Movement from Body Language to High-Speed Handling Highly Flexible, Very Compact

trends in automation

The Festo customer magazine 2.2014

Inspiration Sending signals Interview with Samy Molcho, mime and body language expert

Impulse The hub High-speed logistics at the Customer Service Centre in St. Ingbert-Rohrbach

Synergies Hot topic Thermoforming of car floor coverings

In focus Movement From body language to high-speed handling Highly flexible, very compact

You want simple and precise positioning. You are looking for rapid and free motion in 2D. We provide you with a ready-to-install solution.

More compact? No way! The planar surface gantry EXCM with its kinematic system and integrated drives ensures maximum working space where installation space is minimal. Ethernet and CANopen make it highly connective. The standardised system with double controller is ideal for desktop applications. www.festo.com Always on the move

Dear reader,

At Festo, motion is our business. We feel at home wherever something moves in an industrial automation process, be it fast or slow, simple or complex, pneumatic or electric. Festo has the right solution for any movement task in factory automation and process automation. New developments, such as our mini H-gantry EXCM, allow a wide spectrum of batch sizes to be handled at extremely low cost. You can read more about the new mini H-gantry EXCM from Festo on page 24.

The world of business is also constantly on the move. Modern communication solutions cover thousands of kilometres in a fraction of a second. With markets constantly changing there is no time for industry to procrastinate. Processes need to be more flexible. Even the smallest batch sizes have to be achieved with the highest possible degree of automation at the lowest cost, so what was once considered a contradiction is now mandatory. Speed becomes the decisive competitive factor and I am not only talking about the speed of machines and processes. The speed of internal business processes becomes vital for maintaining a com- Dr. Ansgar Kriwet, petitive edge. Who can present a quotation faster? Who can offer Member of the Management Board, Sales the shortest delivery time? When can we promise the start-up of a new machine? These factors decide whether orders are won or lost. At Festo we are focusing all our efforts to support you in speeding up your processes in design, purchasing and production with tools and services that help you win the “speed competition”. Fast delivery is key in our Customer Service Center, supplying European customers from Rohrbach. On page 20 you can see how we are using automation to speed up your delivery.

This issue of trends in automation is dedicated to movement. Festo is expanding its development horizon with its bionic projects in which future oriented technologies can gain a foothold. The most recent example is our eMotionSpheres. This bionic installation with its flying spheres demonstrates how multiple objects can move through the air energy-efficiently without colliding, thanks to multiple network connections, an indoor GPS system and innovative drive concepts. All of these developments will find applications in future Festo products for the automation world.

Motion is our business and you will find a world of application examples where we are supporting our customers from different industrial areas with their motion tasks. What can we do for you?

Enjoy reading!

Ansgar Kriwet In focus Movement “The Wave” sandstone rock formation is a snapshot of nature in motion – formed over thousands of years by wind and weather. In the world of automation, motion takes place considerably more quickly. Modern, high-speed processes demand ever more flexibility and higher quality. In this issue of trends in automation you’ll find out how this balancing act is achieved. Photo : © Ansgar Hillebrand

trends in automation 2.2014

Editorial 3 Panorama 6 Festo worldwide 43 About this magazine 45 Soft stop 46

Bionic adaptation: 18 the unique jumping behaviour of the BionicKangaroo.

Compass

“You can’t separate movement Harmony in the air 8 from the inner attitude.” With the eMotionSpheres, Festo demonstrates how several flying objects can be coordinated to move in a defined air space. They feature an innovative drive Inspiration concept. 14

Movement is life Developmental leap Interview with Samy Molcho. The renowned With the BionicKangaroo, Festo has tech- mime and body language expert talks nologically reproduced the unique way of about movement as a means of nonverbal moving of a kangaroo. The innovative kine- communication and about signals, feelings matics supports extremely energy-efficient and expectations. 8 jumping. 18 2.2014 trends in automation Contents 4 – 5

Customer Service Centre: Around 20 400 employees ensure that goods are dispatched quickly.

Impulse Ultimate precision: the delta robot 30 EXPT in a multifunctional palletiser Always on the move for the watch industry. Logistical tour de force: the Customer Service Centre in St. Ingbert-Rohrbach handles up to 40,000 order items every day. A high degree of automation helps Synergies to ensure efficient processing. 20 Small in size, great in diversity Hot from the mould Minimalism Switzerland: the country famous all over Fast and gentle: proportional technology The mini H-gantry EXCM is a flexible and the world for the Matterhorn, cheese, is used in a production system for the economical automation solution for a very chocolate and watches is also making its thermoforming of car floor coverings. 37 wide range of handling tasks, including the mark as numerous high-tech companies test system at Visatronic and PKC. 24 play an increasingly prominent role in the Hot recycling coolly calculated global market. 26 Highly productive: with a complete solution spanning several levels of the auto- As precise as a Swiss watch mation pyramid, Festo automated a recyc The delta robot EXPT demonstrates its ling plant for waste from blast furnaces in speed and dexterity in an intelligent sys- Mexico. 40 tem for the watch industry. 30

To the point Festo worked with IPTE to develop an innovative machine concept for the selective soldering of sensors directly in the housing. 34 Photo: © ESA Moved bythewind at altitudesofbetween 8,000 and18,000metres. the jetstreams reach peakspeedsofupto540km/h cloud increases withaltitude. The strong windsof ing, windspeedandtherefore alsotheamountof an altitudeofseveral kilometres. Generally speak- The cloudformationindicateshigh windspeedsat (bottom right)andNorway, withitsmanyfjords. recorded over Seabetween Denmark theNorth The satelliteimagehere shows abandofcloud the weather over thecominghoursanddays. forms shedlightonwinddirection, windspeedand Meteorological Organization (WMO). Their various according totheofficialclassificationof World In meteorology, there are 10different cloudtypes (air thatbecomescolderwithincreasing altitude). form cloudsinanunstablestratified atmosphere ticles onwhichwaterdroplets form. Together they water vapour andcondensationnuclei,tinymicropar To seemovement intheairyou needtwothings: - 2.2014 trends in automation Panorama 6 – 7 Interview Movement is life Samy Molcho is one of the most renowned mimes of the 20th century. As a celebrated artist, he has performed on stages across the world. These days, however, he spends his time sharing his in-depth knowledge of the scope of expression of the human body with a broad public. trends in automation met with Samy Molcho in Vienna and gained a fascinating insight into the world of body language.

trends in automation: Prof. Molcho, you have studied theatre, dance and the art of mime. Your first performance in Europe was About the person in 1961 and since then you have performed in over 50 countries on four continents. That alone sounds quite literally like a life lived Professor Samy Molcho in movement. What does movement mean to you? Samy Molcho was born in 1936 in Tel Aviv, Israel. He graduated Samy Molcho : For me, movement is life. That which doesn’t from drama school and studied classic, modern and Oriental move, doesn’t live. That which doesn’t move, doesn’t react. That dance as well as the technique of mime in Israel. In 1957, he which doesn’t react is not connected to the outside world; there gave his first solo mime performance. His first performance is no interaction. There is no life without movement. For me per- in Europe was in 1961. From then on, he trod the boards of sonally, the most important movement is inner movement. We are some of the most famous theatres in the world until his fare- primarily moved by feelings. This is captured really well in the well tour of 1987. In 1977, he was made a college professor word “emotion”. Here the movement or motion is already con- and in 2001 a university professor at the University of Music tained in the word. Movement or restraint is triggered by feelings; and Performing Arts at the Max Reinhardt Seminar in Vienna, this is also necessary for survival. Let’s just take hunger, thirst and Austria (given emeritus status in 2004). fear for example. This information about our feelings moves us towards a source of nourishment or away from a place of danger. Samy Molcho was already considered an international expert in the field of body language as early as the 1980s. In addition For decades, you performed as a mime on stages to his work as a personal coach, he continues to host success- all around the world. What was so special to you about ful seminars and give talks across the world. He is the best- expression through movement? selling author of several books that have been translated into many different languages. At the moment he is working on a Molcho: Quite simply: life with all its diversity. You suddenly new book on the topic of territorial behaviour. Samy Molcho discover that there is much more in you than you actually use. is an Austrian citizen and father of four sons. He lives with his In the theatre, you expand your own person. By that I mean you wife Haya in Vienna. put yourself into another character structure. For example, you have to think about how your body would react in a specific situ- www.samy-molcho.de ation which it has never actually experienced. In general, of course, all people have the same anatomical characteristics. What makes us different, however, is the vocabulary of our own physical movements. These are influenced, for instance, by temperament, upbringing and social rules that are often in conflict with our internal desires and feelings. These make up the typical “person”. 2.2014 trends in automation Inspiration 8 – 9 “Being able to recognise the signs of body language, being able to interpret and apply them, makes every form of communication easier.”

