trends in automation

The Festo customer magazine Issue 29

Compass Artists of flight Ultralight and collision-free: eMotionButterflies

Impulse Industry 4.0 Changing the future of manufacturing In focus Synergies On the move Communication Gantry and axis unit Of ants, robots and humans provides greater efficiency New CPX Valve Terminal with CODESYS Softmotion Controller and OPC-UA for Industry 4.0

Management level

Control level

This is the future!

Field level

CODESYS V3 Optional OPC-UA Sensor/actuator level für Industrie 4.0

Setting your sights high? Want to achieve more? We show you new ways forward.

Festo CPX: the star of fluid and motion control Ideal as automation platform, valve terminal partner or remote I/O – electric, open and direct. The unique comprehensive function integration and ­diagnostics will increase your productivity significantly. Exactly what you need when you demand the best from your automation solution. www.festo.co.uk Communication promotes productivity

Communication is a fundamental part of what it is to be human. Anyone who has been cut off from communication, even if just for a few minutes, knows how important it can be. The sharing of knowledge sets developments in motion; without it, progress would take place at a snail’s pace. It’s also why we have trends in automation – as a communication link between you and Festo.

In this issue we report, among other things, on a revolutionary change underway in communication: Industry 4.0. A paradigm shift is taking place here, with humans and machines as well as things communicating with each other, and organising themselves while being controlled by people.

A good example of this are the BionicANTs, which work together as a team of self-organising individual components to solve complex tasks in networked systems (page 6). The eMotionButterflies are also providing initial answers about what Industry 4.0 might look like: the ultralight artificial butterflies coordinate their positions in space to avoid collisions (page 10).

Gary Wyles, Key precursors to this communication between things were Managing Director, Festo GB functions such as condition monitoring, preventive maintenance, diagnostics and total productive maintenance (TPM). And they will continue to play a vital role: the MSE6-E2M is a globally unique energy efficiency module which is significantly reducing the amount of compressed air Unilever uses in the production of its ice cream thanks to intelligent information processing (page 30).

There is one factor in all of this that is constant as well as essential and invaluable: personal contact. This is demonstrated by a pioneering solution in a large pharmaceutical company which substantially increased the functionality and flexibility of the plants. Close coordination and good communication speeded up the project and produced a better result (page 34).

I encourage you to keep in touch with Festo whether you are looking for automation solutions, training or consultancy, or just have an idea you would like to discuss.

Enjoy your read.

Gary Wyles

In focus Communication Nowadays, technology and communication are inseparably intertwined. Ultra-modern server parks exchange information at a global level. Machines can now communicate with one another, recognise their environment, make decisions and act inde­pen­dently. In this issue, read what Industry 4.0 means for Festo, how the BionicANTs ‘converse’ with one another and Photo: © Connie Zhou / Google Inc. how close communication leads to successful projects.

trends in automation Issue 29

eMotionButterflies: 10 continuous communication in space.

Editorial 1 Panorama 4 Festo worldwide 40 Compass

Communication in the team BionicANTs: the artificial ants demonstrate, in an abstract manner, how self-organising individual components can communicate with one another and solve a complex task as a holistic, networked system. 6

On feather-light wings eMotionButterflies: with artificial butterflies, Festo combines the ultralight construction of artificial insects with the coordinated flight behaviour of the collective. 10 Issue 29 trends in automation Contents 2 – 3

Industry 4.0: 12 networked and extremely flexible. Impulse

On the move: Networked and intelligent 26 process optimisation thanks Industry 4.0: Festo takes a holistic view to a high-performance unit. of the transformation of production, considering it from various perspectives, and is conducting research into new solutions and technologies together with Synergies its partners. In an interview, Dr. Eberhard Veit talks about the role of people in the On the move When the chemistry is right production of the future. 12 The integration of a coating table and A complete system in Boehringer gantry with 8.5 m long EGC axes optimises Ingelheim’s new technical centre When machines speak to people the processes of Technicon’s 1C PUR demonstrates how the functionality and Let me entertain you! The humanoid robot adhe­sive application system. 26 flexibility of the new plant was enhanced. RoboThespian from Engineered Arts is Communication was the key to the speed equipped with ultra-modern fluidic muscle Maximum pleasure, of the project. 34 technology. 18 minimum consumption The new energy efficiency module DNA extraction now with high Flexible transport MSE6-E2M is helping Unilever to throughput Multi-Carrier-System: this innovative significantly reduce its compressed air Good news for plant and animal breeders transport system supplements traditional consumption in ice-cream and molecular biologists in general – with transport solutions and offers greater manufacturing. 30 the new oKtopure™ from LGC, the fully flexibility in production processes. 22 automated extraction of DNA becomes almost as easy as child’s play. 37 A handling system in just 20 minutes Handling Guide Online: with this new engineering tool, customers can configure and order their new system solution smartly and intuitively. 24 Foto: © xxxxxx xxxxxxx Photo: © Kinez Riza Show ofhands years old,makingthemcurrently the and stencil-likehandprintsare 40,000 methods actually proved thatthe delicate year thatelaborate dating past this until more than10,000years old.Itwasnot that thepaintingscouldnothave been archaeologists hadpreviously assumed Given thetropical environment, that itwaspossibletodatethemprecisely. cave here, butitwasnotuntillast year other animalpaintingswere foundina truly sensational.50years ago,theyand the IndonesianislandofSulawesi are These twelve handprintsdiscovered on

time posingsomanynewquestions. thousands ofyears ago,whileatthesame exciting insightsintowhatlifewaslike of theseearlycommunications gives us pass on information. Today, theevidence tosave served messagesand paintings Whether detailedorabstract, such of theirkind. thought tobetheoldestandbest-known cave paintingsfound inEurope were completely newinsights.Previously the finding offerstheworldofscience oldest suchpaintingsintheworld. This Issue 29 trends in automation Panorama 4 – 5

BionicANTs: cooperative behaviour based on a natural model Communication in the team

Ants go their own way together. Individual action on the basis of collective intelligence has always made these amazing insects successful as a team. BionicANTs are doing the same in the field of automation. Equipped with microprocessors, radio communication and a motion system based on piezo technology, they work together without central intelligence. Issue 29 trends in automation Compass 6 – 7

he formicidae insect family has Networking Technologies. The little six- variants demand technologies that adapt a number of advantages over legged creatures from the Festo research themselves intelligently to changing humans. With a development laboratories make their decisions conditions. Components in the industrial T history that spans 130 million autonomously on the basis of complex systems of the future will have to be years, ants are a good 128 million years control algorithms for cooperative capable of adjusting to one another. older as a species. The number of their behaviour. Created for team work, they Tasks that are currently still performed by individuals and their global biomass far strive towards a common goal without the a central computer, will be taken over by exceeds that of people. Ants can carry influence of a central intelligence, such as the interplay of individual components in many times their own body weight and that of a computer. the future. can survive both at -40 °C and in extreme desert climates. But the most amazing Ants as a template for the future Acting independently and in a network thing about them is that they live in Before taking a look at the detailed The BionicANTs show how individual units colonies of up to 20 million insects on the technical solutions used in the can react independently to different basis of collective, not individual BionicANTs, a brief excursion into the situations, coordinate with one another intelligence. Communication between future of production explains what makes and act as a networked, complete system. ants takes place via scents, so-called today’s bionic ants so important. In a By doing this, the artificial ants push pheromones. The way they live and work few years’ time, individual production and pull an object with their combined together on the basis of collective components will utilise a system similar strength over a marked-out surface. intelligence made them an excellent to that of the ants and work together Thanks to intelligent division of labour, model for the researchers at Festo’s Bionic on a project with a high degree of they efficiently move loads that an Learning Network for a bionic flexibility. The background to this is the individual ant could not move on its own. technological showpiece: the BionicANTS. global trend towards the production Like their role models from the natural “ANT” here stands both for the insect of more customised products. Small world, the BionicANTs work together inspiration and for Autonomous batch quantities and a large number of according to clearly defined rules.

