, and sandwich pressure exhaust. There is also a custom toolbox that contains the most important tools to assemble XV systems.

The next phase of the staged XV release will see the continued launch of new accessories as they become available, as well as greater connectivity. Additional fieldbus protocols will be launched throughout 2025, including Powerlink, CanOpen in mid-2025 and AS-I in late 2025. The valve systems currently support Profinet, Ethernet/IP, EtherCAT, Modbus TCP, Profibus DP and IO-Link.

Next-generation Series XV valves use proven core valve AVENTICS technology and include metal threads, aluminum base plates and compact dimensions to make integration easier. Complete valve systems are easy to commission with the AVENTICS online configurator that streamlines design and layout. To reduce lead times for every global region, three Emerson plants are equipped to manufacture orders.

Providing higher flow rates in a compact valve package, Series XV valves enable more efficient and flexible pneumatic system performance while offering products customized for specific markets, including factory automation, automotive and tire, food and packaging applications. Part of a Floor to CloudTM approach, Series XV valves power machinery and processes at a component level, helping manufacturers boost productivity in applications.

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@AVENTICS @EmersonExchange @Emerson_News @EMR_Automation @mepaxIntPR #PAuto #USA

Interoperable valv pneumatic valves.

Multiple interoperable valve sizes and higher flow rates in a compact design.

Emerson has just launched its AVENTICS™ Series XV pneumatic valves. Series XV valves are designed with interoperability in mind to provide machine builders across multiple industries and factory automation applications with a flexible and cost-effective valve platform. The new valves are ideal for machine builders and end users that operate across the globe, with universal threads and other features that support regional standards and global availability.

Series XV valves provide higher flow rates in a compact valve package that enables more efficient and flexible pneumatic system performance for factory automation, automotive and tire, and food and packaging applications. This helps manufacturers boost productivity and allows them to offer products customized for specific markets and customer preferences.

“In all industries, manufacturers need high-performance technology that gives them the agility and flexibility to stay ahead of rapidly changing market demands,” said Wolf Gerecke, director of product marketing for Emerson’s machine automation business. “The new AVENTICS Series XV pneumatic valves deliver that performance with optimized flow, a wide range of valves and an extensive portfolio of accessories.”

Series XV valves include the XV03, providing flow volumes up to 350 liters per minute in normal conditions (NL/min), and the XV05, scheduled for release in October 2024, providing up to 880 NL/min.

All valves in the Series XV line use proven AVENTICS core technology and include metal threads, parallel wiring, aluminum base plates and compact dimensions to make it easier to integrate into production system designs.

Series XV valves use consistent interfaces and have wide connectivity from single wiring over parallel connections such as D-SUB connectors. They also support leading fieldbus protocols, including PROFINET®, Ethernet/IP, EtherCAT, Powerlink, Modbus TCP, IO-Link, AS-I, to simplify integration into machine control networks.

Series XV valves are also easy to commission. The AVENTICS online configurator supports system layout, providing useful information, while easy-to-understand system documentation in the design phase helps speed up machine development.

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@AVENTICS @Emerson_News @EmersonExchange @EMR_Automation @mepaxIntPR #PAuto 

Digital process controller.

Reliably upgrades performance, safety and compliance by making more data available to operators.

The Fisher™ FIELDVUE™ DPC2K digital process controller (DPC2K) has been announced by Emerson. The DPC2K can be retrofitted to Fisher Wizard pneumatic controllers, and to pneumatic controllers from other manufacturers. The result is greatly improved closed-loop control and reliability, significantly reduced maintenance, improved safety, and superior environmental compliance. It also provides numerous connectivity options, enabling remote setpoints, remote access for configuration, monitoring, and other features.

Pneumatic controllers have served industry well for decades to regulate control valve actions, but they have many limitations. Closed loop control is sluggish and not precise, with significant deviations from setpoint common, and degraded performance over time as their mechanical components wear out. This wear and tear negatively impact reliability, with excessive maintenance required. All interactions with pneumatic controllers must be performed locally at the control valve, creating safety issues by exposing personnel to often hazardous plant environments.

The DPC2K addresses these and other issues, and it can be retrofitted as a direct replacement for the pneumatic controllers installed on most valves, regardless of manufacturer. Closed loop control is greatly improved with configurable loop types, over 150 units of supported measure, 20 times-per-second (50 milliseconds) scan and update rates, configurable dead band, anti-reset windup, dynamic reset limiting, and other features. These features work together to keep the process variable—typically pressure, flow, level or temperature—close to setpoint, along with greatly improved recovery from saturated conditions.

The DPC2K is designed to maintain its high level of performance for years with no required maintenance, and when maintenance is required, it is easily performed using modular replacement components. Another important advantage from this upgrade is the ability to easily interact with the DPC2K locally or remotely. Local interactions are performed via its menu-driven LCD and six-button user interface, with four buttons used for navigation and two for operator input.

The DPC2K has inputs, outputs, and intelligence to perform local closed-loop digital control using the proportional–integral–derivative (PID) controller. It can accept a 4-20mA input from a two-wire or four-wire instrument, typically the process variable (PV). For pressure control applications, an optional pressure sensor can be used to provide the PV.

Fisher LoopConnect software provides the most comprehensive remote access, including configuration and monitoring, networked or direct Ethernet connection, and alerts for troubleshooting. Options include integral, sealed gauge pressure sensor with 0-30, 0-100, 0-300, 0-600, or 0-1500 pounds-per-square-inch range; and pneumatic output with low bleed of less than 3.0 standard cubic feet per hour.