Samy Molcho

It is this very “person”, this aspect of ourselves, that we must the way you hold your body, then your demeanour changes too. expand in the theatre in order to be able to constantly portray If you let positive emotions in, the movement becomes bigger other, very different character structures. and more open. Many people have not learned to open up. They think about the emotional experience of opening up instead of I have also noticed how the reactions of the audience change actually opening up and really experiencing the feeling through when my body takes on certain positions. This doesn’t just work a change in the way they hold their bodies. If no change takes in the theatre of course. For example I am sitting here now directly place, your counterpart cannot tell what you are feeling, where opposite you and I am looking straight at you. Now I move my you stand on the matter. Your counterpart will then feel uneasy head and my direction of view to the left or right, to look briefly or uncertain because he cannot identify your intention. at another person, but I keep my body position with you all the time. That is something quite different to when I turn my entire Let me make an assertion: you are probably of the opinion that body away from you and then turn back. That would express that, what is really going on inside you is no one else’s business. both mentally and physically, I can only be here or there. You Society too tells us often that we should not show our feelings. would immediately react to that and would turn to something Why not? Because someone could use it against us. So we must or someone else too; that would not have happened in the first protect ourselves from the outside world. And so the hands are example. Body language expresses a specific, situation-related in front of the body sealing it off, and the facial expression also intention through movement. reflects this. But it can be so exhilarating to show your feelings. It allows for an exchange to develop, for communication with each When preparing for this interview, I noticed that I have other. It is simply a very different experience. been paying more attention to my own body language and to that of others. Can the body always betray what I am feeling?

Molcho: That’s the intention. When you learn something, you go Molcho: The body doesn’t “betray” in the negative sense of the through a process of greater awareness. This process of becom- word, it simply expresses feelings. Otherwise how can you commu- ing more aware is an analysis, which often also requires a course nicate with an employee or colleague when you are afraid of correction. Many people say: “That’s just how I am.” And I coun- expressing and showing your motivations? You will often hear ter that with: “No, you became that way and you also became in an office situation: “Oh you are so emotional!” I would answer: used to being that way. Change your vocabulary, verbally, in your “Be happy that I am so emotional.” Maybe you were oversensitive thought systems and in your body language, and you will see that or in the wrong, but the reaction was real because you were inter- you can radiate something else and that others will react differ- ested in the subject and committed to it. When one person under- ently to you; but you remain you, just different.” If you change stands the feelings and sees what upsets or disappoints the 2.2014 trends in automation Inspiration 10 – 11 other, then it is possible to take a clear stand and often to Can you give some more examples of body language? come to a joint solution faster. You should therefore express expectations clearly. Molcho: A very typical one perhaps. Many men hold their head very straight, facing directly ahead. But if I tilt it a little to the What do expectations have to do with body language? side, you will smile. Just like that. By inclining my head, I leave one side of my neck free. One can “bite” so to speak, by that I Molcho: In order to be able to express wishes or expectations mean that I’m signalling “submission” or trust that you will not meaningfully, my counterpart must be open and receptive. But bite. Now if I straighten up my head, perhaps pull my eyebrows if my colleague or boss is already sitting in front of me with his or together a little, that can already be construed as confrontation. her arms crossed, that makes me think that he or she doesn’t want Your body reacts immediately again, and this time with tension. to negotiate. If from the very outset that person doesn’t want to Someone who inclines his head slightly tells me that we’re having negotiate, then why should I express what I want? This is why I an open discussion. appeal to all colleagues and bosses: “Open your arms! Then you will experience a willingness to negotiate and become open to For men that is often difficult. “One man, one word”, stand up that which moves others.” Crossed arms convey that you don’t straight and keep your composure. That is so ingrained. He doesn’t want to let the other person in. That is what actually disappoints see that he is already on a collision course, solely because of that. or annoys people. They don’t feel acknowledged or that they are If, on the other hand, he inclines his head, he notices immediately being taken seriously. When do I feel that I am being acknow that he is “softer”. But that’s precisely the problem. Because if a ledged? When I have an influence on others. man equates soft with weak, then of course he doesn’t want to be weak or to appear to be weak to others. But that’s not the case: Why do so many people adopt a “defensive” posture soft doesn’t mean being weak. On the contrary, if he allows him- in communication? self to be soft, then he finds that despite this or indeed because of this, he can be perceived as being strong. He shows that he is Molcho: Because when we open our arms, we leave our torso flexible and is searching for options, and in return he also receives exposed. It is a natural impulse to protect this part of the body more information. with its vital organs. But what could really happen in an office situation? That someone will punch you? Not really. Of course, this Now, what if I do more than just incline my head, what if I also “open arms” stance need not necessarily mean agreement. I can let go of a little of the rigidity and move a bit, then my chest also always say “no” in a discussion, but it is better to say “no” with lowers slightly and I become more receptive. So it is worthwhile my arms open than with my arms folded. A closed posture signals to be able to interpret signals and their effect and to be able to that you have really no intention of letting the other person in at all. respond to them accordingly. 2.2014 trends in automation Inspiration 12 – 13

This interview with Samy Molcho took place on 9 September 2014 in Vienna, Austria. Photography: Peter Mayr

“Around 80 per cent of our responses and decisions are triggered by nonverbal communication.”

Samy Molcho

How does that work for you? With all your experience, Molcho: That’s true. Someone who hardly moves at all and sud- are you always conscious of your movements? denly has a strong feeling that he cannot suppress has a very different experience of himself. If you have never allowed intense Molcho: No, I don’t need to be. I just perceive signals faster per- emotions in your body, then you have never really experienced haps. I am open, engaged and at the same time accepting of the it properly. Body language has nothing to do with acting. It has wishes of other people. If I make myself aware of the signals and to do with a certain extension of behaviour and also with the thus of the needs, then I can respond to them. Being able to rec- opportunity to give more space to others. Too often we think ognise the signs of body language, being able to interpret and “what do I want” and not what the other person would like. apply them makes every form of communication easier. This is But an encounter is the fusion of both points of view. What do not a huge learning process. Because body language is not like you need and what do I have to offer? the virtuosity of a dancer who must study and practise his movements. You don’t have to be able to twine your arms like a snake. Around 80 per cent of our responses and decisions are triggered by nonverbal communication. For example, I can see from body The way you hold your hand is, for example, a very important signals when someone is closing up, when he is afraid, when he means of nonverbal communication. For instance: I am pointing suddenly shuts down. He raises his foot a little, he puts the brakes at this sheet, the back of my hand is upwards, my index finger is on so to speak. The lips press together, he is blocking the other stretched out (page 11, small image in the centre). I, as your su person out, maybe not accepting what is being said. Being able perior or colleague, would like you to do this task. It’s like an order. to perceive these signals gives a person the opportunity to offer I am not expecting any dialogue or any answer. Right now I am something a little different. In order to awaken needs or fulfil them, reducing you to your professional function and I am not perceiv- we must create contact with others. We need reasons to move, ing you as a person. You must do this now in the way shown. If I motivations, and these stem only from our feelings, our emotions. want the same from you and I point to it with an open hand move- If you want to motivate people, speak to their emotions! ment, then this means that this hand can take and give (page 11, small image bottom). That is, I am also prepared to receive information. I am thus recognising you as a person. It’s a small movement with a huge effect. You don’t need to practise for it. If you take this into consideration, it can quickly have a very positive impact on the working environment.