They communicate with one another via with their ability to move. In each of the They are already proving their worth a radio and coordinate their actions and six thighs, there are three trimorphic, million times over in medical technology movements. Each individual ant makes piezo-ceramic bending transducers. This and in the automotive industry. Moreover, its decisions autonomously on the basis is what enables the artificial insect to move developments like function integration, of its rule systems, but in doing so is its legs upwards, forwards and backwards. lightweight construction, miniaturisation subordinate to the common goal and A huge advantage of piezo technology is and decentralised control technology are thereby plays its part in solving the task its high precision, great energy efficiency being continuously integrated into actual in hand. There is no hierarchical order. and extremely low wear. The torsos of the production. One successful example of Instead, all the BionicANTs together BionicANTs were laser sintered using the this is the valve terminal CPX, which can participate in the solution process through SLS process and then fitted with clearly take on condition monitoring tasks distributed intelligence. The required visible conductor structures using 3D MID in­dependently. It will be exciting to see information exchange between the ants technology. The electrical circuits on the how the findings yielded by bionics in the takes place via the radio module in the surface fulfil both design and electrical field of cooperation between components torso of each individual ant. If necessary, functions simultaneously. The insects draw through communication will make their it is also possible to intervene and control their power from two batteries, which they way into production. the interaction from outside. charge themselves via their antennae at the charging station. A modern www.festo.com/bionicants Interplay of modern technologies microprocessor provides the on-board The BionicANTs are high-tech at its finest, intelligence. both inside and out. They perceive their environment via 3D stereo cameras and Real benefits for production optical floor sensors. They can determine It does not take years for research projects their exact position and grasp and move like the BionicANTs to yield real benefits. an object with their gripping tools. The Right now, modern technologies are being pincer movement of their jaws is produced developed, refined and modified so that by two piezo-ceramic bending transducers they can then serve as a template for built into the jaws as actuators. Piezo marketable products such as for example technology also provides the BionicANTs the piezo-proportional valves from Festo.

Ideal platform: research bodies for trialling new technologies. Issue 29 trends in automation Compass 8 – 9

Radio module Communication Charging circuit between the ants Constant conversion from 8.4 V to 300 V, which is Ring circuit with output stages necessary for piezo-ceramic Permanent voltage of 300 V bending transducers and interface to the actuators

Processor Distributes all the necessary signals and activates the actuators

Antenna Contact to the charging station

3D stereo camera Rechargeable batteries Self-localisation and 2 Li-Po batteries in series, 8.4 V, differentiated object detection running time up to 40 minutes

Optical sensor chip Piezo-ceramic bending transducers Piezo-ceramic bending transducers Uses the floor surface to record Move the gripping jaws Pushing movement the distance covered forwards and backwards Lifts and lowers the leg

Well-conceived concept: numerous components, technologies and functions are combined in each ant in the smallest of spaces.

Unique combination: 3D MID technology Highly integrated components: design and on laser sintered part. electrical functions in one. eMotionButterflies: the Bionic Learning Network has developed ultra-light flying objects On feather-light wings With the gentle flutter of their wings the eMotionButterflies are captivating. The latest development from Festo’s Bionic Learning Network shows how several objects can move freely in a space without colliding thanks to incredibly diverse networking. An indoor GPS acts as a guidance and monitoring system and offers new possibilities, for example, in the factory of the future.

The broad perspective With the development of the eMotionButterflies, Festo’s Bionic Learning Network is gathering valuable knowledge for the factory of the future, such as possible solutions for future industrial logistics applications. In addition to lightweight construction and mini­aturisation, the indoor GPS in particular is providing insights into how three-dimensional, centrally controlled complete systems that behave collectively actually operate.

Communication Continuous communication is needed to ensure the reliable and stable flight of the butterflies. To achieve this, an indoor GPS controls the flight paths of the eMotionButterflies. Ten cameras installed in the space record the butterflies using infrared markers and map the space at a frame rate of 160 images per second. The central master computer processes the position data of all eMotion- Butterflies and, like an air traffic controller, coord­inates their flight paths so that they do not collide. Issue 29 trends in automation Compass 10 – 11

Motion The laser sintered torsos of the artificial butterflies contain everything necessary for movement: electronics, battery and two servo motors. The front and rear wings are connected directly to the motors via wing roots. The rear wing is also attached to the torso using a hinge and thus essentially acts as a tail unit. An air gap between the slightly overlapping wings gives the butterflies the aerodynamics they need. Controller The on-board electronics allow both pairs of wings to be accurately controlled. The flight behaviour is controlled by the electronics’ own inertial sensor system. Using the two servomotors, the wing amplitude, wing speed and the respective turning points can be freely and individually selected. This makes the eMotionButterflies fully manoeuvrable, very agile and extremely similar to their biological role model. The knowledge gained from the projects on the BionicOpter and the eMotionSpheres was channelled into the control system for the artificial butterflies.

Lightweight construction 50 cm wide, weighing only 32 g: the gossamer-light aerodynamic slotted wings of the eMotionButterflies comprise wafer-thin carbon rods covered with an elastic capacitor film.

Integration Miniaturisation and lightweight con­struction – the eMotionButterflies work as a highly complex system with reduced materials requirements. The cleverly used function integration together with the smallest possible components save space and reduce materials.

www.festo.com/emotionbutterflies

Industry 4.0 Networked and intelligent

The factory of tomorrow will be networked and extremely flexible. The term ‘Industry 4.0’ is used to describe these developments in the world of production. But for Festo this is about much more than just technological developments. People, their qualifications and their further training are also critical success factors in the factory of the future. Across all its activities surrounding Industry 4.0 Festo focuses on the benefits for the users of automation technology. Issue 29 trends in automation Impulse 12 – 13