Because the DPC2K is configurable, the same base model can be used in a variety of applications, including but not limited to pressure, flow, level, temperature, percentage, volume, and rate control. The DPC2K is rated for use in Class 1 Division 1 or Zone 1 hazardous areas, and it has an operating temperature range of -40-80 degrees Celsius. Inputs of 9-28 volts direct current are accommodated, with a typical power draw of only 1 watt.

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@Emerson_News @EmersonExchange @EMR_Automation @FisherValves @HHC_Lewis #PAuto

Cylinder sensors.

The latest technological advances in solid-state cylinder technology enable maintenance or service engineers to solve multiple pneumatic or electric drive issues with a single device, according to Festo.

“Solid-state switches are today's default technology option,” says Steve Sands, Head of Product Management at Festo GB. “Their absence of moving, mechanical components gives them a long lifespan, with mean time between failure (MTBF) of more than 4000 years. This means solid-state switches are the technology of choice over traditional reed switches in around 90% of pneumatic and electric drive applications.”
 

Modern automation machinery uses positional feedback to trigger sequential movements. In pneumatic applications, this takes the form of cylinder sensors that detect the position of the piston within the actuator. Similarly, the sensors act as movement reference points in electric axes and prevent clashes or over-runs.

Solid-state sensors are typically constructed with four magneto resistive sensors connected in a Wheatstone Bridge. When the cylinder piston magnet reaches the solid-state switch, the individual sensors' resistance changes, altering the bridge voltage. After amplification and processing, this creates an output signal from the solid-state sensor. As a result, solid-state sensors are protected against overload, reverse polarity and short circuits. They are also immune to wear and tear and insensitive to inductive and capacitive loads. Typically, the maximum current is 100 mA, and the maximum cable length is 30 m.

The latest solid-state sensors from Festo have moved the technology on another step. The Festo SDBT-MSX incorporates Hall Effect sensors and a micro-controller that enable approximate setting of the sensor, with the actual switching point being 'self-taught' by cycling the actuator a few times. This means that the actuator is driven to its end positions and the sensor learns the required switching point. Adopting this technology saves set-up and commissioning times and means a person doesn't have to enter inside the machinery whilst the power is on, reducing risk.

Incorporating a micro-controller also means that the sensor’s functions – NPN or PNP switching, Normally Open or Normally Closed switching, or output signal duration – can be modified easily: meaning maintenance or service engineers can solve multiple issues with a single device.

@FestoGB @festo_global @Publitek #PAuto

Resolving electric versus pneumatic dilemma in linear motion tasks.

Machine builders can resolve the age-old dilemma of whether to deploy electric or pneumatic technology for linear motion tasks by adopting a more application-led approach and deploying hybrid solutions claims Warren Harvard of Festo.

Warren Harvard

He explains: “Many machine builders think they need to make a decision between electric automation and pneumatic drives. Some claim that electric actuation is cheaper, more energy efficient and easier to work with. Others feel pneumatic technology is far more rugged, simpler and has a higher power density. But this ‘one or the other’ approach isn’t always helpful in meeting the needs of the application. It’s clearly better to have an efficient overall system rather than to focus on the efficiency of individual components.”

This principle is driving new advances in linear motion, with product manufacturers seeking to combine the advantages of both pneumatic and electric drives in a single solution. For example, the Simplified Motion Series (SMS) from Festo offers an affordable option that is easy to install and operate. There is no need for external servo drives installed in control cabinets because the whole device is mounted directly on the machine.

Their simplified set-up and operation makes SMS electric drives perfect for simple motions between two mechanical end positions, without having to sacrifice electric drive motion characteristics such as pre-defined speed, gently cushioned movement into end positions and selectable force for pressing or clamping functions. They can be simply and securely combined mechanically with other SMS actuators using more advanced electric axes from Festo, or the vast range of pneumatically-driven guided actuators using standardised interfaces and centring rings for accurate positioning and load transfer.

Festo’s free online sizing tool gives added assurance, not only enabling users to select and size their linear motion solutions quickly and accurately, but also to generate the required documentation and drawings for incorporation in their overall machine design.

Furthermore, these drives are equipped with IO-Link® as standard so they can be integrated seamlessly into fully digitalised environments: supporting predictive maintenance regimes and smart air consumption to make a full contribution to optimising production and energy efficiency. 

In conclusion Warren Harvard says, “Each industrial application has its specific requirements with regards to technical criteria: such as speed, acceleration, load capacity and force required, cycle time, holding duration, power to weight ratio, accuracy, control behaviour, torsional rigidity, efficiency or robustness. Pneumatic and electric drive solutions have traditionally offered specific advantages and disadvantages, but the advent of improved solutions such as the SMS Series mean that machine builders can opt for an alternative, more application-led, approach to finding a solution.”

@festo_global @Publitek #PAuto

Six things to Look for in an acoustic imaging camera.

What should be looked for when selecting an acoustic imaging camera? Here FLIR points to six must-haves that could help makefinal purchasing decision.

Compressed air leaks, vacuum system leaks, electrical partial discharge—these are all expensive system issues that consume power, causing companies to deal with unforeseen costs and potential production/uptime issues. Ultrasound imaging with an acoustic camera is an effective way to detect these equipment issues as part of a complete asset management plan. This easy-to-use technology typically allows professionals to complete their inspections 10 times faster than with traditional methods.

Effective Frequency Range
One of the first features to consider is the camera's frequency range. You might think that you need the widest range possible in order to pick up the widest range of sounds. However, in reality, the most effective frequency range for detecting a compressed air leak is between 20 and 30 kHz. This is because using the 20 to 30 kHz range aids in distinguishing compressed air leaks from the background noise in a factory. The amplitude of machinery noise usually peaks below 10 kHz and trends down to zero at 60 kHz, whereas air leaks peak between 20 and 30 kHz. Since there is a greater difference between the air leak noise and the background noise between 20-30 khz, compared with higher frequencies, it's easier to detect the air leak in this frequency range.