In one of your books you wrote that engaging with body language is an experience for everyone. eMotionSpheres: collision-free motion of autonomous systems in an air space Harmony in the air Synchronously or autonomously, the eMotionSpheres show how, thanks to multiple network connections, several objects can be moved in a three-dimensional space without colliding. The indoor GPS system demonstrates a new approach to automation technology, while the innovative drive concept sets new standards for lightweight design and energy efficiency. 2.2014 trends in automation Compass 14 – 15 eMotionSpheres: predestined for use as an indoor GPS to prevent collisions in the workspace of tomorrow.

he eMotionSpheres installation one another’s way. The spheres can also consists of eight white, helium- be controlled individually and, because of fi lled spheres with a diameter of their process reliability, systematic light- T 95 cm. They are powered by eight weight design and fl exible, adaptive pro- small propellers attached to the outer skin. pellers, they are not dangerous to people. The adaptive drives provide the same thrust forwards and in reverse, which is Lightweight construction inspired a genuine innovation with fl ying objects. by nature Together with the camera system and The design of the adaptive propellers an intelligent control system, they are drew on the research carried out for the capable of the widest range of fl ight ma- BionicOpter, the artifi cial dragonfl y from noeuvres. The main computer acts as the Festo. The developers of the eMotion- air traffi c controller. It coordinates both Spheres pursued the wing principle of the the choreography for all the spheres and artifi cial dragonfl y and transferred it to the the free movements. drives used for the spheres. Just like the wings on the BionicOpter, the propellers Three-dimensional aesthetics of the eMotionSpheres are made of a A modern tracking system, consist- sturdy, laser-sintered frame in the form of ing of ten infrared cameras in- a fi gure of eight, covered with a fl exible stalled in the space, record the membrane. As the membrane is not com- spheres via their active infra- pletely taut, it infl ates on one side or the red LED markers and pass on other, depending on which direction the the position data to a main propeller is turning. The propellers supply computer. Preprogrammed up to 42 g of thrust both forwards and paths stored here specify the backwards and are thus equally effi cient spheres’ fl ight paths when fl ying in both directions. As the propellers weigh in formation. Specially stored be- less than one gram, the direction can be haviour patterns allow the individual changed almost immediately. This effi cient spheres to move. The patterns ensure combination of equal thrust performance that even in chaotic situations there are in two directions in fl ying objects is a no clashes, since the spheres move out of genuine fi rst. 2.2014 trends in automation Compass 16 – 17

A new direction for man and machine

The fascinating eMotionSpheres are the latest innovation from the Festo Bionic Learning Network. The Festo network includes renowned universities, institutes and development companies and works closely with specialists from other departments as well as external partners from all over the world.

The Bionic Learning Network is paving the way for the production of the future. The experts develop fundamental technologies for networked systems and the interaction of humans and machines. The eMotionSpheres illustrate safe interaction between humans and machines. In terms of possible industrial applications, they could be used as a control system for production halls, for example. The eMotionSpheres are an impressive demonstration of how the real and virtual worlds are continuing to grow together.

Moving pictures: Simply scan the QR code to watch the video.

Modern infrared technology: Pioneering role model: the BionicOpter wing principle transferred exact positioning of the spheres. to the drive technology of the eMotionSpheres.

Absolute precise movement radio unit, the battery and four power space can therefore be covered with the The eight drives are attached along the LEDs, which light up to provide visual same number of cameras. The fact that “equator” of the spheres, four of them support for the choreography. the markers are not permanently lit and aligned horizontally and four vertically. fl ash for only a millisecond means that The horizontal propellers enable the Viewing the area as a whole they are long-lasting and energy-effi cient. spheres to fl y up and down, climb or To enable free fl ight in a specifi c space, Depending on the fl ight speed, buoyancy descend quickly. The four vertical drives each sphere is recorded by at least two and manoeuvres that are fl own, the move the spheres horizontally in all direc- of the ten cameras. The cameras are pos- spheres spend up to two hours in the air. tions and rotate them about their vertical itioned so that they map out the fl ight area They then stop autonomously at their axis. Four of the propellers turn anticlock- as a whole. The special fi lters of the cam- charging stations. They can therefore wise and four clockwise. This means that eras only capture infrared light and are be used as fl ying objects for several days there is always an anticlockwise drive not sensitive to other light. The cameras without a person having to intervene. located opposite a clockwise one. detect the position of the spheres and The torques are thus neutralised and the their orientation in the space through the eMotionSpheres can be steered in any four infrared LEDs on the outside of each www.festo.com/en/emotionspheres spatial direction to an accuracy of one sphere. They can also tell the optically www.festo.com/en/indoor_navigation centimetre. The spheres themselves are identical fl ying objects apart. The active controlled decentrally by the activation of infrared markers on the spheres offer a the eight motors. The fl ying spheres also decisive advantage over passive refl ectors. contain the corresponding onboard elec- Their light only has to cover the distance tronics with 12 processors, as well as the between the sphere and camera. A larger Unique jumping behaviour: intelligent combination of the integrated components for stable and efficient jumping

3. Switching the valves for take-off

1. Pretensioning the elastic spring element 2. Shifting the centre of gravity forwards

BionicKangaroo: energy-efficient kinematic jumping mechanism Developmental leap

Reducing the complexity of nature to a simple technical Elias Maria Knubben, Head of Corporate denominator is one of the objectives of the Festo Bionic Bionic Projects at Festo. As with other projects such as the BionicOpter and the Learning Network. The researchers and design engineers SmartBird, the only thing that was certain have once again succeeded in doing so, this time with the at the start of the BionicKangaroo project was the deadline. The experts had to BionicKangaroo. The innovative kinematics developed have the project completed in time for the over two years has enabled the artificial kangaroo to jump Hannover Messe 2014. with particular energy efficiency. Successfully cutting the umbilical cord “There is no guarantee of success. All that we have are clear requirements, a highly skilled and motivated team and a common goal,” says Elias Knubben, describing the conditions at the start of bionics projects. he further the kangaroo jumps, Yet the team of 12 people, including the more efficient its energy experts from different departments, train- consumption. This is thanks to its ees and students, succeeded in reaching T unique jumping mechanism. The their goal. kangaroo can store the energy from landing in its strong Achilles tendon and re-use From functional models inspired by biology it for the next jump. This enables it to in- and initial detailed technological solutions crease its speed without using more to the finished overall concept – the project energy. This principle has fascinated the team managed to achieve a spectacular Festo bionics experts for a long time. feat. Step by step, the worlds of biology and robotics were brought closer together. Two years ago, they got the green light for The natural complexity of the original was a Bionic Learning Network project aimed reproduced in fully functioning kinematics at recreating the highly complex natural with as few degrees of freedom as possi- sequences of the kangaroo’s jump as real- ble. The “umbilical cord” that initially istically as possible from both a mechanical supplied the energy for the jumps could and a visual perspective. This was a tough be cut thanks to the use of lightweight, challenge for the project team led by compact compressors and high-pressure 2.2014 trends in automation Compass 18 – 19

4. Evaluation of the sensor values 5. Pulling the legs forward by the control system and lifting the tail

6. Landing and deflecting for the next jump

Choice of materials: the kinematic system is made out of laser-sintered parts reinforced with carbon.