Industry 4.0 is finding its way into production Many of Festo’s components and systems already meet the necessary hardware and software prerequisites for Industry 4.0. he world of production is “Currently, these are still stand-alone changing fundamentally. The solutions which are not yet networked to trend is moving more and more any great extent. In the next stages, these T towards individualised products. and similar components will be connected The small batch quantities and the large together in complete, networked systems,” number of variants associated with this says Prof. Post. trend demand technologies that adapt themselves continuously to changing With the CPX automation platform, Festo conditions. Flexible and networked already has a complete, consistently production systems are therefore the networked component. This electrical ter­ objective of the activities discussed under minal for valve terminals not only offers an the keyword ‘Industry 4.0’. individual customer orders. Any failure of interface to the field and management individual systems or components will be control levels, it also has a diagnostic “The changes to the world of production immediately recognised in a networked capability and can take on condition and thereby also to automation production system and automatically monitoring tasks. The CPX can be technology should be seen as an compensated for by other systems. In the equipped with a fully-fledged CoDeSys evolutionary process,” explains Prof. Dr. future, components will also be able to controller and thus control a subordinate Peter Post, Head of Corporate Research organise themselves – they will log on to function or an entire machine or a sub- and Technology at Festo. “In the future, the main computer auto­nomously via process of a system. Using the safety functions from the management and uniform interfaces, similar to the system function, errors can also be located control levels will be shifted to the shop used by USB technology in computers. quickly and modules can be exchanged, if floor, in some cases even down to the Finally, a virtual image of the systems required. level of the individual components.” For supports users with quick and easy these tasks, decentralised intelligence is commissioning and reconfiguration so Not only can the energy efficiency module increasingly required in the production that it is possible to respond as quickly MSE6-E2M already measure the flow rates systems in order to actively support the and flexibly as possible to new in the compressed air network, it can also production process. The workload and requirements. All this enhances the evaluate the information on the spot and capacity utilisation of the plant could thus availability of machines and systems initiate appropriate measures. For around be quickly balanced out: for example, in while simultaneously reducing the a year now, it has been successfully used the future, production lines could be amount of time and effort required for in the ice-cream production process at automatically adjusted to incoming users. Unilever. ever more complex. This development requires an intelligent sensor system which enables protected and intensive interaction and the flexible interplay between robots and employees. Machines can then be safely used to cooperate directly with people and assist them in their day-to-day work, for example by taking over monotonous assembly tasks. The forerunners were projects from the Flexible processes field of bionics, such as the award- The Multi-Carrier-System, developed winning Bionic Handling Assistant (2010), jointly by Festo and Siemens, shows how which immediately yields in the event of objects can be flexibly transported using collisions, or the ExoHand (2012) from decentralised sensor and intelligence Festo, which could, for example, be used systems (see page 22). The innovative to boost strength when working in transport system for flexible production People and technology interacting production. processes can be freely configured in Technological innovations and changes accordance with specific requirements within the world of production also have Know-how for new working environments and transports objects very flexibly using an impact on the role of people in With Industry 4.0, it is not only the robust carriers. A virtual image of the production. One of the key issues of demands on production technology that system simplifies configuration and Industry 4.0 is cooperation between are increasing; employees’ know-how commissioning. people and technology. In the future, must also grow – in particular in relation robots will actively support people with to their knowledge of industrial IT. Innovative solution approaches manual tasks, of this Prof. Post is Interdis­ciplinary skills are in demand, How complete, networked systems convinced: “People and machines because in the future all participants will organise themselves is also demonstrated complement each other very well: people cooperate more closely and everyone will by the BionicANTs (see page 5). Every year, are very flexible, and can very quickly have to pull together. Some fields of the bionics projects from Festo master a multitude of tasks. In contrast, activity that exist today will not exist in demonstrate innovative solution machines are often static, but they are the future, but new ones will emerge. approaches for im­portant subject areas very fast, accurate and powerful. With Training and qualifications will therefore within Industry 4.0, such as function Industry 4.0 we are working on the play a key role in the factory of the future. integration, intelligent components, optimal combination of these two worlds.” One specific skill which will be critical in flexible and adaptive systems and intuitive People and machines will cooperate more networked production is the ability of operation of machines. closely, while the systems will be getting workers to observe and interpret signs of Issue 29 trends in automation Impulse 14 – 15

“The changes to the world of production discussed under the umbrella of Industry 4.0 are an evolutionary process.”

Prof. Dr. Peter Post, Head of Corporate Research and Technology, Festo

Cooperation to create the future

The commitment to Industry 4.0 goes far beyond company change, analyse issues that crop up, and boundaries. Festo is working with research institutes, universities come up with new, as yet unknown and partners from industry on this topic and many others as part of solutions for them. In terms of future the ‘Platform Industry 4.0’ initiative. This initiative is supported by production, this means that workers will the VDMA, ZVEI and BITKOM associations, companies like SAP, have to be able to plan and assemble as Siemens and Festo as well as the federal government. Festo is well as operate, set up and maintain new represented on both the management board and the steering types of machines, systems and products. committee of the Industry 4.0 Platform. In particular, Festo is actively involved in the creation of a reference architecture for Training for the factory of the future will Industry 4.0 and the development of binding standards and norms involve much more than simply imparting such as the definition of an ‘Industry 4.0 component’. More skills and competencies, it will involve a information on the work of the Industry 4.0 Platform can be found cultural change. In networked production, in the interview with Dr. Eberhard Veit (see page 16). we need a culture of learning and interdisciplinary exchange. This In addition, Festo AG as well as Festo Didactic are working on other willingness to adapt and to learn will initiatives related to Industry 4.0, for example the manufacturer determine the success of companies. independent initiative SmartFactory KL. The objective of this demonstration and research platform at the University of Kaiserslautern is to integrate new technologies and concepts into the factory automation environment and to develop and test how intelligent components from different manufacturers cooperate and network under real conditions. Industry 4.0: Interview Interview Dr. Eberhard Veit talks about the role people will play in the overall context of the factory of tomorrow and how a company can prepare its employees. The Ex-Chairman of the Management Board of Festo AG sits on the steering committee of the ‘Industry 4.0 Platform’ which now includes representatives from the worlds of politics, business, associations, science, and trade unions.

trends in automation: The German federal government will therefore play a key role. In the past, Germany has has announced that it intends to drive forward the already had a huge influence through ground breaking digitisation and networking of production, and the ‘Industry innovations. Now we must build on that inventive spirit and 4.0 Platform’ was officially launched at the Hannover Messe shape the new developments in order to secure and expand 2015. Dr. Veit, you are part of the association’ s top people. our global competitive edge. What is really behind the ‘Industry 4.0 Platform’? You mention interaction. What does that mean precisely? Dr. Eberhard Veit: Firstly I would like to make one comment: How should we see that? in this case, launch does not mean we are starting at zero. The newly formed platform is able to build on the excellent Veit: In the future, people and technology will work a lot work done by its predecessor, the associations’ platform more closely than they do today. On the one hand, we will Industry 4.0. By collaborating closely with representatives increasingly have more direct contact with robots and other from the worlds of politics, associations and industry, we machines, for example in service robotics. In our new have now put this topic on a broad political and social technology plant in Ostfildern-Scharnhausen we have footing and, by involving companies, have once again developed a robot with intelligent sensor systems which significantly strengthened the practical applications. The interacts safely with employees without the need for a participants work in interdisciplinary teams on the topics of protective cage. Or remember the Bionic Handling Assistant the future such as standardisation, research and safety, but with which we won the Deutsche Zukunftspreis back in also on questions relating to new working environments, 2010. Such machines will be able to relieve people of training and legal issues. I therefore believe we are well monotonous or strenuous tasks, for example in assembly. equipped to drive forward this evolution in the world of What is important is that the technology must understand production. people and vice versa – this also applies to using and controlling machines. Going forward, we will have Evolution, however, also means change. What does this completely new operating concepts, for example using mean for companies and what prerequisites must they mobile devices such as tablets or smartphones that are meet? easy and intuitive to operate and will be able to assist the user. I see huge potential there. Veit: Industry 4.0 is not just about introducing new technologies. It is much more about an evolution in So this does not mean that people will be replaced by industrial manufacturing up to and including completely machines? networked and flexible production. This also affects people’s working world: there will be new tasks and Veit: Correct. People are, and will remain, an integral and requirements, and new opportunities for interaction indispensable part of the world of future production. While between people and technology. Training and qualifications new technologies will take over specific production steps Issue 29 trends in automation Synergies 16 – 17

“People are, and will remain, an indispensable part of the world of future production.”