Both the compressed air and machinery noise follow the same downward amplitude trend in the 30 to 60 kHz frequency range, making it difficult to distinguish between them. Therefore, working within the 20 to 30 kHz range is more effective.

For users looking for partial discharge from a safe distance, the 10 to 30 kHz range is optimal. This is because higher frequency ranges travel shorter distances. In order to detect partial discharge from high voltage equipment in an outdoor setting, your camera needs to be attuned to lower frequency, farther-traveling sounds.

Optimal Number Of Microphones
In the pursuit of quieter noises, more is better. Acoustic imaging cameras typically employ dozens of microelectric-mechanical system (MEMS) microphones to collect and characterize sound. While MEMS are small, use little power, and are very stable, they also generate their own noise that interferes with an individual microphone's ability to pick up very quiet sounds. The solution is to increase the number of microphones in use; simply doubling the number of microphones improves the signal-to-noise ratio enough to remove three decibels of unwanted sounds.

For example, one microphone might create enough self-noise to make it impossible for the system to pick up a compressed air leak generating a 16.5 kHz signal.

An acoustic camera with 32 microphones would be able to detect that leak, but the signal-to-noise ratio is still too poor to hear anything quieter.

In contrast, a camera with 124 microphones can pick up both the 16.5 kHz leak and one that is 18.5 kHz, making it easy to detect, locate, and quantify the small leak.

Sound Detection Range
Adding just the right number of microphones to an acoustic imaging camera can also improve the chances of picking up very quiet noises from a long distance. This is especially important when inspecting high-voltage systems, which requires a safe distance from the energized equipment. The force of a sound signal drops significantly as one moves further away from its source. The solution is to increase the number of microphones: quadrupling the number of microphones essentially doubles the sound detection range.

Microphone Placement
The placement of microphones on an acoustic camera factors into how the camera determines the direction and location of sounds. The camera collects data from each microphone, measures the timing and phase differences in the signals, and calculates the source location. These microphones need to be grouped closely together to ensure they collect enough data on sound waves to correctly determine from what direction they originated.

Microphone Performance
Just like frequency, there is a sweet spot for how many microphones an acoustic imager hosts. A potential downside of too many microphones is each requires processing power to convert audio data signals into images—so adding too many has diminishing returns. Some manufacturers balance this by reducing the resolution of the acoustic image pixels, or "sound" pixels, but this will affect the camera's overall performance. It's important to have enough sound pixels to detect corona and partial discharge reliably from a distance and pinpoint its exact source.

With 124 microphones and advanced processing power, the FLIR Si124 provides industry-leading detection sensitivity, excellent acoustic image resolution and a great range.

Intelligent Analytics
The final features to consider are the computing power and analytics provided by the acoustic imaging camera and any companion software. A camera such as the FLIR Si124 offers on-camera analytics, easy-to-understand reporting, and predictive analysis using an AI/web tool. An inspector can classify leak severity, perform leak cost analysis, and partial discharge pattern analysis in real-time during a survey. Once the survey is complete, the inspector only needs to connect to their Wi-Fi network to automatically upload images to the FLIR Acoustic Camera Viewer for further, cloud-based analytics. This includes calculating the estimated yearly energy expense caused by compressed air or vacuum leaks and determining whether a partial discharge issue will require service or replacement. The Viewer can also be used to create reports to share with a maintenance team or client.

@flir @mepaxIntPR #Pauto #Power

Monitoring air loss in pneumatic systems.

Emerson’s new Aventics AF2 flow sensor monitors air consumption, enabling rapid intervention in the event of leakage, preventing excessive cost and machine breakdown

The Aventics AF2 pneumatic systems flow sensor, introduced by Emerson, monitors energy losses, helping to prevent machine breakdowns and the costs associated with excessive air consumption. The sensor continuously monitors the air consumption in pneumatic systems, enabling compliance with the Energy Management standard DIN ISO 50001. Suitable for use in many industries, the device is just one of many components available from Emerson for networked plants in factory automation, known as the Industrial Internet of Things (IIoT).

“The Aventics AF2 series flow sensor is ideally suited to those companies aiming to control and optimise their energy usage,” said Andreas Kliewe, expert for energy management with Emerson’s machine automation business. “The device records the flow rate and compressed air consumption in a system, sending a signal to the controller when pre-set levels are exceeded. This helps avoid excessive energy loss and enables rapid intervention in the event of an issue. After all, the share of energy unit costs in the gross production value is two to three percent – so it’s worth saving here.”

An Organic Light Emitting Diode (OLED) display on the AF2 provides local indication of all relevant operating and diagnostic data. The flow sensor is available as a NO (normally open) and NC (normally closed) version. Analogue outputs can be switched with a signal from 4 to 20 mA. These signals can be interpreted directly by many controllers.

Another possibility for communication is the IO-Link capability of the sensor and the Ethernet interface, enabling customers to use the optimum device to communicate with existing controllers. OPC UA (Open Platform Communications Unified Architecture) and MQTT (Message Queueing Telemetry Transport), the preferred communications protocols for industry 4.0, are integrated into the AF2 sensor. In addition, the AF2 has a web-based dashboard showing real-time data for the users.

Modular construction ensures easy installation, and small dimensions mean it can be installed where space is limited. The Aventics AF2 is delivered pre-calibrated together with its filter. This saves space as no separate stabilisation distance is required. Furthermore, the sensor-filter combination can be configured in any maintenance unit. The flow sensor is suitable for all common applications and industries such as food and beverage or packaging.

@EMR_Automation #PAuto #IIoT @AVENTICS @HHC_Lewis 

Linear actuators.