Teamwork: the complex mechatronic design was developed through interdisciplinary collaboration.

storage devices. In collaboration with vari the precise control technology ensure ous research departments at Ulm Univer- the required stability when jumping and sity, the kinematics could be controlled in landing. such a way that the BionicKangaroo can jump steadily, land perfectly and take off The energy status of the kangaroo, the again in a flawless, fluid movement. manipulated variables and tilt angle are The “umbilical cord” that initially supplied constantly monitored and evaluated. the energy for the jumps could be cut thanks Two steps back, three steps forward Thanks to the kinematic system made out to the use of lightweight, compact compressors and high-pressure storage devices. “A bionics project has to be extensively of laser-sintered parts reinforced with car- redesigned many times before it can be bon, the BionicKangaroo weighs just seven presented to the public. Sometimes you kilograms at a height of around one metre. have to take two steps back in order to It can jump up to 40 centimetres high and move three steps forward,” explains Elias up to a distance of 80 centimetres. Knubben about the uncertainty in innovation projects. Although the deadline www.festo.com/en/bionickangaroo seemed to approach rapidly, the project was still completed on time. The Bionic Kangaroo made its first successful series of Moving pictures: jumps shortly before the Hannover Messe Simply scan the QR code 2014. The condition monitoring as well as to watch the video. Logistics: Festo Customer Service Centre in St. Ingbert-Rohrbach, Germany Always on the move The Customer Service Centre is the heart of the Festo logistics operation. From the delivery area to the goods in department, from the container warehouse, order compilation and packaging areas to the package sorting, shipping and loading areas, the Customer Service Centre shows that high speed doesn’t have to mean hectic. A high degree of automation helps to ensure efficient processing of an average of 36,000 order items each day. 2.2014 trends in automation Impulse 20 – 21

n the world of logistics, a simple click in 1996, we’ve expanded four times to Speedy processing, efficient packaging by the customer sets in motion a keep improving the performance of the To ensure faster turnaround times for cus- “chain reaction”. Whether it’s about CSC.” During a tour of the enormous space, tomers, Rosar and his staff “turbocharged” I placing an order for a standard pneu- the seasoned logistics expert recounts the logistics system with a top-mover area matic valve from the Festo product cata- how “today it is as efficient and innovative and a partially automated packaging logue or configuring a tailored valve as the products themselves”. He goes on system. The top-mover area is dedicated terminal by a Festo technical consultant, to explain how the creation and expansion to around 350 of the most frequently re- the customer is blissfully unaware of what of the CSC also enabled a move from a quested material numbers. They account happens between placing the order and it decentralised system to a centralised one for 40 per cent of all delivery items across being delivered. Like the wheels in a watch for the European inventory. European end all available articles. Three storage towers, mechanism, the process is based on every- customers account for the majority of the each with its own lifting bar conveyor, cut thing working together seamlessly. As the CSC’s incoming orders. It also supplies all processing times for “top movers” by two fast-beating heart of the entire Festo logis- plants, Regional Service Centres (RSC) thirds. tics operation, the Customer Service Centre and national companies around the world (CSC) in St. Ingbert-Rohrbach in the with finished goods and production mater Partially automated packaging of small Saarland keeps the flow of goods moving ials for international customers. To do packages reduces the previously high at full speed. Around 400 employees this it needs space, something put to very manual part of the packaging process, process up to 40,000 order items per day. efficient use in the CSC. “We have 168,000 therefore making it less time-consuming. 41 storage and retrieval vehicles and nine container storage locations, so early on we It takes four staff just one hour to get fully automated order pickers move order- arranged them in two rows, one behind up to 1,000 packages ready for shipping, ing quantities of any size around an area the other,” explains Ralf Rosar. Employees all made possible thanks to intelligent in- of 31,800 m². work round the clock in three shifts to teraction between people and machines. make sure that all incoming goods are pro- With this system, the small boxes are first 100 tonnes a day cessed quickly and without interruption. erected in a fully automated process, then Ralf Rosar, Head of CSC, is justifiably Each day, over 100 tonnes of products standardised insert trays are manually proud of the efficiency and dynamism of pass through the 25 loading bays of the filled with products before being stretch- the logistics centre: “Since it was created distribution centre. wrapped in another fully automated “The Customer Service Centre in St. Ingbert-Rohrbach is as efficient and innovative as the Festo products themselves.”

Ralf Rosar, Head of Customer Service Centre, Festo

(A) 2.2014 trends in automation Impulse 22 – 23

(C)

(B) (D)

(A) High-rise high tech: the CSC is home to over 168,000 storage locations.

(B) Tidy workstation: a system focused on just a few standard sizes speeds up the packaging process.

(C) Cylinders on their way into the world: the CSC supplies all Festo plants, Regional Service Centres and national companies with finished goods and production materials.

(D) Information that works: special attention is paid to labelling of goods for international shipments.

(E) Smooth flow: the CSC receives up to 40,000 order items a day.

(E)

process as protection for the next step of The orders processed there range from Service Centre in St. Ingbert-Rohrbach is machine handling and delivery. Grippers service units to customised packages – to increase the speed at which products pick up the trays and place them in boxes, called pre-packs – and complex tailored are processed. This is how Festo supports while scanners check the barcodes on the solutions with valve terminals, cylinder/ its customers in their day-to-day work and manually applied labels and tell the system valve combinations or semi-rotary drives. at the same time reduces the amount of controller whether the contents match the It is also where installation of non-Festo time products spend in the warehouse. label. parts like mounting plates takes place. The increase in the daily average of custom Complete solutions for customers assemblies shows how big customer A special feature of the CSC is the so-called demand is. They increased from just 380 finishing platform for the small assembly units in 2012 to 430 configured products area. “The concept of the platform dates a day in 2013. The documentation created back to the early days of the CSC, when by project engineers at all Festo locations we built a kind of platform to give us a for the required customer solutions is faith- second level in the logistics area for much- fully followed by 60 assembly professionals needed space,” explains Ralf Rosar. “The at 20 assembly stations. small assembly area sits between picking and packaging in the logistics process The objective of the top-mover area, the and is also being gradually integrated into partially automated packaging process the Regional Service Centres.” and the assembly platform in the Customer Dynamic response in the smallest spaces: the mini H-gantry EXCM has a low moving mass thanks to its parallel kinematic belt drive concept.

Flexible and cost-effective automation in small parts assembly Minimalism

Bringing together in one automation solution all the factors important for success is no easy task. The aim of handling a large range of batch sizes is in direct conflict with the requirement for a lean budget. However, these conflicting demands can be reconciled, as the mini H-gantry EXCM from Festo shows.

roduct lifecycles are becoming There are several requirements to be met, axis. The low moving mass results in a com shorter and shorter, nowhere for example flexible adaptation and scal- pact and powerful system. The H-gantry more so than in the electronics ing of the systems, ease of configuration thus offers an efficient state-of-the-art auto- P industry. One way in which com and setup, and quick commissioning. And mation platform for machine and equip panies can respond is with flexible automa- not forgetting a high degree of reliability ment manufacturers. The basis for material tion solutions, which allow easy retooling and precision as well as a favourable pur- handling and process control always re- for different product variants. The result is chase price and low maintenance costs. mains the same, only the front-end device cost-efficient production of small and With the mini H-gantry EXCM, Festo has needs to be changed. large batch sizes. At the same time, this succeeded in combining all these factors. increases the standard of quality expect- Quick and precise testing ed of both the production process and the Always the same basis A good example of a successful application end products. A high level of automation The mini H-gantry EXCM is a flexible and of the mini H-gantry EXCM is Visatronic helps to avoid errors and boosts precision. economical automation solution for a very GmbH’s Flying Probe test system. Small However, the space available on the pro- wide range of handling tasks. The parallel batch sizes and prototypes make the cost- duction floor is also becoming an issue. kinematic belt drive concept means that effective testing of printed circuit boards What customers want is compact machine the positions of the drive motors are fixed. a real challenge. It was this that motivated designs. Bringing together all these factors This means that the drive motor for the Visatronic to expand its existing Visatest in one automation solutions is a challenge. Y-axis doesn’t have to be carried on this test system. The new test machine pos 2.2014 trends in automation Impulse 24 – 25

itions a test probe on the electronic mod- ules. This verifies that the module has been produced correctly and tests its functionality. The test system is the perfect application for the mini H-gantry. The drive is permanently mounted on the Y-axis and doesn’t have to be carried on the moving axis. The compact design and low moving mass mean that the required travel time of 2 seconds for a complete diagonal and the necessary positioning accuracy of 0.1 mm are no problem. The mini H-gantry Cost-effective testing of printed circuit boards: Visatronic GmbH’s Flying Probe test system can achieve speeds of up to 500 mm/s with the mini H-gantry EXCM. and repetition accuracies in the range of ±0.05 mm in the X/Y system.

