100 years in motion!

“This anniversary is not only a cause for celebration, but also a reminder of what is possible with solidarity, trust, passion, quality, and innovation. Together, we look ahead with confidence to a promising future.”

Creating added value for customers through innovation has been the driving force behind the family-owned company, Festo, from the very beginning and remains the key to the company's success today. With its constant determination to make people's work easier and thus increase efficiency, Festo has shaped an entire era of industrial production. Today, the company is a global player and a front runner in automation technology, as well as a world leader in technical education and training. Festo's anniversary is being celebrated with employees, customers, and partners worldwide throughout the year.

The focus has been on innovation, responsibility, and the future from the very beginning. And it is the people who still make all the difference. “Festo is the work of many hands” – this saying of the company's founder Gottlieb Stoll is still the guiding principle for management and staff worldwide. In 1925, he and Albert Fezer founded the company Fezer & Stoll for woodworking machines in Esslingen am Neckar. Albert Fezer left the company shortly afterwards, and Gottlieb Stoll continued to run the company on his own.

The second generation of owners laid the foundation for the company as it is now. Dr. H. C. Kurt Stoll brought the idea of pneumatics from the USA to Germany in 1950 and, as a pioneer in his father's company, developed it further. This marked the start of pneumatics at Festo and paved the way for its use in factory automation.

Internationalisation played a vital role in the ongoing development of Festo. Dr. Wilfried Stoll concentrated on developing the international markets and establishing national companies.

In 2000, the owners separated the power tools division from the rest of the company and established it as an independent company under the name Festool GmbH.

Education is key.
Lifelong learning is firmly rooted in the corporate culture at the company. This is because successful companies need people who understand, develop, and can apply technologies. Training and developing competencies are thus fundamental success factors for a flourishing workforce. That is why Festo Didactic was established as a worldwide, independent division as early as 1965.

The inventive spirit of Dr. Wilfried Stoll and Dr. Kurt Stoll, their holistic thinking and approach, and their positive customer-oriented perspective have had a lasting impact on the company. Thus today, Festo is one of the leading automation companies worldwide and, with Festo Didactic, the world market leader in technical education and training.

Festo says “Thank you”

Thomas Böck

“We want to say thank you to our customers, partners, and employees and celebrate this unforgettable anniversary with them,” said Thomas Böck, Chairman of the Management Board.

Anniversary activities are planned throughout the year, both in Germany and in the more than 60 Festo companies worldwide – with “thank you” parties for employees, school days for the young talents of tomorrow, customer events, and press events. For representatives of the press and visitors who are enthusiastic about technology, the world's leading industrial fair, the Hannover Messe, will have a special highlight in store. “The project is still top secret. What we can say is that it showcases our wide range of skills, our broad expertise, our passion for innovation, and our aspiration to make the impossible possible,” declared Thomas Böck.

The Hannover Messe will be a strong start, and that momentum will continue throughout the year. There will be, for example, worldwide “Innovation Days”, where Festo will use a new format to share future trends, technologies, and innovations with customers and partners.

“In our anniversary year, we are very much looking to the future since we see it as our responsibility to use our innovations in automation and technical education to help solve the most pressing challenges facing industry and society, and to play a key role in driving industrial transformation as a solution provider,” says Thomas Böck. In the future, topics such as digitalisation, artificial intelligence, biologisation, and the circular economy will give automation a new boost and, in addition, inspire future generations. Festo will be making a considerable contribution to moving these developments forward.

The anniversary will also be the kick-off for an ongoing company-wide initiative to strengthen Festo's guiding principle of social responsibility for sustainable development. “Our Corporate Citizenship Program underscores our belief that companies should not only pursue economic goals, but also play a significant part in society,” he said. As part of the program, all 20,000 employees worldwide can spend one day working on a charitable initiative.

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@FestoGB @festo_global @Publitek #Automation #PAuto #Manufacturing

Feeding and handling solutions.

Afag is now officially part of Emerson*. As a result, Afag's feeding and handling solutions will be integrated into Emerson’s extensive automation portfolio. All content on Afag.com, including product documentation, data, and certificates, has been migrated to Emerson.com under the AVENTICS™ brand. This migration will streamline Emerson’s comprehensive automation offerings, making it easier for original equipment manufacturers (OEMs) to access the solutions they need in a single location.

The AVENTICS brand is globally recognized for its innovation and proven performance. By bringing Afag’s feeding and handling products under the AVENTICS umbrella, OEMs will benefit from single-source access to a broader range of machine automation experts, as well as pneumatic and electric solutions that optimize the performance of new equipment designs.

In the months following the migration, Emerson will gradually rebrand Afag’s products under the AVENTICS line. While the brand name will change, the Afag product portfolio will remain consistent, ensuring OEMs continue to receive the high quality and support they trust. Customers will still be able to contact their existing representatives for ongoing assistance.

The legacy AVENTICS portfolio includes cylinders, valves, air preparation, and pressure technology. The newly incorporated Afag portfolio adds vibratory feeders, refilling devices, control units, linear and rotary axes, rotary modules, grippers, and more, further strengthening Emerson’s machine automation offering.

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* See also Accelerating factory automation capabilities. (19/9/2023)

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

Fluid and pneumatics Tour de Force near you!

The biggest roadshow yet from the global technology and software leader will bring the latest fluid control and pneumatics solutions directly to customer sites.

The newest fluid control and pneumatics solutions and team of experts from Emerson are on their way directly to European customers via their mobile, interactive service centre over the next year. Covering more kilometers than tours past, the Emerson Mobile Roadshow will visit customers in nineteen countries, including new stops in Turkey. With a personal trade show at their doorstep, customers can meet with Emerson experts and receive meaningful answers to their most demanding challenges related to digital transformation, sustainability, machine automation and more.

Austria Belgium Czech Republic Denmark Finland France Germany Great Britain Hungary Italy Lithuania Netherlands Norway Poland Portugal Romania Slovakia Spain Sweden Switzerland Turkey

During the preplanned site stops, visitors can engage with innovations from Emerson’s ASCOTM, AVENTICSTM, TopWorxTM, PACSystemsTM and MoviconTM portfolios in a dynamic way. The hi-tech demonstration truck features an interactive digital experience and an embedded ultra high definition (UHD) screen that offers vibrant demonstrations of the latest fluid control solutions in action.