With the recently announced increase in maximum dynamic load from 10 kN to 16 kN for stroke lengths to 500 mm, and with static loads to 18 kN, Thomson’s Electrak® HD series linear actuators are now an even more compelling alternative to hydraulic and pneumatic cylinders for positioning tasks on heavy-duty machinery and equipment.

Available in Britain, with full support from Heason Technology, the Electrak HD range covers six load-rated models with stroke lengths from 100 mm to 1 metre (in 50 mm increments). With 12 or 24 VDC operation, a wide choice of built-in control options include J1939 CANbus, open or closed loop positioning, analogue and digital position output, axis synchronisation and PLC compatibility. These combine with a comprehensive choice of mechanical interfacing options to make application integration and operation straightforward.

The Electrak HD series has a smaller footprint, requires much less maintenance and is a much cleaner solution than hydraulic or pneumatic cylinder alternatives. In addition, its superior controllability offers easier integration with modern computer controlled systems and more precise positioning control.

The actuators also offer a durability that will suit the harshest environments, with IP67 rating for static use and IP66 for dynamic positioning as standard. An IP69K version is available for the food industry and other automation tasks where frequent washdown is required. The Electrak HD series will operate at high loads in temperatures ranging from -40 to +85 °C. For maximum loads, a generous 25% duty cycle ensures operation for demanding high-throughput positioning tasks.

Safety is available via thermal and voltage or current load protection with end-of-stroke limit switches, manual (mechanical) override and integrated motor-brake for complete safeguarding.

The robust Electrak HD design is well proven in a wide range of applications in automotive, agricultural and construction equipment where the industry standard J1939 CANbus control network is well established. A high-efficiency ball screw system with parallel mounted motor and gear components are housed in a robust hard-coat anodised aluminium housing. Internally the motor and gear unit are housed in a zinc frame providing extra protection. The stainless steel anti-rotation extension tube is fully sealed inside the housing and a wide choice of mechanical interfacing options include rod-end and threaded adapters for straightforward mounting.

#PAuto @heasonmotion @Thomson_Ind

Proportional Valves with Digital Communications Interface.

The ASCO Numatics Sentronic Plus (Series 614) and Sentronic LP (Series 617) proportional pressure control valves with the integration of IO-Link® communications to provide cost-effective and reliable control and diagnostics in support of predictive maintenance practices has been introduced.

Using IO-Link communications to gain insight into these devices on the factory floor supports future implementation of Industry 4.0 and Industrial Internet of Things (IIoT) applications that will contribute toward greater plant reliability, availability and profitability.

These versatile valves enable process optimisation, regardless of application requirements. Sentronic Plus digitally operated pressure regulator valves accurately adjust pressure, flow, force, speed and linear or angular positions. They regulate pressure up to 12 bar (174 psi) and are electromagnetic-compatible according to Electromagnetic Compatibility (EMC) Directive 2014/30/EU. Sentronic Low Power (LP) valves are a highly efficient option for pressure regulation requirements, offering a small footprint, an easy-to-use and modular design, and advanced software capabilities. Their low-power consumption of less than four watts supports applications where power is limited.

IO-Link is increasingly being applied to a range of automation applications, providing a low-cost digital communication interface for sensors, actuators and controllers via unshielded, industry-standard M12 I/O cables. To reduce maintenance time and complexity, the IO-Link module allows the Sentronic valves to identify and configure themselves automatically during component replacement, thereby eliminating the need for reconfiguration via a laptop. Supporting greater ease-of-use, the addition of IO-Link technology to the Sentronic valves uniquely enables device parameters to be changed directly with the PLC during a process without the need of data acquisition software.

“Emerson is a leading innovator in driving IIoT technologies and strategies to facilitate the digital transformation of our customers’ operations across a broad range of industries,” said Harald Steinle, engineering manager for proportional products at Emerson Automation Solutions. “Adding IO-Link capability to the Sentronic Plus and Sentronic LP valves creates significant benefits for users. It not only makes the devices easier to control and operate, but also prepares them for future integration with IIoT applications, enabling improvements in plant reliability and availability.”

Increasing flexibility of choice, the new IO-Link interface is compatible with the full range of Sentronic LP Series 617 valves, as well as the Sentronic Plus Series 614 valves in sizes DN3 and DN6. These valves enable process optimisation in applications such as filling machines in food or cosmetics factories, assembly machines, conveyors and robotic hands.

@ASCO_EU  #PAuto 

Pilot valves for harsh environments.

The VOFD is a new robust pilot valve for process automation applications from Festo.

 The valve is exceptionally tough and provides excellent performance even in harsh environments found in the pharmaceutical, chemical, petrochemical and oil and gas industries, enabling operations managers to improve uptime and productivity.

“Festo is committed to the expansion of our Process Automation portfolio and helps customers in this sector to maximise their productivity,” says Steve Sands, product manager at Festo. “Following the introduction earlier in the year of our VSNC low cost NAMUR solenoid valve for standard applications, we are now expanding the range to address the more demanding applications. The VOFD sets the highest standards of performance and reliability. We are very excited that our significant investment in new products for this sector is really starting to come through to the market. I am confident that for the next few years there will be a continuous flow of new product developments in this area, putting Festo at the forefront of innovation in core and specialist area, continuous flow processes.”

The valve is perfect for actuation of butterfly valves, cylinders, diaphragm drives and rotary drives. It is also ideal for emergency shut-down functions and for safety-orientated systems up to Safety Integrity Level 4 (SIL 4) as per IEC 61508.

The VOFDs have a titanium dioxide plated surface which guarantees a high abrasion resistance and makes it extremely resilient within highly aggressive and chemical atmospheres. Furthermore, it is available with several Ex-protection methods to best serve the needs of each application and it provides ATEX protection for zone 1/21 (gas and dust).