Dr. Eberhard Veit, Ex-Chairman of the Management Board of Festo AG

from workers, for example by gathering, evaluating and factory and with its range of seminars for Industry 4.0. In using data to control processes, other work steps will be our Scharnhausen technology plant too, learning plays a introduced and this is where we reach a crucial point: key role. We have integrated our own learning factory there further training and qualifications will become a critical so that we have a direct and practical way of passing on success factor, much more so than they are today. In training content on site. networked production, we need the ability to work in an interdisciplinary way, we need a culture of learning. When you talk about Industry 4.0, what time frame are you envisaging: 10, 20, 30 years? And is this even a process Can you give us an example of what you mean? that can achieve a clearly definable goal or is this an open- ended development into the future? Veit: Think of the profile of a mechatronics engineer: it combines mechanical, electronic and IT elements – so Veit: For Festo, Industry 4.0 is a highly interdisciplinary precisely the interdisciplinary knowledge that we need in future project on which we will continue to work. In our view, the factory of tomorrow. In general, engineers increasingly the automation pyramid will change in an evolutionary way: require know-how in the field of IT, while IT specialists must functions from the higher levels will move down. In the adjust more and more to the needs of the engineering coming years, the first industrial transformations that we environment. Software development, electronic engineering can expect to see are in the field of comprehensive energy and hardware development are joining forces with machine management and condition monitoring. What is important is and system engineering – Festo is a pioneer in this field. that we deliberately tackle in particular those work areas where there is still a great need for action, for example IT So employee qualifications will become increasingly security and standardisation processes. To sum up, Industry important. What does that mean for companies? What 4.0 is a development process which will still require a long prerequisites must they meet? time to be fully implemented. With the work of the Industry 4.0 Platform and its predecessor we are making excellent Veit: Industry 4.0 will bring about very different progress. developments for companies and their employees. What these will be precisely only the future will tell – one thing is for sure, the offer in terms of training and further education must be adjusted to suit. Because excellent Research & Development resources and the availability of skilled staff are more important than ever if we are to ensure the future viability of companies at a global competitive level. Our subsidiary Festo Didactic takes this into account both with its teaching and research platforms like the cyber-physical RoboThespian: the robot actor communicates and interacts with people in many different ways. He responds to keywords and his movements are extremely true-to-life. Photo: © Engineered ArtsPhoto: © Engineered Ltd. Issue 29 trends in automation Impulse 18 – 19

RoboThespian: fascinating interaction When machines speak to people

Captivating the crowds with every appearance: RoboThespian is entertaining his public around the globe with his surprisingly lifelike ways. He greets visitors to NASA’s Kennedy Space Center in Florida, provides information at the Phaeno Science Centre in Wolfsburg and interacts with visitors to Australia’s National Science and Technology Centre, Questacon – and he has even made it to the front page of the New York Times. To make his movements seem as natural as possible, the ‘robot actor’ is equipped with ultra-modern fluidic muscles and piezo valve technology from Festo.

eople enjoy engaging with this and recognises faces and gestures. There humanoid robot – and are now more than 60 of these robots RoboThespian enjoys “reaching captivating visitors to museums, P out” to people too. He was universities and companies around the invented and developed in the UK, by world, either in shows, as part of Engineered Arts Limited in Penryn, exhibitions or to greet company Cornwall, which is also where he is customers. Universities in Great Britain manufactured. RoboThespian is 1.75 m such as Bristol Robotics Laboratory and in tall and weighs around 33 kg. His chassis the USA are using them to study human- is made from aluminium, and his body robot interaction (HRI). The first version of shell from plastic. He is brought to life by RoboThespian was designed in 2005 a total of 30 motion axes which are all specifically to communicate and interact controlled by an integrated computer; this with the public. His name speaks volumes: is what makes him move his head, arms “thespian” is an old English term for an and hands in an incredibly lifelike way. actor. Finally, he interacts and communicates with the people he meets via a A keyword is all it takes touchscreen. When the robot’s human counterpart says specific keywords, RoboThespian gives Intelligent actor pre-defined responses thanks to his Depending on the programming and ability for speech interaction. For precise technical equipment, RoboThespian can answers and instructions he can also use even converse actively with people. This search machines independently and find clever droid speaks several languages information on the Internet. If he is

“We use the fluidic muscle from Festo because it makes RoboThespian’s movements appear very natural.”

Will Jackson, Director of Engineered Arts and inventor of the RoboThespian

Photo: © Engineered Arts Ltd.

controlled by a person using a wireless headset and tablet, he can even speak individually to visitors. In this mode, the tablet shows the camera view of the robot, so he can be made to look at and address a particular person.

Natural movement through artificial muscles For the most part, his humanoid movements are generated by pneumatic muscles, or fluidic muscles. These contract and relax like real muscles. The arms and hands are each moved by a total of two and eight fluidic muscles respectively (DMSP-10 and DMSP-20). The finger movements are executed by the new, small DMSP-5. The fluidic muscle (A) is a membrane based actuator comprising (A) Movement via muscle power – fluidic muscles of a flexible hose embedded with and 30 motion axes give the robot actor great rhomboidal shaped multifilament yarns. dynamism and range of movement.

(B) Lightweight top performer, perfect for Precise control using piezo technology humanoid motion sequences – the latest piezo The artificial muscles are actuated by, valve technology is particularly small, offers among others, piezo valves VEAB from extremely fast switching times, is powerful and Festo. Piezo valves are often a better very precise. alternative to conventional solenoid valves,

(C) Nimble fingers: the new, small fluidic muscles especially in the areas of flow and DMSP-5 produce the movement of the fingers. pressure control and as directly controlled proportional valves, as used in the RoboThespian: they are small, lightweight, extremely precise, very durable, incredibly fast and require up to 50% less energy. Furthermore, they hardly generate any heat Issue 29 trends in automation Impulse 20 – 21

Bernd Lorenz, Head of Membrane (B) Technologies, Festo

One more question

trends in automation: What advantages make the fluidic muscle the ideal choice for the RoboThespian?

Bernd Lorenz: The muscle is perfect for this application as it acts like a human muscle, it contracts and relaxes without friction resistance or breakaway torque, and it is (C) even stick-slip free. It is hermetically sealed and clean, as no lubricant is required. All movements, whether slow or quick, are jerk-free and perfectly smooth. With its flexible structure and its compliant behaviour it is the perfect drive for cooperation between man and machine. and work almost silently. These properties mean that they are ideal for use in Activation via piezo valves makes these properties even laboratory and medical technology more apparent. And of course with the fluidic muscle, automation. there is no need for any complex hydraulic or electrical constructions. These advantages are particularly critical Ambassador of Industry 4.0 in the area of animatronics, which is all about RoboThespian is a fascinating example of combining the most lifelike movement possible with human-machine interaction. It epitomises appro­priate communication. This is precisely what the future potential of Industry 4.0 in a people expect when they encounter humanoid most impressive style: humans create and technology and interact with it. Festo already has a program the machine which then responds great deal of expe­ri­ence in the field of live largely autonomously and flexibly to its entertainment, from magic shows and driving environment. simulators right through to shaking seats in 4D cinemas. www.festo.com/fluidicmuscle Are there other potential applications?