The Finnish company PKC also uses the mini H-gantry EXCM in a tester for mobile devices with touchscreen and buttons. The EXCM carries out the movement to the different test positions as well as movement within the test sequences. The main selling points of the ready-to-install handling solution were its compactness, attractive price, high flexibility and scala- ble mechanical system.

A more economical system Further arguments in favour of the mini H-gantry EXCM are its economical purchase cost and the option of operation and flexible control via Ethernet. All setpoints such as target positions and travel speed can be input directly in the slim, cost- The Finnish company PKC uses the mini H-gantry EXCM in a tester for mobile devices. efficient system. The system takes over More about this in the next issue of trends in automation. control of the two servo motors, which means that the motion sequences of the mini H-gantry are easy to program in terms of target position, path speed and direction. At a glance: mini H-gantry EXCM The mini H-gantry EXCM is an ideal system component for laboratory automation, High dynamic response: the mechanical design of the stationary motors electronics production and the production, reduces the moving mass and superimposes the drive performance of the assembly and handling of small parts. two motors. This enables a high dynamic response of 10 m/s².

www.festo.com/catalog/excm High system accuracy: the kinematic design enables a system repetition accuracy of ±0.05 mm (along X/Y-axis).

Shorter design time: complete system with specific interfaces and dimensions.

Easy ordering using just one order number. The simple configuration offers a fully harmonised handling system including motors, controllers and cables.

Easy commissioning: the EXCM is easily configured using a PC or Notebook with the Festo Configuration Tool (FCT) via Ethernet LAN. Roger Federer spent a total of 302 weeks at the top of the world tennis rankings. The highest peak is the Dufour Peak at 4,634 metres. The best-known mountain is the Matterhorn.

The 1,000 franc note has the highest denomination in the world.

NASA astronauts carry Swiss pocket knives on their space missions. Photos: © Shotshop.com

70% of the agricultural land in Switzerland is grassland. This represents one third of Each of the 8.21 million inhabitants consumed on Switzerland's total area. average 21.05 kilos of cheese in the past year. 2.2014 trends in automation Synergies 26 – 27

Switzerland: model of success in the heart of Europe Small in size, great in diversity

Picture-postcard scenery. A growing economy. A nation with a steadfast desire for democratic self-determination. Switzerland is a model of success and offers a quality of life that is hard to beat. Festo has been part of this since the late 1950s. Recent investments in the new Swiss headquarters underline the com pany’s strong commitment to the country.

witzerland is not only a model of economic success, but also attracts people from all over the world with its natural beauty. It offers 60,000 km of hiking trails, almost S matching its 71,400 km road network. The Eiger, the Mönch and the Jungfrau or the Matterhorn are quintessential destinations for mountain climbers. It also has a large number of scenic lakes, including Lake Geneva and Lake Lucerne, Lake Zurich and Lake Constance or Lake Maggiore in Ticino with its Mediterranean flair. The diversity of the landscape is matched only by the diversity of the people in a country with four official languages. Other than German, French and Italian, these also include Rhaeto-Romansh. The political system in Switzerland is characterised by a desire to participate in direct democracy, as demonstrated by its numerous democratic referenda. It spans an area of 41,285 km² and has a population of around eight million. Apart from a slight downturn during the global financial crisis in 2009, the country has maintained a strong economy with steady growth in gross domestic product between 0.85 and 3.85 per cent in the period from 2004 to 2013. One of the main contribu- tors to this is the mechanical and electrical engineering industries with their high share of exports. Festo has had a presence in Switzerland borders five countries: Germany, France, Austria, Liechtenstein and Italy. Switzerland for almost 60 years with its own national company.

Diversity and quality of life Switzerland, officially the Swiss Confederation, was founded in 1291. The first day of August has been recognised as the date of foundation since the 19th century, and is a national holiday in Switzerland. By 1815, a further 23 cantons had joined the original three founding cantons of Uri, Schwyz and Unterwalden. The federal state came into being in 1848. It laid the foundation for the preservation of the cultural and linguistic diversity with a solid constitution. Switzerland has an especially high quality of life, a fact reflected in the cost of living. Studies show that Switzerland Bernina Express: The train journey from the snow-covered Swiss Alps to the palm trees of Northern Italy takes in 55 tunnels, 196 bridges and gradients of up to 70 per cent.

is the third most expensive country in Europe, behind Norway Swiss-French architect, designer and urban planner is consid- and Iceland. Nevertheless, Zurich and Geneva came first and ered one of the pioneers of modern architecture. To name second in an international comparison of the quality of life in just a few. 350 cities. Nation of entrepreneurs Research goes deep Switzerland is also a nation of entrepreneurs. Many small and Inventiveness and entrepreneurship have resulted in decades medium-sized companies are still controlled by their founding of economic prosperity and success in the field of research. For families and their descendents. In 2011 there were 550,000 example, Geneva is home to CERN, the European Organization commercial companies in Switzerland, including over 400,000 in for Nuclear Research, and its Large Hadron Collider particle accel- the service sector and around 90,000 in the industry sector. The erator, the largest in the world at 27 km, located 100 m below latter came to prominence through the watch industry, which ground. Swiss researchers have also played a leading role in cut- played a pivotal role in making Swiss industry synonymous with ting-edge inventions, for example in the area of nanotechnology. high quality, reliability and innovation. An example of this is the scanning tunneling microscope, developed by Swiss scientist Heinrich Rohrer and his German colleague, The largest industrial employers are the mechanical and elec Gerd Binnig. The two men were awarded the Nobel Prize in Physics trical engineering industries. They provide around 330,000 jobs, in 1986. which account for as much as 32.5 per cent of Swiss exports with a value of over 65 billion Swiss francs. More than half of Sport, art and culture these goods are exported to the European Union, while just Switzerland is also the birthplace of many well-known inter under a fifth are exported to Asia, the second-biggest sales region. national sportspeople such as Roger Federer. He has been number The mechanical and electrical engineering industries are high-tech one in the world tennis rankings for over 300 weeks in the last sectors working at the highest technological level, and count ten years. Martina Hingis was the youngest Wimbledon winner in many international leaders among their ranks. Swissmem, the the 20th century. Ski jumper Simon Amman was the first Swiss Swiss association of the mechanical and electrical engineering athlete to win four Olympic gold medals. Pirmin Zurbriggen is industries, expects the growth course of these industries to con- one of the most successful skiers of all time. The works of Swiss tinue. A year-on-year comparison of turnover for the first quarter writers Friedrich Dürrenmatt and Max Frisch are literary classics, of 2014 showed a 9.2% increase. Incoming orders went up by are required reading in schools and have been adapted for the 10.5% in the same period. Exports of machinery grew by 10.6%. stage and film both at home and abroad. Switzerland is home to the consortium behind the yacht Alinghi, the first European boat Six decades of customer proximity to win the world-renowned America’s Cup. Le Corbusier was born For Festo, establishing a presence in a country with a pro-innova- on 6 October 1887 in La Chaux-de-Fonds in Switzerland. The tion reputation like Switzerland was an early step towards a global 2.2014 trends in automation Synergies 28 – 29

European Organization for Nuclear Research (CERN): Meyrin in the canton of Geneva is home to fundamental physical research, in particular into the composition of matter using large particle accelerators. Photos: © Shotshop.com

presence. Festo AG in Dietikon was established in 1956, followed Bruno Huber, by Festo SA in Yverdon in 1981. Festo Microtechnology AG in General Manager of Pieterlen commenced operations in 2002 with its Global Produc- Festo Switzerland tion Centre for proportional valves and pilot controls for valves. From mid-2015, Festo AG will move into a modern new building “Festo helps its customers in Lupfig in the canton of Aargau. The new building concept is geared towards making internal processes more effective and to maintain their more efficient. There will also be greater inter-departmental cooperation in the development of ideas for customer solutions. global competitive edge A generous assembly area will enable a fast and flexible response to customer requests. The building will also provide spacious by delivering highly premises for successful basic and further training of customers innovative solutions.” by Festo Didactic.