Roadshow presentations will reveal how sophisticated, smart pneumatic technologies monitor plant operations in real time, how intuitive PACSystems Edge computing and control systems powered by Movicon.NExTTM HMI/SCADA automation software provide advanced analytics and powerful visualization and how these scalable solutions work together to systematically optimize processes and drive plant sustainability, productivity and profitability. Manufacturers of all sizes can learn how to digitally transform their operations and turn collected data into actionable insights that empower decision-making and can significantly improve energy efficiency, overall equipment effectiveness (OEE) and much more.

Visitors will also find proven products with global certifications that are engineered specifically for their needs. Highlights include reliable industrial automation fluid control technologies for combustion, dust collector systems and industrial and commercial machinery, as well as ASCO components for process, industrial, rail, analytical and medical applications.

By visiting the innovative mobile service centre and experiencing the Roadshow, companies across Europe can GO BoldlyTM. Emerson is committed to helping the world’s leading companies reliably reach their sustainability goals and optimize their operations. GO Boldly is an invitation for companies to join Emerson in making the world healthier, safer, smarter and more sustainable.

@EMR_Automation @Emerson_News @EmersonExchange @mepaxIntPR #PAuto #LifeScience #Europe 

The 4 bar future.

Roy Schep, Manager Energy Efficiency, SMC Netherlands on helping OEMs develop energy-efficient machines.

Roy Schep

OEMs traditionally design their pneumatic machinery and equipment for an operating pressure of 7 bar. However, by reducing this to 4 bar, I know from experience that end users can cut their energy costs by up to 29% in some instances, creating a powerful USP for the OEM. To help achieve such a desirable outcome, increasing numbers of OEMs are engaging with our team of experts here at SMC, who can offer both the know-how and products to turn this concept into reality.

The shift to 4 bar standard operating pressure is already taking place at some large manufacturing companies. While not seeing mainstream adoption just yet, we believe it will become standard practice in the not-too-distant future as regulations tighten and public pressure for more energy-efficient industry grows.

With this thought in mind, OEMs must begin preparing for a 4 bar landscape. By making the transition now they can become industry pioneers, not only helping to capture a larger share of a rapidly emerging market, but significantly boosting their corporate image. Sure enough, while this task may at first appear daunting, working with the right technology partner can help ensure a painless changeover.

Although the vast majority of machine components will still perform at 4 bar, we should of course keep a close eye on some of them to ensure they operate as intended.

Actuators: pushing ahead.
When designing a machine from scratch, it makes sense to start with the components that do the work: the actuators. In general terms, these are the elements that may not perform at their best, or sometimes not at all, using lower pressure.

Two variables are key: force and speed. In my experience, actuators in the majority of horizontal applications operate at lower supply pressure because they are only acting against friction, not force. As a result, it’s normal to size actuators for use in horizontal orientations to perform at a certain speed.

In vertical applications, however, the story can be different as the cylinder pressure has to overcome the load pressure. These applications tend to be more critical and usually demand specific considerations to ensure the actuator meets its intended objective. Reducing the pressure to 4 bar in vertical applications may require the use of a larger bore actuator to ensure the required force. If using a larger bore size is an issue due to lack of space, our VBA series pressure boosters can provide the required pressure level in that local part of the application without having to increase the main line pressure, making it possible to use the existing actuator size.

In either case, a simple calculation can indicate the theoretical force of the cylinder: F= P x A, where F is force in Newton, P is pressure in bar and A is the effective area of the cylinder bore in cm2. As a point of note, if working at 4 bar demands a larger bore size, the saving in air consumption will offset any additional cost.

One challenge that could arise is that of space. What if a cylinder with a larger bore will not physically fit with your designated design space? Here, scrutiny is required to select a supplier that can provide compact and lightweight actuator solutions. A company such as SMC offers more compact cylinder solutions than its competitors. These products also feature a lower minimum operating pressure and a number of energy-saving concepts.

The other option is to use a different technology, such as a double-force cylinder. Again, tapping into the expertise of a reputable pneumatics supplier will prove useful in specifying the optimal solution.

Valves: take control.
It’s not really high or low pressure that controls actuator speed, but the flow of air it receives. If you need higher speed; the valve will control that for you. With the cylinder bore and force defined, it’s possible to select the valve size. We offer directional and process valves with the lowest power consumption, making them ideal for use at 4 bar.

Blowers and vacuum units.
When it comes to blowers and vacuum units, higher pressure does not mean higher performance, but quite the opposite, which is why a product like a high-efficiency nozzle has the potential to deliver notable gains. This solution can maximise air blow efficiency thanks to a more focused blowing impact. Indeed, governed by the Bernoulli Effect, you can improve air blow thrust by 10%.

We recently saw this in action at a customer producing liquid detergent. The company’s bottle un-scrambler machine housed 25 air nozzles from an SMC competitor, costing €22,441 in annual air consumption. After application analysis we recommended that the customer adopt our high-efficiency nozzles. These products could provide the same blowing performance (flow and impact force), but with a lower nozzle diameter - thus allowing lower inlet pressure. Reduced air consumption led to savings of €6,183 a year, delivering amortisation in just 1.57 months. Performing the same replacement process on six further lines led to total annual savings of €37,098.

SMC’s firm commitment to 4 bar is also visible with our vacuum units, which actually function at their best (maximum efficiency) when using low operating pressure. At 4 bar, we ensure the vacuum pressure necessary to hold the component or product securely. Beyond this pressure, air (and money) is simply wasted and the vacuum unit loses efficiency. By turning up the pressure, you are not getting more force or speed, just more inefficiency.

Regulate to accumulate.
As regulators handle point-of-use pressure they can be good collaborators in the 4 bar journey, largely because we can use them to reduce the pressure even further at points where it’s possible. This might include air blow or vacuum applications, endowing the machine with even more energy efficiency. Every little helps.