Lorenz: The fluidic muscle is suitable for a whole host of other applications. The pneumatic muscle has already proven and established itself in three application areas within the field of industrial automation. As a pneumatic spring to control tensile stresses on belts, ropes, chains etc., and to regulate them sensitively. As a means of generating high clamping forces on a small diameter, for example when fixing components in moulds or machines. And for targeted shaking and fast vibration, as required in feeder and filling technology.

Intralogistics system: Multi-Carrier-System MCS® Flexible transport

Today filling and packaging thousands of bottles of perfume, tomorrow just a few tubes of cream and the day after batch size 1 – everything on one and the same system. How this works is demonstrated by the Multi-Carrier-System MCS®, a joint project of Festo and Siemens, put to work in a filling and packaging machine from the machine manufacturer Optima.

he days when large quantities of On track to Industry 4.0 Maximum flexibility the same product were produced The Multi-Carrier-System already Within the system, the containers that day in, day out on one line are incorporates options which are relevant need to be filled, such as bottles, cans or T very much in the past. A growing for Industry 4.0. These include the flacons, move one by one on carriers that number of product and packaging particularly flexible electromechanical can handle multiple formats and are variants, ever shorter product life cycles design for cost-­effective manufacturing individually actuated. The self-propelled as well as the trend towards customised down to batch sizes of 1, as well as the carriers are driven by linear motors. In packaging and products are posing huge decentralised sensor and intelligence order to avoid jams, they move according challenges to manufacturers of filling and systems of the workpiece carriers and to the rules of swarm behaviour and in packaging machines and their end drives. Even the simulation function, synch with the process – either customers. The Multi-Carrier-System now including a virtual twin, is fully prepared individually or in groups. The carriers can offers them a solution which provides for future system optimisation and be freely and seamlessly fed in and out of more flexibility and greater dimensioning. Program data can even be the Multi-Carrier-System. Linking to an competitiveness. generated from the simulation. existing intralogistics system couldn’t be Issue 29 trends in automation Impulse 22 – 23

Format adjustment at the push of a button is possible with the Multi-Carrier-System.

Joint project: Optima filling and packaging machine.

“The Multi-Carrier- System anticipates three trends of the simpler. The carriers can be accelerated, reduced maintenance costs, lower rates slowed down and freely positioned, of wear, and the ease of cleaning are future: batch size 1 independently of one another. Thanks to further advantages of this versatile integrated RFID chips, they carry all the transport system. as standard, information that the machine needs to produce the end product. As a result, The potential applications of the Multi- flexibility in the single-unit productions are thus, Carrier-System are practically unlimited; it software and mechanically speaking, possible. is suitable for all industries that manage a large product diversity. These include the intelligent, self Format adjustment at the push of a button cosmetics industry with its huge number of The Optima packaging machine comprises product variants, the food and drinks learning machines.” three modules: filling, closing and laser industry with its quick seasonal changes engraving. The modular machine design and industrial manufacturing of one-off Rainer Feuchter, Managing Director of Optima requires flexible transport: the machine products ordered by end customers using can fill six bottles during transport and an online configurator. subsequently seal two of them at the same time. This means that carriers need to www.festo.com/mcs move in groups of two so that production can continue without pile-ups. For customised laser engraving, the system requires only one carrier – something that can be easily achieved with the Multi- Carrier-System.

The possibilities are endless The Multi-Carrier-System travels at up to 3 m/s and achieves acceleration of up to 40 m/s² – completely jerk-free and with optimum precision. Shorter set-up times, Handling Guide Online A handling system in just 20 minutes

The right standard handling system including CAD model and net price in just a few clicks – that’s what Festo’s Handling Guide Online can do for you. The individual steps, enquiry, design, offer, CAD design and order which previously took 10 to 15 days can now be done in just 20 minutes thanks to the configuration and ordering platform.

hree steps to the right handling selects the most suitable handling system own requirements. The selected handling system from these suggestions. The data sheet system is then transferred to the Just three steps are all it takes to and the correctly configured CAD model shopping cart with the click of a mouse. Tarrive at a fully configured are immediately made available for A final click transmits the order to Festo. handling system. During the first step, the download in all common data formats for Festo’s handling experts deliver a ready- engineer selects the desired type of direct integration into the customer’s own to-install system including all user handling system and enters the design engineering system. documentation in accordance with the EU application data in the Handling Guide Machinery Directive specifically for the Online. The tool calculates the During the third step, the engineer uses machine or plant within an extremely appropriate handling systems, including additional options to configure the short lead-time. price. During the second step, the planner selected system in accordance with his Issue 29 trends in automation Impulse 24 – 25

The Handling Guide Online is integrated in Festo’s The data sheet and the correctly configured CAD model are immediately online product catalogue. made available for download in all common file formats.

Individually developed In addition to flexible standard products, Festo also develops handling systems based entirely on individual, industry- specific requirements, for example with freely definable axis geometries for shorter cycle times or for integration into machines with minimal space requirements. Because if the handling systems suggested by the Handling Guide Online should fail to meet the specified requirements despite the great variety of options, the design engineer can simply forward the entered application data to Festo’s handling before the Handling Guide Online was experts with a single click in order to available, but we had to choose every obtain a personalised quotation. single component individually and insert them one by one into our CAD Time-to-market reduced plans. The Handling Guide Online has As well as saving on design and ordering, simplified these steps enormously; all the standardised handling systems also we have to do now is click and select. reduce the assembly and delivery times from a little under two months to just a What do you regard as the greatest few weeks. The parameterisation and advantage of the Handling Guide commissioning time is also significantly Online? reduced. Machine and equipment Steve Selwyn, Automation manufacturers are thus able to reduce Engineer at Intersurgical Ltd., Selwyn: Previously we would have their time-to-market for integrated Great Britain spent a great deal of time selecting all handling systems by up to 70%. the right components and testing these together with the Festo www.festo.com/handling-guide In practice technology team to make sure they were compatible with our trends in automation: Your applications. As the new software is company is one of the leading so intuitive to use, it simplifies the developers and manufacturers of entire process. The option to single-use respiratory products in download project documentation Europe. You are one of the first users immediately also saves time. All in all, of the Handling Guide Online. How the software was a huge help to us in has it changed your processes reducing the costs of our projects.

Steve Selwyn: We were using Festo www.intersurgical.com engineering software tools even

Process optimisation in campervan and caravan construction On the move Manufacturers of production plants for lightweight composite materials are under pressure. The quicker they get machines to customers and up and running, the better their competitive edge. This demands precise procedures for efficient and therefore environmentally-friendly use of raw materials. This can be accomplished through innovative system components and good advice, both for the manufacturers and the customer. With the new solution from Festo, Technicon is expanding its innovative lead with large-area adhesive application systems. Issue 29 trends in automation Synergies 26 – 27

The new unit comprising coating table and spray nozzle gantry simplifies transport and reduces the assembly involved in Technicon’s 1C PUR adhesive application system.

(A)

(B) (C)

(A) 26 ball valve actuator units controlled by a valve terminal CPX-MPA ensure an extremely even adhesive application.