Right from the outset, customer-oriented thinking and action in the three main official languages of French, German and Italian were as important to the success of Festo as the high-quality products. A total of 130 employees, around 80% of whom are involved in sales and engineering, cover the entire spectrum of services offered by Festo. This ranges from consulting, sales and system solutions to basic and further training. The investment in the new headquarters in Lupfig lays the foundation for further growth and better support for Swiss industries.

From mid-2015, Festo AG will move into a modern new building in Lupfig in the canton of Aargau. Photo : © Shotshop.com 2.2014 trends in automation Synergies 30 – 31

Faster palletising with the delta robot EXPT As precise as a Swiss watch

The Swiss watch industry protects the legendary reputation of its watches with the quality label “Swiss Made”. This level of quality can only be achieved with fast and accurate automation equipment. This led Amax Automation AG to create a multifunctional palletiser – with robotic and handling systems such as the ready- to-install delta robot EXPT from Festo.

ccording to surveys, consumers Maximum accuracy up in the trays. Two integrated vision sys- from all over the world are will The multifunctional palletiser is very tems and a specially developed turning ing to pay up to 50% more for flexible and fast. With a throughput of 120 system ensure that only correctly oriented A a watch if it carries the quality parts per minute, it can set down up to parts are set down. label “Swiss Made”. This label also means, eleven different small parts in six different according to legislation by the Swiss par- lattice trays or two different JEDEC trays. Hard to distinguish liament, that in terms of production costs The machine can be easily set up for other The actual process of palletising then be- more than 60% of these fine watches must parts via teach-in using the control panel gins. The intelligent vision system SBO..-Q have been manufactured in Switzerland. and the software. The subsequent steps detects the position of the watch parts on in the process require the parts to be set the conveyor belt and signals this to two This is one of the reasons why the Swiss down in the trays to a high degree of accur delta robots EXPT. The delta robot uses a watch industry is carrying out more and acy. The parts must always be right side specially developed vacuum gripper to more of the production steps for watches and watch parts in Switzerland. Another reason is that rising wage costs are making the suppliers in low-wage countries less and less attractive. Coupled with this is the fact that these countries often cannot attain the reproducibility required for sophisticated, hand-made parts. There were also quality losses due to the precision stamped parts being handled as bulk material. This led to more wastage and higher cleaning costs.

By producing in its home market, the Swiss watch industry benefits from faster and shorter transport routes and simpler production control. The palletisers supplied by the Swiss special machine builder Amax ensure accurately sorted and precisely stamped parts for further processing such as electroplating, painting, pad printing and assembly. The high-precision parts are different for each watch model and each brand and are extremely thin, with a thickness in the range of tenths of a millimetre. Maximum precision is required when inserting the watch parts. pick up the parts from the conveyor belt the right robot technology is crucial,” and to set these down, depending on the explains Rolf Wirz, Managing Director application, in either a lattice tray or JEDEC of Amax. tray. This process is not quite as simple as it sounds. As the small parts are so light, Robot with delta kinematics a draught of air can easily change their “It was clear that only a robot with delta position on the belt. What is more, they kinematics could achieve the necessary are so thin that the vacuum gripper can flexibility and speed required to pick up only just distinguish between a part and the small parts in the working area,” Wirz the belt. Reliable production therefore re- continues. “We have had our eyes on the quires a handling system which provides Festo delta robot EXPT for a long time but highly precise and consistent motion didn’t have a suitable project until now. sequences that don’t affect the position The deciding factor was the optimum of the parts on the belt but enable them cost-benefit ratio and the fact that we have to be gripped reliably. “This is why using already been working together successfully with Festo Switzerland for many years,” explains automation expert Wirz.

“Festo was asked to develop the vacuum gripper system on the basis of its experience in pneumatic automation,” says Wirz. This required a great deal of know- how, since it is not easy to generate the right amount of vacuum at the right time for the gripping and ejector pulses. “It was advantageous that Festo could provide both pneumatic and electric automation technology, and that we were able to use the gripper system and the robot to create a discrete development package. This also resulted in a reduction in the number of interfaces and the associated cost,” says Wirz, describing the benefits of working with Festo.

Fine-tuning in the Festo Application Centre However, before the tripod could be put The delta robot uses a specially developed vacuum gripper to pick up the parts to work in the palletiser, a large number from the conveyor belt and set these down in either a lattice tray or JEDEC tray. of validation tests were required. “We therefore asked our colleagues in the Application Centre at headquarters in Germany for support,” says Daniel Minger, Sales Engineer, Industry Cluster Small Parts Handling and Electronics with Festo Switzerland. In order to achieve 120 cycles per minute, two delta robots would be necessary: the first one would pick up as many parts from the conveyor belt as possible, while the second one would pick up the rest. A Festo vision system with an integrated PLC would control both tripods. At least this was the theory.

But in practice the situation was different: with complex applications, screen simula- tions are often not enough. In these cases, tests in the Festo Application Centre are needed. Under real conditions, and using parts supplied by the customer, the cycle times and repetition accuracy of handling The electric axis EGC-HD, known for its rigidity and precision, moves a systems are tested, with movements mechanical gripper horizontally. This lifts several parts at a time, swivels recorded using a high-speed camera from 90° and sets them down in a lattice tray. Festo. Software and hardware can thus be precisely matched. 2.2014 trends in automation Synergies 32 – 33

Rolf Wirz, Managing Director of Amax (right) in discussion with Daniel Minger, Sales Engineer, Industry Cluster Small Parts Handling and Electronics with Festo Switzerland.

Two delta robots EXPT fill the JEDEC trays with a throughput of 120 parts per minute.

In the case of the Amax palletiser, the set- Festo delivered the ready-to-install system such as low moving mass and better down accuracy in the trays was particularly solution, fully assembled and tested and accessibility, while also offering high critical. The laboratory conditions in the with a functional guarantee, directly to system rigidity and thus good repetition Application Centre were therefore ideal as the machine. “We took advantage of the accuracy. a way of analysing the set-down accuracy engineering know-how of the Festo auto- and the subsequent settling times of the mation specialists, which saved a great www.festo.com/catalog/egc delta robots, developing appropriate soft- deal of time throughout the process, www.festo.com/catalog/expt ware algorithms and optimising these in especially during testing and commission- order to obtain the required cycle times. ing,” says Rolf Wirz, underlining the com- prehensive range of services which Festo Engineering know-how saves a lot of time provides. The two delta robots EXPT were supplied by Festo as a complete ready-to-install New ground for delta technology system with the robotic controller CMXR “With our custom automation solutions, and the motor controller CMMP-AS in a we are often working at the limits of tech- suitable control cabinet. These were com- nical knowledge and feasibility. We expect plemented by the intelligent compact vision our partners to be enthusiastic about in- Amax Automation AG system SBOI...-Q which optically detects novation and to be willing to work with us parts on the conveyor belt and signals pos to meet new challenges and open up new Kirchbergstrasse 211 ition data to the robotic controller. Other applications. We found such a partner in 3400 Burgdorf ready-to-install handling systems were Festo,” says Wirz. “The delta robot EXPT Switzerland supplied for tray changes. Electric axes is only one example of many which show www.amax.ch ELGR push the trays forward, and pneu- how Festo is able to provide us with in matic cylinders then lift and clamp them. novative products with which we can suc- Area of business: The electric axis EGC-HD, famous for its ceed in the market,” says Amax’s managing Assembly and production automa- rigidity and precision, moves a mechanical director. Wirz believes that the Festo tripod tion, special engineering and cup gripper horizontally. This gripper lifts sev- with its attractive price/performance ratio handling systems eral parts at a time, swivels 90° and sets makes delta technology viable in areas that them down in a lattice tray. Vertical move- were previously the preserve of SCARA ment is provided by an electric axis EGC. robots. It benefits greatly from advantages Selective soldering of sensors in the protective housing To the point

Distance sensor

Axle load sensor Wheel speed sensor

The production of sensors for the automotive industry requires increasingly sophisticated solutions. A new machine concept developed by IPTE Factory Automation enables fast and reliable soldering of printed circuit boards in the plastic housing. The ready-to-install handling system from Festo used in the concept enables cycle times of less than three seconds, despite a moving mass of more than 60 kg. 2.2014 trends in automation Synergies 34 – 35

The typical car today has on average up to 100 sensors on board. Sensors located outside the car interior, of which a selection can be seen here, need special protection and demand special production methods.