Reliability of the 3/2-way valves is exceptional as an exhaust protector ensures that no atmosphere or environmental contaminants such as dust, ice or snow can enter the valve and degrade it. This ensures it provides a long service life even in demanding applications.

With the VOFD, internal and external pilot air functions have been integrated in a single valve and it can be converted simply by turning a screw depending on the function required. As a result, machine builders and engineers only need to stock one part and can simplify their stock management and make associated cost savings. The valve has two connection options: a NAMUR-port for direct installation on an actuator as well as G and NPT threads for in line connection. The NAMUR interface valves are exceptionally quick and easy to install. No tubing is required and as the valves are installed directly on a drive, engineers can save further set-up time and costs.

Solution for complex valve island applications.

Cabinet mounted valve islands now offer simplified installation and maintenance requirements as part of customised solutions for a range of industries

Emerson have unveiled a panel mount adaptor plate for the ASCO Numatics 501 Series of pneumatic valve islands, enabling the valve island to be directly mounted to the cabinet. The 501 Series valve provides the flow of a 15 mm to 20 mm valve in a compact 11 mm size, addressing customer needs for space savings and simplified construction and assembly.

Many of the complicated internal connections found in traditional cabinet solutions are eliminated, and the design is considerably streamlined. This offers customers increased versatility and reduced component complexity when using valve islands and electronics in small spaces, or damp and aggressive environments.

Emerson’s design has the smallest footprint on the market, allowing for assembly possibilities where they would have previously not been possible.

“The 501 Series panel mount adapter plate fulfils our customers’ needs for space savings, easy panel construction and assembly.” said Yannick Guenard, Valve Island Product Manager for ASCO Numatics. “It eliminates the need for complex tubing routing and bulkhead fittings, reduces custom machining and drilling and simplifies panel layout.”

As with traditional cabinet systems, this ASCO Numatics solution is also highly resistant to corrosion thanks to cabinets that are constructed from anodised aluminum or AISI 316L stainless steel for high protection and resistance against regular cleaning from harsh chemicals – very common in applications where hygiene is a top priority.

Designed for easy maintenance, the systems also include an integrated valve shut off accessory to individually isolate any valve in the circuit, allowing for valve maintenance and replacement without shutting down the entire process.

The mounting plate adapter allows original equipment manufacturers (OEMs) and end users to directly connect the 501 Series valve manifold to a panel in the wall or floor of a cabinet. All panel strength, integrity and certifications are maintained.

“With our space saving cabinet mounted solutions, we have managed to provide a versatile and economic solution that will stand the test of time in these typical environments without compromising on performance. Our cabinet mounted solutions consider the unique requirements of each individual customer,” continued Guenard.

The panel mount adapter plate is ideal for applications in the process industries, for example for food and beverage, pharmaceutical and packaging machinery, plus general machine automation.

Diaphragm valve with pneumatic actuator.

GF Piping Systems has added the new diaphragm valve type 604/605 with integrated pneumatic actuator to its product range. This long runner – available beginning of October 2015 – combines compact design with best flow performance for an economic price-performance ratio.

A spokesperson for te company stated, "Open your application in water treatment, the chemical process or other industries for the diaphragm valve type 604/605 and you will be astonished what this small valve can handle."

The valve’s compact design fits standard installation lengths. Its integrated pneumatic actuator with quick opening and closing times enables more than one million closing cycles over its long service life. That is what GF Piping Systems calls a durable hard worker. The valve is flexible in its operating modes and offers fail safe to close (FC), fail safe to open (FO) and double acting (DA) options.

The actuator housing can be opened quickly for service due to the central housing nut. The connection with the valve body is full plastic without any metal parts.Therefore all materials have the same temperature expansion coefficients which prevents leakages and avoids re-torqueing of screws. Thanks to the optimized linear flow characteristics the kv value is up to 30 percent higher than with comparable valves. The valve is available in DN15 with the pressure rating of PN6.

The small six-arms phenomena is living all over the world in equally cozy or harsh environments. Like the GF Piping Systems diaphragm valves. The wide range of materials offers highest adaption and resistance to chemical fluids and environments. The valves are available in PVC-U, CPVC, PP-H and PVDF. Diaphragms in EPDM, FPM, PTFE/EPDM and PTFE/FPM enable the handling of aggressive media as well as neutral fluids. That makes them even more flexible and reliable for all your applications. Valve type 604 can be mounted into your system with true union connection matching all standard GF unions and inserts and solvent cementing. Type 605 has a spigot for welding resp. cementing. The valves meet the standards ISO, BS, ASTM and JIS.

As communication in an ant colony is very important they share all necessary information. The new diaphragm valve will communicate with you as well. A unique QR code on the product leads to installation manuals, online training videos and certifications.

Position transmitter for simple stroke measuring & feedback!

Festo has launched a new range of pneumatic cylinder position transmitters, the programmable SDAT-MHS.  Economic and easy to set up, the high performance pneumatic cylinder mounted sensors give accurate position feedback over stroke lengths up to 160mm, enabling engineers and machine builders to gain position feedback and conduct simple object measurement or identification.

There are five transmitters available with 50, 80, 100, 125 and 160mm sensing ranges. They offer excellent repeatability, measuring absolute values such as lengths, thicknesses and heights, and are therefore ideal for process monitoring and object detection, for example for monitoring components and displacements in applications such as assembly, riveting, ultrasonic welding, pressing or adhesive bonding.

Typically two cylinder switches are used in basic pneumatic ‘end-to-end ‘movement applications, but for multiple positions or intermediate positions multiple switches and PLC inputs are required to detect and interpret the position.  Now, with the new SDAT-MHS, engineers and machine builders need only one transmitter, which enables them to save significant installation time. 