(B) A servo motor EMMS-AS drives the two 8500 mm long axes EGC. he campervan industry is standards in terms of transport, setup and (C) Two 8500 mm long axes EGC move the booming, and this is having commissioning as well as seamless gantry safely and precisely over the 2500 mm positive knock-on effects for integration into existing production lines. wide coating table. T machine builders specialising in One company that is reaping the benefits production plants for composite materials. is the caravan manufacturer and plant In addition to precise and therefore operator Swift Group Limited, based in resource-efficient production, speed in Cottingham in England. the production and assembly of plants is an important cost factor. Technicon – Long-term sealing and insulating Technik mit System GmbH, one of the top High-quality adhesives play a crucial role companies in the field of process in the construction of campervans and automation for sandwich panel production caravans. These adhesives are light, with large-area adhesive application effective and seal the composite systems, has now, in conjunction with framework made up of an outer shell, Festo, developed a new system for insulation and interior wall for many applying 1C adhesives. The combin­ation years. In order to achieve this, the of a coating table and gantry system Technicon system bonds the side walls, produces an efficient unit that sets new front and rear walls as well as the roofs Issue 29 trends in automation Synergies 28 – 29

“For us, the integration of a coating table and gantry using 8.5 m EGC axes from Festo means greater efficiency in logistics and during commissioning. We want to go a step further with the next project with a 15 m long axis system.”

Robert Vedder, Managing Director of Technicon

and floors of caravans. The system easier and faster. In these systems, the consists of a coating conveyor on which coating table and gantry have been the various layers of the composite integrated through the use of two material are laid, and a nozzle gantry that 8500 mm long EGC axes from Festo. The moves over it to apply the adhesive and system can now be supplied and installed water evenly. The nozzles are actuated by as a compact unit. This means no more Group Photo: © Swift 26 ball valve actuator units VZBA and the time consuming assembly and measuring. valve terminal CPX-MPA, both from Festo. The new system is therefore not only Technicon uses a laser-assisted application extremely efficient and reliable thanks to On the move: Technicon’s systems are used technique based on CAD data that applies Festo automation know-how and by Swift in England. The British company adhesive with pinpoint accuracy using products, but also reduces transport and manufactures caravans, campervans and mobile holiday homes. individually 3D printed nozzles to ensure assembly costs in the long term. both an economical and perfect gluing result. This eliminates overspray, which is www.festo.com/cpx harmful to health and causes soiling. The www.festo.com/egc system can apply up to a tonne of www.festo.com/mediavalves adhesive per day. Technicon – Technik mit System GmbH Integration speeds up commissioning The predecessor model of the 1C PUR Eichkoppel 14 adhesive application system featured a 24214 Gettorf solid steel frame installed around the Germany coating conveyor of the application www.technicon-kiel.de system. During assembly at the customer’s site, the adhesive nozzle Area of business: gantry had to be moved over the coating Development, consulting, design table using a motorised carriage in a and manufacture of production cumbersome and time-intensive process. plants for process automation Just measuring the steel beams and aligning them with existing machines took up to two days, depending on how much space was available on the caravan manufacturer’s shop floor. With the new generation of 1C PUR adhesive application systems, this is now much

Photo: © Unilever

Energy efficiency module reduces compressed air consumption Maximum pleasure, minimum consumption

Energy-saving measures are a cornerstone of the corporate philosophy of global firm Unilever. The company is now significantly reducing its compressed air consumption on a machine producing Magnum ice creams by using the new energy efficiency module MSE6-E2M. Issue 29 trends in automation Synergies 30 – 31

ce cream is refreshing and with its was of huge importance to Unilever. immediately obvious if consumption is proteins and carbohydrates is Previously, the consumption on the too high.” As part of the Unilever considered a source of energy. individual production lines had not been Sustainable Living Plan there had already I However, it also takes a lot of energy determined. “Until then we were just been successes in other areas of the plant. to mix ingredients like milk, dairy unaware,” says Alexander Hemmerich, Energy-intensive geared motors were chocolate, sugar and vanilla beans into Automation Engineer at the Unilever Plant, replaced with more efficient ones, the finished product. Electricity and Heppenheim. “Air is not visible, so it is not achieving energy savings of up to compressed air play an important role in the thermal and kinetic processes for everything from mixing and extruding the ingredients, deep-freezing to -25°C, dipping into various chocolate coatings through to final packaging. Energy efficiency is therefore right at the top of Intelligent module optimises compressed Unilever’s list of priorities. As part of the air consumption Unilever Sustainable Living Plan, this global corporation has succeeded in saving more than 150 million euros in The energy efficiency module MSE6-E2M monitors and regulates the energy costs from efficiency compressed air supply in new and existing systems – fully automatically. improvements in production alone since Similar to the start-stop system in a car, the intelligent MSE6-E2M detects a 2008. standby mode and automatically shuts off the supply of compressed air. Compressed air consumption is thus reduced to zero during system In the area of pneumatics too, the use downtimes and breaks. In addition, the MSE6-E2M makes it possible to of innovative developments offers the measure leaks as it reports back if the pressure drops too quickly during potential to save energy and thereby lower downtimes. Moreover, it continuously delivers process relevant data such as costs. In the Unilever plant in Heppenheim, flow, pressure and consumption, which it sends to the machine controller via Germany the energy efficiency module Profibus. MSE6-E2M has recently been deployed to reduce the compressed air consumption of a plant manufacturing Magnum ice creams. Unilever and Festo worked together closely to get this prototype of the energy efficiency module ready for series production. This process also showed that it is not just in the field of energy consumption that less is more.

Sustainability along the entire line The Heppenheim factory is one of the main Unilever production locations for ice cream. These include products of the well- known Wall’s line including Magnum, Feast, Viennetta and Carte d’Or. High production quantities form the basis for supplying other parts of the European market. Just one of the five Magnum production lines in Heppenheim produces Result of successful cooperation: first generation MSE6-E2M energy efficiency more than 20,000 ice creams on a stick modules were deployed for continuous operation at Unilever, Heppenheim. The per hour. This requires a lot of energy. In single, integrated unit pays for itself, saving air providing energy transparency. order to reduce the compressed air consumption of the pneumatic components, the ability to visualise and measure the compressed air consumption 60 per cent. Numerous 18 kW ventilators in the cooling tunnels, which previously ran for 24 hours in continuous operation, were also converted to frequency converters with variable torque loads. This lowered the energy consumption of the ventilators by around 40 per cent. High-tech for maximum pleasure: the Heppenheim factory is one of the main Unilever production locations for ice cream. Energy consumption made visible Hemmerich and his team took the decisive step towards lowering compressed air consumption with the introduction of the energy efficiency module MSE6-E2M from Festo. “The energy efficiency module gave us the opportunity to see the amount of compressed air we were using during operation of a line,” explains Hemmerich. “In addition, we were able to determine how the compressed air requirement developed when we switched off individual consumers. We were thus able to locate leaks and eliminate unnecessary consumption.” One of the core functions of the MSE6-E2M is the automatic shut- off of the compressed air in stand-by mode, which made it possible to establish how quickly the system empties. The energy efficiency module MSE6-E2M immediately reports an unusually quick drop in pressure to the system controller.

Perfectly portioned: the extruder outputs one Magnum core per second. At the same time, the automatic pressure The stick is inserted in the ice cream during extrusion. shut-off function prevents further compressed air consumption while the system is not in operation. Thanks to its onboard intelligence and the specific model for operating the compressed air systems, the MSE6-E2M independently identifies when a system is in production and when it is at standstill. At Unilever, however, they decided to use the alternative option to operate the MSE6- E2M via the system controller so that all information is merged centrally.