Steering angle sensor

Reliable soldering in the housing Sensors located outside the car’s interior have to withstand harsh environments, Outside temperature sensor with temperatures ranging from below -40 °C to over 100 °C, and they also need to be corrosion and shock resistant. These sensors are enclosed in a tough housing to protect them. However, the inner parts of the sensor cannot be inserted into the housing fully pre-assembled. Certain sol- Camshaft sensor dering work has to be done directly in the housing. Conventional soldering tech- Temperature sensor niques such as wave or reflow soldering are not possible here, since the plastic housing would not be able to withstand the temperatures involved. The only option is the more demanding technique of selective soldering. An essential require- EGR valve sensor ment for this technique is applying the right force at the right angle. The high process quality, repetition accuracy and production speed needed to achieve this calls for fully automated processes.

Development of a new machine concept IPTE developed a new, programmable selective soldering system for connecting the battery and printed circuit board Lane departure warning sensor directly in the protective housing of the car sensors. A complete machine concept Transmission sensor was created for this in cooperation with Festo. The ready-to-install handling sys- Blind spot sensor tem by Festo enables a cycle time of less than three seconds through quick and precise movements along the X-, Y-, Z- and W-axes, despite a moving mass of more than 60 kg. The solder is fed with an accur acy of 0.1 mm and the speed at which the solder is uncoiled from the reel is con- hese days, a car is much more robust sensors will be in greater demand. trolled. Other advantages of the compact than just a means of getting from Innovative production solutions are need- IPTE system include automatic tip calibra- A to B. It can also provide intelli- ed in order for the production process to tion, integrated tip cleaning, operation T gent feedback thanks to all kinds keep up with this level of sophistication. with solder reels, colour detection and an of comfort and safety functions. The typi- Belgian company IPTE Factory Automation option to switch to unleaded soldering. cal car today has on average up to 100 n.v. has met the new challenge head on A reliable suspension system ensures that sensors on board, with the number set with its latest systems. The experts in the soldering tip is applied to the printed to increase further in the future. With factory automation worked with Festo to circuit board with the right force for opti- the number of sensors on the rise but the develop an innovative machine concept for mum thermal contact during soldering. available space staying the same, more the selective soldering of sensors directly An integrated crash sensor protects the compact and in some cases also more in the housing. boards against excessive pressure. A snug fit: IPTE concentrates the entire soldering process All in one: mechanical components, servo motors, controllers, in the smallest of spaces. compressed air preparation and valve terminals from Festo.

Custom-made and complete package tasks such as dispensing. The gantry, which IPTE designed the XYZW-gantry system includes servo motors and controllers of IPTE Factory with four degrees of freedom, with sup- the type CMMP with EtherCat interface, is Automation n.v. port from Festo during the design and adapted by Festo to the specific require- production process. The X-, Y- and Z-axes ments of the different applications and Geleenlaan 5 use standard spindle and toothed belt supplied as a ready-to-install complete 3600 Genk drives of the type EGC and EGC with inte- system. Festo provides an additional level Belgium grated displacement encoder and mini of reliability by guaranteeing the function www.ipte.com slide EGSL. For the rotary unit (W-axis), of the system on delivery. The customer Festo developed a custom-made module. not only receives a ready-to-install hand Area of business: The gantry for flexible and controlled ling system, he can also be sure that it will Development of turnkey automation speed and acceleration (XYZ-axis) and function properly right from the start. solutions for the production, testing a rotary module ERMB were specially and further processing of printed adapted to the system and are used for www.festo.com/catalog/cmmp circuit board assemblies and end lifting and rotating the soldering needle. www.festo.com/catalog/egc products This means that the system can reach www.festo.com/catalog/egsl even difficult to access locations in the sensor housing, and solder at precisely the right angle with the right force. It is capable of high-speed positioning, despite the high moving mass.

Guaranteed more reliability IPTE’s new machine concept can be used anywhere. Apart from soldering applications, it can also be used for many other 2.2014 trends in automation Synergies 36 – 37

Production of car floor coverings with proportional technology Hot from the mould Floor coverings for car interiors are no different to muscles in one respect: they need a good warm up before they can be stretched. Although this needs to be done as quickly as possible, it is also important not to overstress the material. A new production system at Maschinenfabrik Herbert Meyer GmbH achieves this with the help of advanced proportional technology from Festo.

loor coverings for car interiors pendent adjustment of the 24 individual are heated to over 200 degrees, grippers of the main conveyor, as well as stretched, pulled and pressed, all infinitely variable, fast and highly precise F with one goal: obtaining the per- gripper control. fect shape. All that is demanded of them in return is that they keep their good The perfect contour looks as they travel the highways and by- The advanced system for thermoforming ways. However, they have their first brush car carpets produces different blanks in with speed long before they are fitted in a widths from 1.2 m to 2 m and lengths car. The blanks, cut from rolls of material from 1.5 m to 3 m. The blanks are first up to 1.5 km in length, run through the heated to a temperature between 150 °C production systems at Maschinenfabrik and 210 °C, depending on the material, Herbert Meyer in 80-second cycles. One of using a contact heating press. This is their latest developments uses advanced done in just a few seconds by applying a pneumatic proportional technology. The massive 130 kW of heat from above and valve terminal CPX/MPA enables fully inde- below. From there, the blanks are (A)

“Festo’s proportional technology makes our thermoforming systems even faster and gentler on the material.”

Arnd Zander, Head of Design at Maschinenfabrik Herbert Meyer

transferred fully automatically to a feed Moving as gently as possible moulds. All that needs to be adjusted table heated by 90 °C water. A radiant Every gripper on the main conveyor has are the blank dimensions and the tensile heater located directly above this table four degrees of freedom, can be opened forces. A positive side effect of the in- brings the blanks to their final processing and closed individually and approached creased system precision is reduced mate- temperature without any contact. The vertically and horizontally using propor- rial consumption. This is because saving flexible combination of contact and radi- tional valves. This allows the system to even a few square centimetres of floor ant heat enables different blank types to adjust flexibly to different blank sizes. covering can very quickly add up to several be heated in the most suitable way, thus A further cylinder type DGC-K is used on million euros when dealing with the quan- avoiding the problem of unsightly pres- the vertical axis. Its floating position tities used in the automotive industry. sure marks. Once the blank has been uni- ensures perfect adaptation of the gripper formly heated comes the most important to the mould’s contour. The gripper reacts Being slim saves money step: thermoforming. For this step, the flexibly to the tensile forces exerted by Advanced proportional technology from main conveyor picks up the blank using the moulds on the blank during the form- Festo enables the drives of the main con- its 24 grippers – eight per side and four ing process. The grippers can also be veyor to move with different pressures each in the infeed and outfeed area – and pivoted on an axis of rotation in the feed depending on the mould and the blank positions it on the lower mould. The up- direction. This enables them to freely material. The valve terminal CPX/MPA per mould is then dropped, pressing the track the mould contour. The benefits of permits fully independent adjustment of blank into its final shape. After pressing, this are twofold: firstly it ensures very the 24 individual grippers. When the the moulds open again and the main con- gentle forming of the blank material with- product is changed, the settings for the veyor transfers the blank to a belt moved out any weak spots, and secondly it does specific material and mould are changed by a rodless drive DGC-K for cooling and away with the need to reprogram the grip- at the press of a button. This means that further processing. pers for specific products when changing the system is completely modular and 2.2014 trends in automation Synergies 38 – 39

(A) Under pressure: the main conveyor trans- ports the blanks over the lower mould and on to a belt after positive pressing with the upper mould.