SDAT-MHS can be set up with analogue current output 4-20mA, a switching output and an IO-Link combined in a single device. As a result, users can benefit from maximum flexibility in their choice of signal processing method with just one device. 

A simple interface allows up to four channels to be programmed in IO-Link mode.  This means that almost all applications can be controlled without having to program the analogue input of the PLC.

SDAT-MHS is the only position transmitter of its type that is IP65 rated, therefore providing excellent protection against the ingress of dust and water in more demanding application areas.  In addition, the transmitters feature three LEDs which uniquely help with set up and alert the user if they are within or outside the measuring range. The transmitters can be fitted easily to any cylinder with a T-slot and are available with up to 20m of cable.

“With our new SDAT-MHS position transmitters it’s now possible to measure longer stroke lengths, extending the scope for pneumatic cylinders being used as measuring devices giving accurate closed-loop position feedback,” says Steve Sands, Product Manager at Festo.  “We’re delighted to extend our range of cylinder mounted sensors. The ease of set-up compared with individual switches or older designs provides a far more elegant and cost saving alternative."

2000 smart device macros stem from partnership!

2,000 Festo devices macros developed for EPLAN users

Partners Festo and EPLAN are each pushing forwards with the aim of connecting the worlds of configuration in electrical and pneumatic engineering. A data package developed by Festo specially for EPLAN users with over 2,000 smart devices macros now gives extra strength to the mechatronic orbit of the CPX terminal. Users of the EPLAN Platform can use this to simply and easily create overview drawings, electrical and pneumatic circuit diagrams, and PLC overviews.

The new exclusive macro collection of over 2,000 device macros for valve terminals with Festo's CPX electric terminal brings together configurations in electrical and fluid project engineering. The device data is available in six languages and comprises intelligent module configurations that already contain their electrical and fluid engineering connection logic, including function templates. The final type code of the configured Festo valve terminal is the link. It comprises two ID codes, one for the electrical and one for the pneumatic section. The designer can use this ID code to select the most appropriate of the predefined device modules and place it by Drag & Drop, into the electrical or fluid engineering documentation. Users of EPLAN Electric P8 and EPLAN Fluid can use this to quickly create 2D overview drawings, electrical and pneumatic circuit diagrams and PLC overviews. The data can be downloaded from Festo's website at no charge with ease.

Versatile for any field of application
The benefits of guided configuration using Festo's tools are combined with logic-based documentation in EPLAN. Thanks to an individual combination of different functions, the valve terminal's configuration can be matched to the application precisely – wide ranges of application are guaranteed. The Festo CPX terminal is perfect here: electrical and open to all current field bus standards and all customer-specific installation standards. Customers benefit from ease of handling: out of the control cabinet into the plant, network electrics and pneumatics, saving installation effort.

Free download
The macros, available for all CPX terminals (electrical peripheral equipment and field bus nodes) and some MPA valve terminals, contain the following functions and can be used as parts master data in the creation of the parts lists:
• Structural overview with individual module feeds and ordering code
• Circuit diagrams in all-pole representation, terminal diagram and PLC overview
• Overview of control cabinet with type codes and in a scale of 1:1

The data is available for download at no charge as a complete package from www.festo.de/EPLAN and can also be downloaded from the Festo online product catalogue under 2D/3D CAD. Availability through the EPLAN Data Portal is also in preparation.

Common target: user benefit
For some years, Festo and EPLAN have worked together to develop solutions with the aim of making engineering easier for their common customers. For instance, Festo's mechatronic components can be designed and documented simply thanks to the direct connection between EPLAN Fluid and Festo's product catalogue. In addition, the subsidiary Festo Didactic has been distributing the EPLAN Education software for industrial foundation and further training for some years.

Cost-effective pneumatic valve terminal

Festo has launched a new pneumatic valve terminal that delivers high performance in a compact and robust unit. The cost-effective VTUG multipin terminal is a simple-to-apply universal valve device that has many electrical connection options, giving machine builders and end users greater flexibility for ease of control and installation.

The VTUG gives excellent performance with a high flow rate and high pressure for its compact size and is ideal for food, beverage, packing, electronics, semiconductor and light assembly industries where assured performance is essential.

This valve terminal is connected and controlled via D sub or ribbon cable connectors for easy connection and simple system integration. This multipin connector can be easily swapped out for an iport connector allowing connection to the industry standard IO-Link network as well as to many Fieldbus and Industrial Ethernet protocols.

The valve terminal is also available with various pneumatic working port connection options including semi-inline, sub-base as well as a sub-base solution with working ports underneath, making it ideal for control cabinet installation as the manifold itself forms part of the cabinet. This enables the fast build of cabinets and saves on the cost of separate gland plates to get the tubing in and out of the cabinet.

It is a robust and reliable terminal and is available with up to 24 valve positions on a single valve terminal and with two 3/2 valves in one position you can achieve up to 48 functions on one manifold. Alternative products do not have as many valves on one manifold, and as a result, it saves cost and space as well as making machines easier to build.

The valves are suitable for low and high pressure operation, from -0.9 to 10 bar, and can support positive pressure and vacuum on one manifold thanks to being able to create multiple pressure zones on one terminal. This means that machine builders no longer need two separate manifolds, therefore saving cost and space.

Users can easily switch between external and internal pilot air without having to specify prior to building, making the terminal ideal for use with vacuum or low pressure applications. This flexibility means OEMs can change their mind during the build without ordering additional parts.

VTUG is robust and tough, with an IP40 or IP67 rating providing reliable operation in a wide range of environments and in ambient temperatures of up to 60°C, meaning that one standard product is suitable for all applications.