Monitoring the pressure.
Although a pressure switch plays no direct role in the 4 bar concept, it can prove beneficial in the long run. For instance, when designing a machine for 4 bar, you need to monitor pressure as the margin is low. In the first instance, pressure monitoring acts as a control measure for the machine to receive the 4 bar it needs. Secondly, pressure switches can monitor air consumption and identify any pressure losses. Air leakage is something that no machine can afford, especially at 4 bar.

The 4 bar future.
OEMs should propose that end users adopt machinery which operates at 4 bar in order to stay competitive. To help expedite a project that involves designing a machine for this operating pressure, SMC’s expert team can deliver the optimal outcome for both OEMs and end users. Through early project engagement we can provide the correct sizing for each pneumatic component and ensure it consumes less energy without compromising machine performance. In addition, we can deliver solutions with minimal impact on surrounding or connecting components, thus avoiding any unnecessary time and cost for redesigns. Retrofit projects also benefit from this approach.

@SMCPneumaticsUK @SMCPneumaticsNL @mepaxIntPR #PAuto

A new era of human-robot collaboration.

What if there was a robot that was easy to operate, did not require a safety fence and was also attractively priced? That would introduce a whole new era in human-robot collaboration. This new era is now dawning – with the world's first pneumatic robot from Festo.

Hardly any industrial market segment will grow as rapidly over the next few years as human-robot collaboration. Cobots relieve employees of particularly strenuous or monotonous tasks, giving them new levels of freedom and making their work easier and healthier. And no other technology has such a sensitive and flexible approach to human-robot collaboration as pneumatics.

The benefits of pneumatics
The Festo Cobot owes many of its advantages, such as its sensitivity, weight and value for money, to the benefits of pneumatics. The direct drives in the articulated joints are very cost-effective and particularly lightweight because, unlike electric solutions, no heavy gear units or expensive force-torque sensors are required. The world's first pneumatic cobot is a result of the exceptional expertise in controlled pneumatics from Festo.

Cost-effective option – even for small and medium-sized companies
The Festo Cobot even makes using cobots cost-effective for small and medium-sized companies, which often rely on manual work processes. Its flexible application options mean that small batch sizes or work steps can now be processed automatically. Thanks to its uniquely intuitive and simple commissioning and programming, it is quick and easy to get to grips with so extensive training is not required.

Dr Frank Melzer

The pneumatic Festo Cobot will be cheaper than electric cobots in the same class. It will provide excellent value for money in its main application area of small parts handling with payloads of up to 3 kg. "When it goes on sale in 2023, the Festo Cobot will set new standards in human-robot collaboration with its ease of use," explains Dr Frank Melzer, Member of the Management Board for Product and Technology Management at Festo.

Easy to operate and flexible to use
The Festo Cobot consists of the hardware itself, a handheld module and the Robotic Suite – software for intuitive commissioning and programming. This package makes it possible to commission and program the Cobot in less than an hour. Prior knowledge of robotics is not required either, because the self-explanatory "Robotic Suite" software contains clearly visualised and standardised function blocks. Pneumatic drives enable the robot arm to be guided by hand easily and without any resistance so that waypoints or paths can be taught quickly and precisely.

For small and medium-sized companies in particular, cobots are only attractive if they can adapt quickly to take on a new task and are not just permanently used for the same purpose. The Festo Cobot meets this requirement as it doesn't require an additional control cabinet (which can be difficult to connect and cumbersome). The compact controller that is integrated in the Cobot’s own base makes it particularly flexible. Simple connections also allow it to be used ad hoc without long changeover times. Common bus standards enable fast connection to higher-order controllers. It also requires less space.

Thanks to state-of-the-art, lightweight construction methods, the Festo Cobot weighs in at well under 20 kg so that it can be deployed quickly and flexibly at other locations.

Working safer and faster

Christian Tarragona

With a length of 670 mm, the Festo Cobot is just like a human arm and has the right reach for it to be perceived as a helping third hand when working with a member of staff. It moves – like a real colleague – within a manageable radius. Thanks to the flexibility of the pneumatic drives, the cobot acts sensitively – at a speed appropriate to the situation and with fluid, harmonious movements. It is as soft to the touch as human contact.

The cobot's pneumatic direct drives and its light weight reduce its contact energy. Says Christian Tarragona, Head of Robotics at Festo: "Thanks to precise pressure regulators in the articulated joints, the robot recognises when it is being touched and responds with appropriate safety functions." Employees can work together with their careful technical colleague in complete safety.

@FestoIE_NIE @festo_global @Publitek #Robotics #Manufacturing #Pneumatics

New flow control app for compressed air and gases.

Filling containers with compressed air or other gases such as nitrogen can be achieved more profitably and economically with the new Flow Control Motion App from Festo, developed for use with its VTEM Motion Terminal. As a leader in industrial automation, the company is continually developing new Motion Apps for the VTEM in order to reduce complexity and time to market for machine builders.

The VTEM combines digitalisation with pneumatics, marking the start of a new age of automation technology. Digitised pneumatics intelligently connect the mechanical system, electronics and software, ensuring better overall equipment effectiveness (OEE) combined with lower energy consumption. The quickly activated Motion Apps can be used to control the piezo piloted valves for almost all pneumatic tasks: increasing flexibility and energy efficiency to accelerate production processes.

For example, it is common practice for food product containers to be purged with inert gases like nitrogen. With the new Festo Flow Control Motion App, users can control the flow rate of compressed air and gases at up to 600 l/min digitally and simultaneously on up to eight independent channels. For more precise dosing, the integrated sensors can be combined with external flow sensors. This saves energy and reduces wastage of expensive process gases.

The versatility of this App-controlled approach becomes evident when we expand this filling example. Controlling the flow using the app allows the gas to be precisely dosed. The closed loop control enables the precise filling quantity to be defined. Another advantage is that this flexible, digitised gas control is tamper-proof. The Selectable Pressure Level App can be used to move filling nozzles to bottles or containers quickly and accurately, achieving flexible parameterisation – which in turn shortens the cycle times. After filling, the nozzles are retracted at reduced pressure to save energy.