Significantly reduced energy consumption Thanks to the new condition monitoring for the pneumatic components of his Magnum machine, Alexander Hemmerich now has continuous process-relevant data. Issue 29 trends in automation Synergies 32 – 33

“We’ve been able to reduce our com- pressed air consumption on the Magnum production system step by step with the energy efficiency module from Festo.”

Alexander Hemmerich, Automation Engineer, Unilever plant, Heppenheim, Germany

The MSE6-E2M regularly exchanges thus optimally tailored to the important measurement parameters, such requirements of machine operators and as flow, pressure and consumption, with builders. It makes energy monitoring Unilever Deutschland the machine controls via Profibus. It is simple and effective, and supports Produktions GmbH & easy to operate via the control panel. companies such as Unilever on their path “We’ve been able to reduce compressed to effectively increase their sustainability. Co. OHG air consumption on the Magnum production system step by step with the Heppenheim Plant energy efficiency module from Festo. And www.festo.com/catalog/mse6 Langnesestraße 1 the Profibus connection had the 64646 Heppenheim advantage that we did not have to add Germany any more cables when converting our www.unilever.de existing systems.” On the Magnum line, the costs for compressed air consumption Area of business: were reduced by more than 500 euros per Production of Wall’s ice cream year.

Concentrating on the essentials The Magnum line at Unilever provided an ideal environment to field test the MSE6- E2M prototype. The pilot use in the Heppenheim plant and the close cooperation with Festo developers showed what daily operation would be like. While the first version of the energy efficiency module still had I/O slots, the final MSE6-E2M uses a Profibus interface. The exhaust valve of the first product generation was also dropped. It was more important to keep the energy efficiency module compact, especially given the limited installation space of existing systems. Thus the MSE6-E2M was designed on the basis of a combination of pressure and flow sensor, shut-off valve and fieldbus node.

As a complete series product it is now only On the belt: one of the five Magnum lines produces about half the size of the prototype and more than 20,000 units per hour. Standard: Festo quarter turn actuators DAPS control ball valves and butterfly valves on the reactor.

Controlling inert gases with proportional valves When the chemistry is right

Proportional valve technology in process automation offers a great deal of flexibility and produces high-quality control results. A complete system supplied by Festo and installed in Boehringer Ingelheim’s new technical centre demonstrates the performance that modern pneumatics can deliver. The project was developed in close communication between the Festo team and automation experts from the pharmaceutical company, allowing it to move forward quickly.

n Biberach, at Boehringer Ingelheim’s Festo: 12 inert gas stations, 40 valve involves flammable solvents, many largest research and development terminals CPX-MPA to control the process processes are carried out in reactors, location in the world, a new technical valves and around 200 automated ball centrifuges and dry cabinets with inert Icentre is safeguarding the production valves and butterfly valves. atmospheres. While with the previous of innovative pharmaceutical active instal­lation three pressure levels were ingredients. A total of 15 chemical Gases regulated proportionately required in order to regulate the argon reactors supply the required quantities of As the solutions provider in the field of and nitrogen, each with its own piping substances within the 2,700 m2 pilot process automation, Festo was involved network, control valves and flow meters, in plant. The size of the new technical centre in the project from the very beginning. the new installation this function is is illustrated by the products supplied by Since the production of active ingredients provided by highly efficient compact Issue 29 trends in automation Synergies 34 – 35

“In each phase of the project, we felt that everyone involved was completely committed to its success. For us, this was the difference between having a supplier and having a partner.”

Boehringer Ingelheim

proportional pressure regulators VPPM. Thanks to their wide control ranges, two pressure levels are sufficient.

In order to minimise the installation space required, the Festo proportional pressure regulators VPPM were integrated into a valve terminal MPA. Together with the automation platform CPX, this forms a Together to the finish line: the Festo project team for Boehringer Ingelheim. compact solution. A pressure measurement module measures the gas input pressures in the relevant installation areas. The comprehensive monitoring Communication accelerates the project made possible by this solution opens up a variety of new diagnostic options Even large projects start small. The first step in the cooperation between compared with the previous solution. Boehringer Ingelheim was a telephone conversation between the head of the industry segment Process Automation at Festo HQ and the person responsible Processes permanently in view for automation at Boehringer Ingelheim. During the subsequent meeting about Festo proportional valves in combination the proportional pressure valve VPPM the question was discussed as to whether with flow meters and pressure sensors the VPPM could be used to regulate process gases and thereby regulate both the are also used in the new technical centre pressure and the flow. to supply mechanical seals. When connected to the process control system After the first successful tests in the Festo laboratories and on site at Boehringer, via the CPX and the integrated fieldbus the Festo project team and the relevant people at the pharmaceutical company node, the valve terminal MPA can monitor discussed how to continue their collaboration. The solution, to control the the gas consumption of seals centrally components decentrally, seemed to be the obvious choice given the ability of and control the pressure as a function of Festo to deliver complete ready-to-install, standardised control cabinets both for the internal tank pressure. This the reactors and for the centrifuges and drying cabinets. In addition, Boehringer continuous condition monitoring reduces Ingelheim assigned the Festo project team the task of project engineering and maintenance costs. procuring the quarter turn actuators for the system. They also had to prepare CAD drawings of the process valves so that they could conduct the collision test for The integration of proportional valve construction of the pipeline. The close cooperation and constructive, short technology from Festo offers Boehringer communication channels saved time and costs throughout the entire process and Ingelheim a huge number of advantages. contributed to an amazingly quick development phase for a high-performance The multi-sensor control of the VPPM solution. pressure regulator, through integrated pressure sensors and PID controller, produces high-quality results and “A project like this can be compared to the construction of a house, where all the different tradespeople must coordinate with one another.”

Alexander Kelm, Project Management Components PA Europe, Festo Photo: © Boehringer Ingelheim

The new K62 Technical Centre at Boehringer Ingelheim in Biberach, Germany.

Compact: the control cabinet was pre-assembled as a ready-to-install solution.

robust control behaviour. The fact that the Functional, flexible, cost-effective Boehringer Ingelheim control cabinet is installed in the technical The installation can now be controlled Pharma GmbH & corridor instead of the reactor room saves much more flexibly and easily. What is money on EX protection. more, Boehringer Ingelheim was able Co. KG to reduce installation costs compared with It is often the small solutions that, when the technology previously used. Birkendorfer Straße 65 put together, offer many plus points. For Functional, flexible and attractively 88400 Biberach an der Riß example, stainless steel pipes with small priced, the proportional valve technology, Germany nominal sizes of up to ½” can be replaced developed and supplied as a complete www.boehringer-ingelheim.de with easy-to-install and cheaper tubing. solution by Festo, ensures long-term The power supply to the proportional increased efficiency in the inertisation Area of business: valves and signal transmission to processes in this pharmaceutical Research, development, PROFINET are routed directly via the valve company’s technical centre. medicine and biotechnology terminal, thus eliminating the need for cables in the field. www.festo.com/vppm Issue 29 trends in automation Synergies 36 – 37

oKtopure robot with precision electric handling unit from Festo DNA extraction now with high throughput