Festo’s VTUG pneumatic valve terminals operate with air filtered to 40 microns, so only one air filter is required in the air preparation system. With alternative products, air needs to be filtered three times, to five microns in particulate size. However, each time air is filtered, energy is lost, so as a result of using the VTUG, end users can increase energy efficiencies throughout their process.

VTUG is exceptionally easy to order using Festo’s online configurator. Users simply enter their specifications and the configurator produces one part number and a 2D or 3D CAD drawing. It is then delivered fully assembled in just one week.

“The VTUG is one of the most economic, reliable and simplest to use universal valve terminals with a long service life,” says Jacqui Hanbury, product manager at Festo. “It is pre-built and tested before being delivered, so it arrives ready to plug in, which means it is exceptionally easy to install, therefore saving time and reducing errors and risk of air leakage associated with having to build a terminal from separate parts.”

Slip sliding away -

OEMs and machine builders are now spoilt for choice – Festo launches two new series of precision mini-slides – one pneumatic, the other electric

Festo's new EGSL electric precision mini-slide is ideal
for applications demanding short and precise moves,
and has a repetition accuracy of ±15 microns.

Festo has launched two new series of mechanically compatible precision mini-slides – one pneumatic, the other electric – enabling OEMs and machine builders to mix and match different drive technologies with impunity. Both series of slides feature hardened steel guide rails, which are precision-ground together with the body after assembly, and use caged re-circulating ball bearings between the rails and the hardened steel slide. The overall effect is that the body and the slide jointly form the guidance system, conveying an exceptional level of rigidity to the design.

Both series of slides provide exceptionally fast and accurate positioning capabilities; all DGSL series pneumatic slides have a repetition accuracy of ±10 microns, while all EGSL series electric slides have a repetition accuracy of ±15 microns. The slides are ideal for applications demanding short and precise moves, and their low profile and mounting flexibility – they can be ‘piggybacked’ and oriented in any aspect, including vertically – makes them especially suitable for use where space is limited. Principally intended for use in handling and assembly automation, both types of slides are likely to prove popular in the food processing and packaging industries, as well as in semiconductor and pharmaceutical manufacturing.

Festo’s DGSL series pneumatic slides are available with a choice of eight different sizes, from 4 to 25, and nine different stroke lengths – from 10 mm to 200 mm – depending on the model. The slides are double-acting, with the larger models capable of advancing and retracting at speeds as high as 0.8 m/s. The size 25 slide can produce up to 483 N of force when fed from a nominal 6 bar compressed air supply.

All DGSL series slides use an innovative piston technology that incorporates the guide tape and sealing element, together with an embedded magnet for position sensing purposes, in a single compact component. This results in less friction and air leakage, leading to steady and smooth movement, better speed constancy, and a long working life. The slides also all offer a choice of three types of end-position cushioning – hydraulic, elastomer and adjustable elastomer – which can be set up very easily from one side of the unit’s body.

The new EGSL series electric slides offer users a choice of four different sizes, from 35 to 75, and five different stroke lengths, from 50 mm to 300 mm, depending on the model. The slides’ exceptional rigidity means that they can easily tolerate bending moments; two slides can simply be bolted together to form a cantilever axis, and all their surfaces feature centring rings to remove shear loads from the mounting bolts. The size 75 slide – which is large by any standard – can accommodate a horizontal load of up to 14 kg, and can generate up to 450 N of feed force.

All EGSL slides are capable of accelerating at up to 25 m/s2, and can achieve speeds as high as 1.3 m/s. To help put these figures in context, this typically means that a 200 mm EGSL-45 slide with a 6 kg payload can accomplish a complete positioning sequence in under 250 ms! The slides’ ball screw spindle is completely enclosed, rendering it impervious to contamination, and three of the four models offer a choice of spindle pitches to further simplify applications matching. The ball screw features an integral magnet, enabling inductive sensors or reed switches mounted on the outside of the slide’s body to be used, and easily adjusted, for position sensing purposes. 

EGSL electric slides are fully compatible with Festo's range of stepper and servo motors and controllers, and can also be used with third-party motors; Festo also produces a comprehensive range of motor mounting flanges and couplings, as well as slide mounting plates, axial mounting kits, optional cover kits and steel sensor flags for these slides.

Festo has also developed a powerful PC-based software tool, backed by native CAD models, to help machine designers and other potential users make best use of electric drive technology such as the EGSL slides.

'Clean Design' pneumatic actuators provide cost-effective solution for food industry automation

Round and guided cylinders use FDA-approved lubricants and seals

Festo has launched a new generation of pneumatic actuators designed to provide a cost-effective alternative to specialist high-end components for the food and beverage industries. The actuators employ 'Clean Design' principles to help minimise contamination risk, and are ideal for use in aggressive environments where frequent wash-down procedures are implemented. The first products in this new range include corrosion-resistant round and guided cylinders that use FDA (U.S. Food and Drug Administration) approved seals and USDA (U.S. Department of Agriculture) approved H1 food-grade lubricants.

The new Clean Design cylinders are intended to help OEMs building food safe automation overcome the apparent dichotomy between expensive custom components and non standards compliant off-the-shelf equipment. Festo believes that there is a market for automation components that steer a clear middle road, produced using a combination of standard parts, specialist materials and the latest fabrication technologies.

Their new CRDSNU round cylinders and DGRF guided cylinders are the first products to embody these principles, following extensive research into surface friction, lubrication and wear, materials analysis and computer-optimised design. Both product families are characterised by very smooth, corrosion-resistant body profiles that are free from protrusions, to facilitate efficient wash-down and removal of any bacterial contamination.

The CRDSNU stainless steel round cylinder is available in eight ISO 6432 compliant sizes spanning stroke lengths from 1 to 500 mm. The cylinder uses Festo's patented PPS self-adjusting pneumatic cushioning technology, which automatically adapts to the prevailing load and speed conditions to provide optimum end-position cushioning. This technology offers maintenance-free operation, and has the additional advantage that by obviating the need for a manually-adjustable cushioning screw, it helps preserve the cylinder's clean wash-down lines and ensure optimum machine operation with minimal noise.