Adding the Leakage Diagnostics Motion App means maintenance is simplified too, as it automatically monitors for leaks. Malfunctions can be detected and pinpointed to a specific actuator using diagnostic cycles and defined threshold values – the reliable basis for predictive maintenance.

Thanks to the easy activation of additional functions via Motion Apps, machine developers can create a basic machine type using the Festo VTEM Motion Terminal and then select the relevant Motion Apps to equip it with added value functions and features as per the customer requirements or market opportunities. The ability to copy and transfer parameter sets makes commissioning easier and saves time. Assigning functions via software has the added benefit of preventing operator tampering and protecting know-how, since it’s not possible to tell from the outside which functions the valves are executing.

@festo_global #PAuto 

Training courses for fundamentals of pneumatic system design and operation.

Would you know what to do if your pneumatic system was experiencing intermittent pressure fluctuations? Are you confident that the component you have just replaced was actually the cause of the fault? How can you extend mean time between failure to optimise productivity?

According to Festo, these are common dilemmas faced by engineers with responsibility for pneumatic systems in industries across Britain. From pharmaceuticals to machine tooling, electronics assembly to food production and packaging, pneumatic systems play a fundamental role in performing, highly repetitive tasks. Understanding how pneumatic systems work and being able to diagnose and correct faults effectively are therefore vital engineering skills. 

Drawing on its experiences as a manufacturer and employer, Festo has been running training courses for many years that take engineers through the fundamentals of pneumatic system design and operation. It has recently added a new course, available from July 2021, that focuses on troubleshooting and fault diagnosis to further improve skill levels in the pneumatic systems arena.

Hakan Emince, Head Trainer for Festo Didactic, explains: “The performance of pneumatic systems in industry directly impacts overall equipment effectiveness, productivity and competitiveness. Our new course, Troubleshooting and Maintenance in Pneumatics, offers an introduction to common mistakes, fault finding, maintenance and inefficiency in pneumatics and electro-pneumatics systems. Using a combination of theory and practical exercises, the course aims to improve how engineers approach maintenance of pneumatic systems and enable them to deal with breakdowns more efficiently.”

The practical sessions are used to simulate various common problems, helping delegates to understand reasons and consequences of issues from real life. Among other things, participants will learn how to interpret pneumatic system diagrams, how to establish the root cause of a problem quickly, fix faults faster, and avoid costly downtime; and how to optimise system performance to improve the quality, efficiency and lifecycle of the machine. Aspects such as hazard identification and safety are also covered.

Troubleshooting and Maintenance in Pneumatics is a two-day course and is applicable for personnel in multiple engineering type roles, who already have a grasp of pneumatic system fundamentals. Courses take place at Festo’s dedicated purpose-built training centre in Northampton (GB), although there is an option to run courses at the customer’s site for groups where circumstances allow. If potential attendees are unsure if they are at the correct level for the course then they can complete a free knowledge check via the Festo Didactic website.

@festo_global #Pauto 

Air service units.

The new MS2 air preparation units from Festo allows machine builders and design engineers to put precision and accuracy close to the process without compromising on flow rates. The MS2 is designed to deliver the optimum combination of compact design, low weight and high flow rates that are ideally suited to end of arm tooling applications in electronics and small parts assembly. 

Aruj Abbas, Festo Product Manager, says: “We believe that our new MS2 air regulators and filters are the smallest currently available on the market. They not only deliver superior control performance but also their size envelope allows installation directly on moving components in dynamic applications such as pick and place, which makes the latter extremely responsive. Being so light, these MS2 units have negligible or no effect on the kinematics of the machine or system on which they are placed.”

The MS2 LR compressed air regulator weighs in at just 28g-31g, while the MS2 LFR filter weighs no more than 38g. In addition, these air preparation units feature clever integrated push-in fittings, which remove the need for connecting plates or additional parts: reducing assembly time and cost, and delivering space savings of up to 40%. 

MS2 units are up to 50% lighter than rival components with comparative flow rates. They are made from state-of-the-art polymer materials, which makes them robust as well as light. For such diminutive products, they offer a best-in-class flow rate: 350 l/min for the pressure regulator and 310 l/min for the filter regulator, using a 5µ filter. Tubing with an outside diameter of 6mm can be connected directly to the MS2 when using QS6 connections.

Concludes Abbas: “Festo has been employing the MS2 regulators in testing, gripping and handling applications within their own manufacturing facilities for some time, so we are confident about the performance, space and cost benefits they can deliver. Now, they are being made available to customers worldwide as a valued addition to Festo’s core product range, meaning they are competitively priced and stocked locally for fast delivery.”

@festo_global @Publitek #Pauto #Pneumatics

Knife production at the cutting edge.

Festo automation technology is being used to help STANLEY® Tools in Britain to meet continued demand for its renowned safety knives, while continuing to maintain the highest standards of safety and quality. 

Festo automation sits at the heart of a new rotary assembly cell designed and supplied by PCE Automation Ltd. The new production cell also contains Festo mini slides, axes, cylinders, valves and grippers – all of which contribute to the high precision alignment required for STANLEY knife assembly. 

Josh Roberts, Festo Business Development Consultant, says: “The STANLEY knife rotary assembly cell presents a great example of how automation can be applied to replace manual repetitive tasks and deliver benefits, such as improved productivity and quality. 

“PCE involved Festo at the earliest possible stage, which meant we could work in partnership and combine our respective specialist knowledge as system builders and automation specialists to deliver the optimum solution for Stanley Black & Decker.”

The customer required an assembly cell that could be used to produce safety knives with two different sizes of blade capable of swapping production efficiently between their 9mm and 18mm width options. To meet demand, a cycle time of 20 parts per minute was necessary. In addition, Stanley Black & Decker needed a compact solution to fit in the existing footprint at their British production facility. 

PCE Automation Ltd won the contract to design and build the new automated assembly cell under competitive tender, against international competition. In partnership with Festo, they were able to demonstrate the levels of responsiveness and aftersales support that their customer was looking for. 

Their solution is an eight-station rotary assembly cell featuring Festo automation. The blade handles are held in position on the central rotary assembly and the components, including blades, are placed with high precision to build up the final product. The fully assembled STANLEY knives are subject to camera inspection for quality control as they leave the cell on a conveyor.