Good news for plant and animal breeders and molecular biologists in general – with the new oKtopure™ from LGC, the fully-automatic extraction of DNA becomes almost as easy as child’s play. This DNA extraction robot combines high sample throughput numbers with high-quality standardised DNA purification and thus relieves highly-qualified personnel of the need to carry out routine activities. Part of the solution is a handling system based on electric axes, motors and controllers from Festo.

oKtopure: robot from LGC. Fully-automatic extraction of DNA becomes almost as easy as child’s play: thanks to the oKtopure from LGC.

any breeding programs contaminants. sbeadex is based on a two- involve a significant increase stage binding mechanism, so that water in the number of samples, can be used for the final washing step. Mwhich can be technically This avoids having to dry the DNA and, in challenging for breeders if they are to addition, efficiently removes analyse plants rapidly and precisely. The contamination. The resulting highly pure first step in the selection process consists DNA can then be used for all molecular- of purifying the DNA, which needs to be biological technologies, including purified for analysis or, in other words, sequencing. sbeadex purification also free of contamination. enables KASP™, LGC’s unique SNP genotyping chemistry, to be used. The oKtopure from LGC was developed to speed up breeding programs and many The oKtopure itself is equipped with a other molecular biological analyses. The 96-fold pipetting head and eight magnetic robot allows 8 x 96 Deepwell plates to be blocks. These magnetic blocks bind the purified in parallel, enabling up to 5,000 magnetic particles at the base of the samples to be extracted in the course of a Deepwell plates, allowing extraction normal eight-hour working day. The buffers and thus contamination to be precise throughput depends firstly on the removed efficiently. duration of the extraction protocol and secondly also on the starting weight or Individual complete system volume. It also depends to a large extent The high level of automation is provided on the sample material itself (leaf and by a handling system from Festo, whose seed material, animal tissue, hair, etc.). experts in the production of pneumatic and electric automation technology sbeadex – high-quality DNA preparations adapted this precisely to the The oKtopure utilises the sbeadex™ requirements of the customer’s laboratory extraction chemistry developed by LGC, application. The required high precision which is based on the use of magnetic for the three-dimensional gantry for liquid particles. These particles can specifically handling is made possible by the electric bind nucleic acids such as DNA and thus toothed belt axes EGC on the X- and allow the separation of DNA from other Y-axes. The double Z-axis EGSK with Issue 29 trends in automation Synergies 38 – 39

“We took advantage of the engineering know-how of the Festo automation specialists”.

Dr. Dietrich Köster, Product Manager with LGC

spindle drive ensures exact positioning of themselves with the details of automation the dispensing head. The three- technology. “The fact that Festo could dimensional gantry for liquid handling offer us a complete package from Festo is supplied as a complete consisting of hardware, system. software and a consultancy service is what tipped the The gantry is easy to commission and can balance in their favour,” also be integrated quickly into machines. explains Dr. Dietrich Köster, EGC electric toothed belt axis. The pre-parameterised drive and Product Manager with LGC. controller package gives users the security of knowing that they can Concentration on core processes concentrate on their own core Festo delivers its ready-to-install system competencies without having to concern solution fully assembled and tested

directly to the test facility. The scope of delivery includes all design data and circuit diagrams and a comprehensive functional guarantee. Under a single part number, users not only receive hardware in the form of a ready-to-install module or subsystem, but a complete added-value package.

Complete solutions ease the burden on technical personnel, keep design costs low, simplify the procurement process and reduce process costs. “We took advantage of the engineering know-how of the Festo automation specialists, which saved a great deal of time throughout the process, especially during testing and commissioning,” emphasises Köster.

About LGC

www.lgcgroup.com

Area of business: Manufacturer of solutions for DNA extraction with its own extraction laboratories and producing its own chemical substances for the extraction process. Ukraine Dust-free grain loading Pulse valve in dust extraction systems

Ukraine is one of the top three grain exporters in the world. Between July 2014 and the start of March 2015, the country on the Black Sea exported more than 24 million tonnes of grain. In Odessa, one of the largest and most important ports on the Black Sea, amongst the terminals for oil, gas and containers, there are also imposing loading stations for grain.

For more than twenty years, Grain Capital has been developing systems and technologies to extract dust during grain processing. These can also be found in the huge port terminal in Odessa. The company’s modern extraction systems have been successfully counteracting the health- endangering effects of the dust that is created when loading ships, thus also reducing the risk of explosions in dust/air mixtures. In the tough environmental conditions of the dust extraction systems used at the port, the reverse jet valve VZWE impresses all round. Several of these robust valves are actuated simultaneously in order to generate a short, high- volume air blast. They guarantee high flow rates and extremely fast opening and closing thanks to their application Imposing loading station: TIS grain terminal at the port specific design. of Juzne,˘ Odessa region.

www.zeo.ua

The reverse jet valve VZWE is mounted between the compressed air reservoir and the pipe valves in order to blow the dust off filters using compressed air. Issue 28 trends in automation Festo worldwide 40 – 41

Slovenia

Planica is world-famous for ski jumping and ski flying. Safety in jump valley Solenoid valves control windbreaks

Traditionally, the finale of the ski jumping world cup is held every year in Planica, Slovenia, not far from the popular winter sports resort of Kranjska Gora. For many years, the famous ski jumping hill, Letalnica bratov Gorisek,˘ was the largest in the world and currently is the second largest. This year, the Slovenian, Peter Prevc, set the record here with a jump of 248.5 metres.

Tailwinds slow down the jumpers, while updrafts help them to achieve great distances. Both can be calculated very easily. Crosswinds, on the other hand, cannot be calculated and when gusty can be dangerous for the athletes. The wind acts directly on the body; the ski jumper can be thrown off balance without warning. Many jump complexes use windbreaks or curtains to help with this. The same is true in Planica.

Pneumatic cylinders raise and lower the windbreak on both sides Solenoid valves VZWF: behind the scenes, up to a top height of 18 metres. These are controlled by Festo they ensure safety in the event of crosswinds. solenoid valves type VZWF. With relatively small solenoids, they control high pressures at large nominal sizes. Another advantage is that they switch off already at 0 bar and automatically close via the NC function in the event of a loss of pressure in the control circuit. Photo: © Connie Zhou / Google Inc.

Communication at full speed About the magazine All images, graphics and texts are Data centres work at full speed to keep the digital world protected by copyright law or connected. Billions of bytes of information are exchanged over the other intellectual property rights. Internet every day in modern server farms. Around the clock. Any reproduction, modification or Google is at the forefront of this. This search engine provider’s use in other print or electronic website is the most visited in the world. According to a statement publications is prohibited without from the company, three billion search queries were processed the express consent of Festo AG & per day in data centres during one year. Co. KG.

The cover picture is of the data centre in Council Bluffs, in the American state of Iowa. On an area measuring 10,000 square metres there are rows and rows of servers all connected to one another. All of the company’s data centres can also communicate Great Britain globally with one another. Festo Ltd Applied Automation Centre Caswell Road Brackmills Trading Estate Northampton NN4 7PY

Phone +44 (0) 800 626422 Fax +44 (0) 1252 775015 E-mail [email protected] www.festo.com/gb

Ireland

Festo Ltd Unit 5 Sandyford Park Sandyford Industrial Estate Dublin 18

Phone +353 (0) 1 2954955 Fax +353 (0) 1 2955680 E-mail [email protected] www.festo.com/ie

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