For applications that involve high torque moments, Festo has introduced the new DGRF guided cylinder, which features lateral piston rod support guides. These cylinders offer a choice of six different bore sizes from 20 to 63 mm, and are available with stroke lengths from 10 to 400 mm.

As standard, Festo's CRDSNU and DGRF cylinders are fitted with FDA-compliant lubricants and wiper seals, suitable for use in environments involving direct contact with food products. However, for particularly aggressive applications demanding frequent detergent-based wash-down, the cylinders are also optionally available with UHMWPE (ultra high molecular weight polyethylene) self-lubricating seals. These non-toxic seals combine high abrasion resistance with an exceptionally low coefficient of friction, which helps to ensure a long service life when 'dry-running' operations are encountered.

Unique pneumatic valve terminal accommodates four different valve sizes

Festo has further extended the capabilities of its popular VTSA pneumatic valve terminal, which can now accommodate 55 mm ISO size 2 valves, as well as 18 mm, 26 mm and 42 mm valves. This additional capability enables the terminal to handle flow rates as high as 3,000 l/min - 30% more than the previous model - and opens up entirely new application areas in medium to large machine control.

The new valve terminal is capable of housing up to 32 pneumatic valves - in any combination of the four permissible sizes - on the same manifold, without the need for adapter plates. It is the only terminal on the market offering this level of configuration flexibility, making it an obvious first choice for OEMs and machine builders seeking a fully scalable control solution.

Its high flow rate capability - together with its easy integration with the metal version of their CPX electrical terminal and the availability of specialised safety function valves - makes it ideal for machines used in heavy-duty manufacturing environments. Typical applications include automotive presses, tyre manufacturing machines, brick and ceramic tile production machines, and large palletising systems. Supplied fully-assembled and pre-tested, the valve terminals are 100% compliant with the international ISO 15407-2 and ISO 5599-2 standards.

VTSA valve terminals feature robust, all metal sub-base modules, and employ generously proportioned air ducts designed to maximise flow rate. Festo offers a wide range of compatible 5/3, 5/2 and dual 3/2 and 2/2 valves, all of which have an operating pressure range of -0.9 to 10 bar. The valves are available in 18 mm, 26 mm, 42 mm and 55 mm sizes, with respective flow rates of 500 litres/minute, 1,100 litres/minute, 1,400 litres/minute and 3,000 litres/minute. All four valve sizes offer a choice of 24 Vdc and 110 Vac solenoids for maximum applications flexibility, and can be configured so that their solenoid breather ports vent into the exhaust port instead of to atmosphere.

Festo is introducing a series of pneumatics products featuring integrated safety functions, to help users comply with the new EN ISO 13849-1 safety standard. A number of these products, including soft-start valves, and 5/2 fail-safe valves for lifting and rotary cylinders, are compatible with the VTSA valve terminal.

A unique feature of this valve terminal is that it allows the valves to be oriented so that all pneumatic and electrical connections are accessed from one side of the unit. This leads to a very clean installation, which requires less physical space and simplifies servicing. Furthermore, the valves all feature front-panel LEDs and the pressure regulators are equipped with swivelling pressure gauges, making it easy for operators to see the overall system status from a single viewpoint.

The VTSA valve terminal can have individual electrical connections, a multi-pin connection or can integrate directly with Festo's CPX terminal controller, which is a modular, high functionality hub with an Ethernet interface and extensive fieldbus protocol support. The controller enables advanced remote diagnostics capabilities to be easily incorporated into factory-wide local area networks, to provide centralised control and monitoring of individual valve performance. Local diagnostics can either be performed using the valves' front panel LEDs, or via Festo's unique CPX-MMI handheld control unit.

Ultra-fast jet valves

The operating boundaries of solenoid valves for switching compressed air are being pushed back aided by advanced CAE techniques. Festo has launched a new series of jet valves providing exceptionally rapid switching times of less than 1 ms – an order of magnitude faster than standard pneumatic solenoid valves. Based on a unique design featuring just one moving part, the new MHJ series jet valves also provide very high switching time repetition accuracies, and have an industry-leading service life of 10 billion switching cycles. The jet valves are ideal for diverse high-volume sorting applications, especially in the food processing and waste recycling industries.

These MHJ series jet valves are designed for use with standard 40 µm filtered compressed air supplies, and accommodate a wide range of operating pressures from 0.5 to 6 bar. They offer a choice of three 2/2-way fast-switching models, with nominal flow rates of 50, 100 and 150 litres per minute. The valves employ a special short-stroke solenoid and patented damping plate, developed using extensive CAE modelling of the magnetic, temperature and flow characteristics, to optimise switching characteristics. To switch at this speed and provide such a long life, the novel design completely dispenses with dynamic seals and lubrication. The design of the solenoid and damped flat plate also enables the valve to deliver the consistent switching repetition of less than 0.1ms required throughout the operating lifetime of specialist sorting machines.

The MHJ series jet valves have a trigger signal voltage range of 3 to 30 Vdc, enabling them to accommodate standard 5 V PLC-level signals without any need for voltage conversion. The valves have a power consumption of 7 W, which can be reduced to 2 W after the initial turn-on period by use of a holding current control feature, which can be supplied by Festo either integrated into the coil assemblies or incorporated into the application control board.

The valves are available as individual units with integrated push-in fittings, and can be supplied with sub-bases for manifold mounting. Festo also produces customised manifolds which enable a group of valves to share the same air supply, and these can be fitted with integrated jet nozzles, if required.