The customer did not want the assembly cell to require constant overseeing by an operator. So, hoppers are used to feed components down to vibrating bowl feeders. The hopper feeds will keep the cell running for approximately one hour without the need for operator intervention. The bespoke vibrating bowl feeders were manufactured by PCE’s sister company Premier Bowl Feeders. 

Introducing the knife blades into the assembly cell raised a particular challenge for PCE. The 9mm and 18mm length blades are presented to the assembly cell in stacks of 400, but each blade is only 0.4mm or 0.5mm thick, which makes them tricky to pick and place accurately. There was a real risk of the blades jamming and halting production if not correctly positioned, so it was critical to be able to pick off one blade at a time and place it in the correct orientation. PCE used magnets to hold the blades effectively. Festo grippers are used to pick and place all the other components.

The nerve centre of the new rotary assembly cell is the Festo CPX-AP-I (see box-out), which acts as a single control network and facilitates the use of a single cable for all communications and power. It also allows flexible positioning of valve terminals and other components around the assembly cell – all of which simplifies installation and lowers overall cost. Festo DGST precision mini slides and grippers are used for accuracy and repeatability in presenting the plastic components for assembly. These are complemented by DFM guided actuators and air preparation units from Festo’s core Blue Star range of best priced and availability, pneumatics.

Ellen Blackie, Senior Project Manager, PCE Automation, comments: “As an existing Festo Integrator, we had every confidence that their product portfolio would offer the quality and precision that the STANLEY knife assembly application demanded. Breadth of product choice, coupled with Festo’s on time delivery record and parts availability, were critical in helping us win the Stanley Black & Decker contract. As a systems builder, we appreciate the proactive support that Festo offers in exploring alternative solutions. We also found their online software tools particularly helpful, especially the ability to track parts and lead-in times online.”

@FestoGB @PCEAutomation #PAuto #Pneumatics

Driving on air!

The International AVENTICS Pneumobile Competition demonstrates Emerson’s long-standing commitment to the future workforce, including supporting over 350 academic institutions globally in a variety of programs.

Ádám Detzky sits in the Budapest University of Technology and Economics winning vehicle with teammates Milán Bolgár and Máté Szentes behind him. Standing from left to right are Dr. Zsolt Farkas, Réka Tobak, Zsolt Németh, Tamás Szlobodnik, Zoltán Fatér, Gergő Kimpán, Gábor Lengyel and Zoltán Takács. The team won for Most Innovative Vehicle.

The winners of the 13th annual International AVENTICS™ Pneumobile Competition have been announced. The vehicle designs, which are based on Emerson’s pneumatic components, programmable logic controllers and edge gateways, were evaluated by a panel of eight Emerson judges following a modified, virtual design format using technical documentation and CAD drawings submitted by the student teams.

The competition began in October 2019 and participants had until the end of last year to submit their design and project documentation. A total of 48 teams entered this year’s competition from 26 different learning institutions and nine countries, with almost every Hungarian university represented.

“We see the impact that these kinds of STEM programs have in developing the abilities of new engineers,” said Istvan Gödri, managing director of Emerson’s AVENTICS Hungary Kft. “In fact, three of the eight Emerson judges, including the head of the jury, participated in the competition themselves when they were college students.”

The competition recognizes the best technical documentation, the most innovative vehicle, the most beautiful bodywork and the best controller solution presented by the teams. Winning teams were awarded a variety of prizes.

More than 1,600 engineers have participated in the event during the 12 years it has run. This competition has given students hands-on experience in pneumatics engineering concepts, teamwork and project management. “The task of designing a vehicle for the pneumobile competition is a great way for the next generation of engineers to apply the skills they’ve learned to real-world challenges,” Gödri said.

Here are this year’s competition winners:

Best Technical Documentation (Tie) • BME Műszakik AiR-115 Team Budapest University of Technology and Economics, Hungary • Technics 5 Estonian University of Life Sciences, Estonia Most Innovative Vehicle • BME Műszakik AiR-115 Team Budapest University of Technology and Economics, Hungary Most Beautiful Bodywork • Technics 5 Estonian University of Life Sciences, Estonia Best Controller Solution • BME Löködönc Green Thunder Team Budapest University of Technology and Economics, Hungary

@EMR_Automation @AVENTICS #PAuto #Pneumatics

Intelligent displacement sensor added.

With their BMP series Balluff has added a new intelligent displacement sensor which provides not only the absolute position signal for the stroke travel of a piston via IO-Link but also information about the sensor status and the current ambient conditions.

It monitors for example the sensor temperature, the number of starts and issues warnings when a configurable limit value is violated. An internal counter continuously monitors the operating hours over the entire life of the sensor, both since the last service and the last start-up. This makes it possible to plan for a possible needed replacement at the next service interval.

The integrated IO-Link interface also offers flexibility; it enables for example fast format changes thanks to time-saving parameterization functions. This magnetic, non-contact and wear-free sensor continuously detects the absolute position of a piston, is compatible with virtually all cylinder types and is quickly installed. Preferred applications include those where the exact execution of a defined piston stroke is essential for the process and product quality, for example in assembly, handling and factory automation.

#Pauto @Balluff @mepaxIntPR

Self-adjusting double-acting air cylinders.

RS Components (RS) has expanded its offering from factory automation manufacturer Festo to include new double-acting pneumatic cylinders in the DSBC product range. Aimed at both machine builders and maintenance engineers, DSBC air cylinders are convenient, reliable and economical linear motion generators featuring patented self-adjusting cushioning technology.

Double-acting cylinders feature dual compressed air ports to develop a linear output force during both extension and retraction as well as a braking force toward the end of each stroke. However, setting them up manually does not necessarily optimise for individual applications, resulting in setting errors in up to 80% of cases.

With Festo’s self-adjusting end-of-stroke pneumatic cushioning method, known as PPS, the cross-section of the air ports is adjusted automatically to vary the braking effect according to changing loads and speeds. PPS even reacts to changes in friction and working pressure, optimising cushioning without the need for manual adjustment. This saves time during both installation and maintenance of DSBC cylinders, while minimising wear, noise and vibration and allowing continuous operation over a long service lifetime.

A magnetic high-alloy steel piston rod allows contactless position detection via proximity sensors in the cylinder body, while further enhancing service life.

The DSBC range comprises over 300 variants, with stroke length and cylinder bore size configured to suit a broad range of applications via a quick online selection tool. Cylinder bore size options are 32mm, 40mm, 50mm, 63mm, 80mm, 100mm and 125mm, while numerous stroke length options are available from 1mm up to 2800mm. Cylinder output force ranges between 483N and 7363N.

The round actuators of the DSBC range conform to ISO 15552 specifications, providing interchangeability with commonly used hydraulic and pneumatic cylinders such as Festo’s previous-generation DNC and DNCB series. Optional mounting accessories allow the cylinder to be attached with a swivel bracket for free movement, foot mounted to support high loads, or combined with other actuators to give a wider range of movement.

The DSBC range is part of an ongoing introduction of over 10,000 new Festo devices to the RS product range and is available now in the EMEA region.

#PAuto #Automation  @RSComponents @FestoAG

Air preparation products.

The ASCO Numatics™ 653 Series air preparation products suitable for applications where high-flow-rate is required.

The ASCO Numatics 653 Series of air preparation products are announced by Emerson. Available in 3/4” and 1” port sizes, the 653 Series has a high flow rate for its size. This enables customers to power more products from the same Filter-Regulator or Lubricator (FRL), or reduce pressure drop across the system, both of which enable potential energy and cost savings. The range of the 651, 652 and 653 Series consists of filters, regulators, filter regulators, lubricators, soft starts, quick exhausts, diverter blocks and shut off valves.

“The introduction of our 653 Series greatly expands our global offering of high-flow air preparation products.” said Scott Weickel, Vice President of Engineering for Machine Automation applications at Emerson. “The addition of the new port sizes enables international manufacturers to select a comprehensive range of advanced technology air preparation products in sizes ranging from 1/8 to 1”, all from one supplier. This makes selection and purchasing simpler.”

With the industry’s highest flow characteristics, related to size, the ASCO Numatics 651, 652, and 653 Series are ideal for use in any application that requires high volumes of air or where space is limited. Original equipment manufacturers will benefit from the wide temperature range (-40°C to 80°C), and ATEX and CUTR certification, which enables this product to be used in challenging and harsh environments, and applications such as valve piloting in the process industry. The modular air preparation products have a robust construction and are easy to assemble, mount, and position. New endplate flanges allow the removal of the manifold assembly without disconnecting the piping.

The 651, 652 and 653 Series incorporate front-facing easy-to-read, low-profile gauges. Optional integral red/green pressure range indicators make it easy to monitor the desired pressure. The small footprint and clean lines help achieve robust, modern-looking equipment. Long-lasting laser-etched tags and covers ensure product information will remain visible even in challenging - environments. In addition, an optional 3-micron pleated pre-filter has been added to the line’s coalescing filters and coalescing filter/regulator combination units. This eliminates the need for a separate particulate filter unit and reduces cost, size, and weight.

@ASCO_EU  #PAuto @Emerson_News

Acquisition improves smart pneumatics technologies capabilities!

Emerson has agreed on terms to acquire Aventics from Triton for a cash purchase price of €527 million*. Aventics is among the global leaders in smart pneumatics technologies that power machine and factory automation applications. Aventics significantly expands the Emerson's reach in this growing $13 billion (€11m) market.

Mike Train

“Aventics brings technologies, capabilities and expertise that are critical to digitalization of manufacturing, including predictive maintenance through integrated diagnostics, an important priority for our Automation Solutions business,” said Mike Train, Executive President, Emerson Automation Solutions.

Aventics builds upon and strengthens Emerson’s capabilities and solutions in key discrete and hybrid automation markets, including food and beverage, packaging, automotive assembly and medical equipment. Emerson’s expanded offering creates one of the broadest portfolios of fluid control and pneumatic devices that incorporate sensing and monitoring capabilities to improve system uptime and performance, enhance safety and optimize energy usage. These technologies complement Emerson’s extensive innovation and leadership in improving operations through digitalization, pervasive sensing and asset health monitoring.

“We will now offer the industry's widest range of fluid automation products and solutions with unmatched delivery, reliability and performance, and now with the addition of Aventics’ expertise, Emerson is positioned to be the most capable global company when it comes to fluid automation technologies,” said Emerson Chairman and Chief Executive Officer David N. Farr.

“This acquisition adds another strong, complementary technology portfolio into the Emerson family, creating value for our customers and more opportunities for growth.”

With central offices in Laatzen, Germany, Aventics has approximately 2,100 employees globally with five manufacturing locations and 2017 sales of $425 million (€361m).

“With Aventics," added  Mike Train, "we will gain a valuable footprint in Germany, a key market for automation technology and investment. This acquisition also brings opportunities for Emerson to better serve customers in hybrid markets like food & beverage, providing intelligent devices and solutions from processing through packaging.”

The acquisition is expected to close in the fourth quarter of fiscal 2018 subject to regulatory approvals, Aventics’ finalization of necessary consultations and other customary closing conditions.

* Greenhill & Co., LLC served as financial advisor to Emerson and Freshfields Bruckhaus Deringer LLP served as legal advisor.

@EMR_Automation  #PAuto @AVENTICS

Measuring high pressure in hydraulic & pneumatics systems.

To measure high pressure in hydraulic and pneumatics systems or highly dynamic pressure measurements in shock tubes or blast tests, Kistler Instruments has the answer. The new 1,000 bar, miniature Type 603C piezoelectric (PE) pressure sensor has a very high natural frequency of 500 kHz which makes it suited to a wide range of applications where highly dynamic pressure transients need to be measured.

A unique characteristic of the 603C PE sensor is its ability to measure small pressure fluctuations, superimposed on a high static pressure, with exceptional resolution. The integrated acceleration compensation ensures reliable measurements even under highly vibrating conditions. Add long life reliability and calibration at 10% and 100% of FSO making the sensor easily matched to changing needs resulting in exceptionally low cost of ownership.

With linearity typically better than ±0.4% FSO and operating temperature from -196°C to +200°C, the new sensor is big in performance but small in size. A 5.5mm diameter, robust, high pressure membrane is mounted in a hermetically sealed, welded, stainless steel housing available in both long 37.8 mm and the short 15 mm long overall versions both with a 6.3 mm overall diameter.

The new Type 603C PE pressure sensor has been designed for use with the recently introduced dual-mode LabAmp Type 5165A series for dynamic pressure and the Type 5167A series for both dynamic and quasi-static pressure measurements.

#Kistler #PAuto

Seamless integration of pneumatic systems and process control.

The ASCO Numatics 580 CHARMs node enables simple Electronic Marshalling of pneumatic systems

Pneumatic systems are an essential part of many process plants, in industries such as chemical, life science and food & beverage, particularly those where ancillary machines are used. Although an essential part of the process, these machines are often stand-alone and are not connected back to the process control architecture. This could mean that should there be a problem with the machine’s pneumatic systems, it may not be communicated back to the control system, therefore leading to a breakdown of the machine. The plant may then continue to produce products that cannot go on for further processing or packaging.

Current architecture
Process control systems are normally able to accommodate pneumatics systems through the implementation of an additional fieldbus network, such as PROFIBUS-DP® or Modbus® TCP. However, this approach adds complexity through additional configuration and data mapping, and whilst supplementary diagnostics is possible, a second programming environment, with its associated costs, is not desirable and may not easily support communication and power redundancy.

In 2016 Emerson introduced electronic marshalling for pneumatic systems. This solution enables users to easily integrate the ASCO Numatics 580 Series valve islands, with Emerson’s DeltaV control system for a complete Emerson Automation I/O and pneumatics system solution for process plants.

What is Electronic Marshalling?
Control engineers and project managers working on continuous or batch-oriented processing plants will be familiar with the problems associated with commissioning I/O in distributed control systems. The traditional method involves field device connection through multi-cored cabling, wired to terminal blocks in control cabinets, with each connection then manually cross-marshalled to its appropriate I/O card. As system complexity increases and the number of connections accumulates – inevitable I/O changes abound – thus, difficulties arise in keeping track of each and every physical connection in the marshalling panel. Every change adds cost, delays, and most importantly risk to the project. Adding redundancy causes even more headaches. Furthermore, future maintenance and system modification is often made difficult with staff changes and system unfamiliarity, which can adversely affect down-time.

Whilst manual marshalling is still considered adequate for small projects, large-scale batch and continuous processes in areas such as chemical, pharma, and food manufacture - where lost production can result in truly excessive costs - increasingly turns to more risk averse and reliable process system design strategies.

Electronic Marshalling does away with the manual and labour-intensive practise of cross marshalling. The cables from the field are still wired in to the marshalling cabinet, but from there on in the connections to the controllers are handled electronically. It is now possible to map each I/O channel to any controller. Emerson manage this mapping with their CHARMs (CHARacterisation Modules). These are essentially analogue to digital conversion cards that may be characterised to perform any signal function (AI, AO, DI, DO, RTD etc.). They are ‘clicked’ on to CHARM I/O Cards (CIOC), which are in-turn mounted on DIN rail terminal blocks where field wiring is arranged; the field device is identified and the appropriate CHARM card is set up and Electronically Marshalled through a hidden digital bus to ANY controller in the system. Fully redundant power and communications connection is included, and autosensing each I/O channel means that identification, configuration, diagnostics and design changes are easily carried out by the DCS.

The technology provides many benefits, from the first design stages, to commissioning, and through the lifetime of processing oriented manufacture. As digital or analogue I/O of any type can be bound to specific controllers at any stage in the project without manual rewiring, hardware and design costs can be more predictable from the outset. Design changes – adding new I/O or changing I/O types - can be catered for without intensive labour and disruptive re-wiring costs. Projects become easier to scale, safety is assured. Configuration and diagnostics are taken care of by a single integrated software platform – Emerson’s DeltaV Explorer. Importantly the Total Cost of Ownership is significantly reduced, measured by increased operational certainty, process reliability and increased machine availability.

Integrating pneumatic valve islands into automation systems with CHARM technology
The 580 Series CHARMs allows control engineers and project managers working on continuous and batch-oriented manufacturing projects a straightforward, cost saving and fast-track approach to the integration of pneumatic systems within the process control environment. The node facilitates single connection from the field to Emerson’s DeltaV™ DCS offering Electronic Marshalling, native configuration and diagnostics plus built-in redundancy - for a truly integrated system architecture.

With the introduction of ASCO Numatics’ 580 CHARMs node, pneumatic systems’ integration with Electronic Marshalling is made possible within a single network platform – a one package and one supplier solution - for the first time. The 580 CHARMs node directly links to the DeltaV system via the CHARM baseplate and natively combines autosensing and Electronic Marshalling through redundant power and communication connection, harnessing the full native diagnostic capabilities of the DeltaV. From the DCS, each pilot valve is managed in exactly the same way as the other system I/O. The DCS can identify and marshal all the pneumatic connections through a single redundant connection with up to 48 valve solenoid outputs connected to each CHARM node.

The 580 CHARMs node interfaces with ASCO Numatics 500 Series valve islands. These high performance, “plug-in” directional control valves feature the highest flow capability for their product size, helping to keep machine footprints compact and lowering system costs, whilst a comprehensive range of accessories and options makes for easy installation, configuration and modification.

The cost and time benefits of simplified machine architecture
When compared to a manually, cross-marshalled, process manufacturing system for batch and continuous production scenarios, the benefits of a CHARMs technology based solution with Electronic Marshalling are apparent and compelling. When pneumatics require integration, and the solution is compared with the introduction of a fieldbus such as PROFIBUS-DP®, the benefits are even more convincing with the easy-to-use, task-based engineering environment that the DeltaV offers.

The elimination of a secondary network allows substantial savings in components, associated I/O, wiring, and commissioning time. The Emerson single network solution means single point responsibility for products, documentation and support, with savings for personnel, programming resources and system training. Reduced component count and direct connection equals a reduced risk of system failure. Design changes throughout project development and future troubleshooting is made easier with embedded intelligent control with autosensing and plain message workstation diagnostics. Shutdown time is significantly reduced thanks to integral diagnostics directly on the valve island or displayed on the DeltaV systems workstation. Reliable redundant connection ensures safety and reduces maintenance down time. Further compelling benefits include flexibility in process control thanks to every CHARM I/O from voltage and current sensors to alarms and pilot valves sharing the same DeltaV Explorer configuration, and being available in the ‘cloud’ to any controller in the network.

These factors combine for a tightly integrated solution for I/O and pneumatic valve islands that delivers more complete project and operational certainty, comprehensive control optimisation and processing reliability.

 @ASCOValve #PAuto @ASCO_EU 

New man in mechanical division.

Martin Ralph has joined the Hanley Controls sales team in Clonmel (Irl). He is to specialise in their Mechanical Division representing Pneumatics/Vacuum and associated products in which he has great experience in his field and we hope that he enjoys working with us at Hanleys.

Before joining HCL he was was with a pneumatic sales and distribution company for over 29 years which gave him vast and wide experience.

He said that his aims are "To grow, develop and expand my product knowledge, to increase Hanley Controls presence within the market place. To increase our customer base with Hanley controls with our customer services team."
He particularly enjoys, "Meeting new people and going out visiting customers. Also the staff at Hanley Controls - they are very approachable and there is always help at hand."

Martin coaches under 10 and under 14 soccer and he also plays golf and enjoys DIY.

@hanleycontrols #PAuto #Ireland

HD pneumatic valve island.

A major update to the ASCO Numatics G3 Series electronic valve island platform, enabling a reduction in installation costs has been announced. The valve island has been expanded so that it can control up to 128 solenoid valves on a single valve island assembly. This allows more valves to be controlled from a single node, enabling savings in the number of nodes and the cabling, internal tubing and electrical connections in the cabinet. Customers will benefit when they control a high density of valves or pneumatic equipment in a packaging plant or on a skid.

“The new functionality enables designers to minimise expensive cabinet space and have fewer nodes dedicated to pneumatic valve islands,” said Uwe Claus, Global Vice President Marketing. “Now, designers can place more valves in a single cabinet or use a smaller enclosure to house the same number of valves. In addition, installers will only have to set up and configure one node, saving time and labour cost.”

The expanded valve platforms can support up to 128 11mm solenoid valves and up to 80 18mm and 26mm valves. To increase the valve platforms’ capacity, mid-station blocks were added with valve drivers and auxiliary power connectors. This flexible approach allows customers to pay only for the capacity and functionality required in their design. A wide variety of communication protocols are supported, including Ethernet/IPTM DLR, Profibus® DP, and Valve Sub-bus for distribution.

It is highly recommended that customers use the flexible and powerful online Dynamic Product Modelling (DPM) tool when designing pneumatic valve island installations to save time in design and selection. The DPM tool enables the valve islands to be fully configured. It produces a unique specification for that product and enables a CAD drawing to be downloaded.

“Our new G3 Series platform is ideal for use in life science (pharmaceutical and biopharmaceutical), food and beverage, fine chemicals, and water/wastewater applications,” Claus said.

@ASCO_EU  #Pauto @Emerson_News

Poppets or spools!

Festo offers free advice to help engineers designing and specifying pneumatic systems to select the best valve for their application. The intention is to give confidence when choosing from the company’s Blue Star Core Range of products, which are available for next day delivery and combine proven Festo quality with attractive pricing.

Andy Parker-Bates, Product Manager for pneumatics at Festo, says: “Production demands have led to an extension of the range of available technologies and valve types, models, and their properties, so choosing the best fit for your application has become increasingly complex in recent years. We felt it was time to share our expertise and help our customers to choose the best valve for the job.”

Included in the guidance are descriptions of poppet and piston spool valves (the most commonly used valves in pneumatic applications), their operation and respective pros and cons. For example, poppet valves are lower cost and offer good switching times, but provide lower flow and can be noisier than other alternatives. Hard-sealed spool valves will also experience leakage and lower flow rates but are more durable and do not stick after long periods of inactivity.

Soft-sealed spool valves have traditionally been relatively expensive due to seal wear, but now normally come with a cartridge which holds the gaskets and sealing rings. This greatly reduces wear and increases their working life, as well as enabling the valve to operate at up to 16 bar and with vacuum. If you are looking for a valve with low leakage, the option of vacuum and ejector pulse, or if you require higher operating pressures, the most suitable option is probably a piston spool valve with cartridge sealing technology.

In addition to valve operation, Festo’s guidance also covers associated topics such as connectivity, mounting and correct sizing of valves. “Oversizing valves can lead to connectors, tubing and sometimes actuators being larger than necessary, which adds additional component cost as well as using more air and therefore energy,” says Andy Parker-Bates. “Undersized valves on the other hand cause restrictions in the circuit and can seriously impair the performance of the system.”

Festo’s guidance is available free online in a number of formats, including a series of short videos as well as top tips and, for those seeking more in-depth information, a white paper giving a technical comparison of available solenoid valves.

@FestoAG #Pauto #Pneumatics

Filter, regulator, and lubricator (FRL).

Emerson has introduced the ASCO Numatics 651 Series filter, regulator, and lubricator (FRL) line of air preparation products. This new FRL line broadens the company's high flow-rate 650 Series family to include products with G1/8 and G1/4 port sizes.

"The 651 Series FRLs require less space and are designed to fit in compact applications and in machines that require a high volume of air," said Enrique Pelayo, ASCO European Product Marketing Manager. "With the highest flow rates for their size, these highly versatile air preparation products are ideal for packaging and other applications that require space-saving designs."

The 651 Series extended high and low temperature capabilities (-40° C to 80° C) enable them to be used in applications across a broad range of industries, including those in harsh environments. The modular FRL products are of a robust construction and are easy to assemble, mount, and position. The new manifold endplate flanges allows the maintenance engineer to remove the manifold assembly out of service without disconnecting from the piping. Front-facing, low-profile gauges are easy to read and are unique in products of this type.

@ASCOValve #PAuto @ASCO_EU