(B) Gentle giant: the advanced system for thermoforming car floor coverings produces blanks of different sizes in 80-second cycles.

(C) Small size: the compact design of the valve terminal CPX/MPA saves space and also enables existing systems to be retrofitted with proportional technology quickly and cost-effectively.

(D) Flexible movement: the floating position of the cylinder DGC-K ensures perfect adaptation of the grippers to the mould’s contour. (B)

(C)

(D)

highly flexible. The valve terminal with its development and design time at Maschi slim design also saves a huge amount of nenfabrik Herbert Meyer. Close cooper Maschinenfabrik space compared with individual valves ation with the Festo engineers right from Herbert Meyer GmbH mounted in the traditional way, and en the start further accelerated the project. ables centralised control via PROFIBUS. The end result is an exceptional thermo- Herbert-Meyer-Straße 1 The new modular technology used in the forming system for car floor coverings, 92444 Rötz main conveyor delivers one other benefit: which has gone from development to Germany the flexible gripping system reduces commissioning in just five months. www.meyer-machines.com the costs of the moulds compared with systems where the gripping technology is www.festo.com/catalog/cpx Area of business: part of the mould itself. Development, design and production of systems for thermoforming, Ready in just five months laminating, stamping and coating Thanks to its compact design, the valve terminal CPX/MPA can be used to quickly and cost-effectively retrofit existing systems for proportional technology. If nothing else, the considerable reduction in the cabling required also increases reliability of assembly and commissioning. The added simplicity of design and handling was a major factor in the significantly shorter Photo: © Shotshop.com

Steel industry: automated recycling of waste from blast furnaces Hot recycling coolly calculated

Disposal and fuel costs are an important competitive factor in the steel industry. Industrial waste management company Diproinduca operates a highly productive recycling plant for waste from blast furnaces on the site of the ArcelorMittal steelworks in Mexico. Festo provided a complete solution spanning several levels of the automation pyramid for the plant. 2.2014 trends in automation Synergies 40 – 41

n Lázaro Cárdenas – strategically important as Mexico’s largest seaport – ArcelorMittal, the world’s biggest steel manufacturer, produces steel slabs Automated raw material hopper: the weighing system measures I out the required quantity of waste materials for the specific batch. using the DRI-EAF method. This production method provides a uniform surface texture and improves the quality of the 3.8 million tonnes of slabs produced each year. An important ingredient in slab production is coke. It provides the required heat in the blast furnace during the production pro- Water, cement and selected chemical addi- Successful on all levels cess, but it must be recycled afterwards. tives to bind the individual substances are “The Mexican engineers put all of their added to the waste. expertise in process automation, including Slab production all the different levels of the automation A slab is an ingot of cast steel, aluminium In Lázaro Cárdenas, precise metering of pyramid, into developing the complete or copper whose width and length are the individual ingredients is performed solution,” explains Vargas, who supervised many times its thickness. Slabs are pro- by a Festo automation solution. “This is a the project from the start from Festo duced by means of casting and rolling, truly complete solution, where everything headquarters, offering expert assistance and are the primary material for sheets from development of the technical concept when requested. At the sensor/actuator and strips. The slab size is adapted to the through to delivery of the control technol- level, all the applicable liquid media flows dimensions of the required product. ogy was handled by the system solutions in the plant are controlled by various auto- engineers from Festo Mexico,” explains mated process valves such as the quarter One of the by-products of slab production Alexander Vargas, Head of Process Auto- turn actuator DAPS for opening and closing is combustion residues from the blast mation Product Management at Festo. the butterfly valves. furnace such as coke breeze and furnace sludge. These can be processed and sub- Perfectly mixed and then shaped At the field level, three distributed CPX sequently returned to the combustion The integrated automation system features terminals connected via PROFIBUS DP col- process. That is why the steelworks site is a weighing system equipped with load lect the signals from the field instruments. also home to a recycling plant, operated by cells on the conveyors and on the cement Well-protected in stainless steel control Diproinduca, where this waste is recycled. hopper developed especially for the appli- cabinets delivered ready to install, they cation. Other components include can even withstand the tropical climate of Secret to successful recycling pre-mixer and mixer technology complete the Mexican Pacific Coast when installed An international company headquartered with electric motors as well as the meter- outdoors. in Canada, Diproinduca has made a name ing technology for water and chemical for itself over the past twenty years in the additives together with the necessary A CECX-X-C1 used as a PLC at the control recycling of waste materials from industrial pneumatic process valves. The weighing level acts as the “brain” of the plant. A processes in mining and steel manufactur- system measures out the exact quantity SCADA system visualises the various areas ing. The company has recycling plants in of waste materials for the specific batch and equipment in the plant for the oper Canada, Mexico, Venezuela and Trinidad. at the raw material hopper. These are then ator. Communication with the PLC and the The specialists in recycling industrial transported to a pre-mixer, where they are SCADA system takes place via an Ethernet waste transform the waste from the steel homogenised. Next, water, cement and network. The PLC program together with manufacturing process into briquettes chemical additives are added in the mixer. the SCADA system monitors the entire that can be reused in the steelwork’s blast Once the mixture has the appropriate manufacturing process, which can either furnace. A crucial element in the produc- composition, the mixer is opened and the be fully automatically or manually con- tion of the briquettes is the accurate entire batch is transported to the briquette trolled. The PLC master in the form of the mixing ratio for the individual ingredients. machine, which shapes the briquettes. controller CECX-X-C1 processes the (A)

(A) Perfect climate: the stainless steel control cabinets protect the CPX terminals against the tropical climate of the Mexican coast.

(B) The brain of the plant: the CECX...-PLC at the control level.

(C) The quarter turn actuator DAPS opens and closes the butterfly valves for the liquid media flows at the sensor/ (B) (C) actuator level.

“Process automation solutions incorporating several levels of the Diproinduca Canada Limited automation pyramid give 9140 Leslie Street, Suite 404 our customers peace of Richmond Hill, ON, L4B 0A9 Canada mind – worldwide.” www.diproinduca.com Alexander Vargas, Head of Product Management Process Automation, Festo Area of business: Plant construction for industrial recycling information and passes it on to the SCADA recycling of coke, which is valuable as a software. Four screen views show the fuel, and in the process helps the environ- ArcelorMittal general layout of the plant, parameters, ment and improves the productivity of events and reports relating to the plant. slab production. Berkeley Square House, 7th Floor Berkeley Square Lasting improvement in productivity www.festo.com/catalog/cecx London W1J 6DA “The Mexican system solutions engineers www.festo.com/catalog/daps United Kingdom employed all their automation knowledge www.arcelormittal.com throughout every step of this project, from technical development through delivery Area of business: of the control technology to after sales World’s biggest steel manufacturer service,” emphasises automation expert with steelworks and iron ore mines Vargas. The integration of automation com- around the world ponents from all four levels of the automation pyramid results in highly efficient 2.2014 trends in automation Synergies/Festo worldwide 42 – 43

High-speed handling: the tripod EXPT. A gripper HGPL mounted on the servo rotary unit ERMH picks up the individual swing tops.

Pop! High-speed positioning of swing tops

Their retro style is trendy and they are gaining in popularity worldwide because they are resealable. Brazil alone consumes up to 15 million bottles with swing tops each year. AMS Getränketechnik GmbH specialises in the development of sealing machines for swing tops. It is setting standards in speed and productivity with its latest, fully automated sorting system. Thanks to a customised complete solution consisting of a camera, high-speed handling unit and cylinders from Festo, the system can achieve throughput rates of up to 2,500 swing tops an hour.

The high-speed camera SBOC-Q-R2B detects the position of the individual swing tops on the conveyor in a fraction of a second and forwards their coordinates to the robotic controller CMXR-C2. Together with the servo controllers CMMP, it controls the high-speed movements of the tripod EXPT. The gripper HGPL mounted on the tripod picks up the swing top and places it on a transfer unit. There the swing top is stopped using cylinders ADVU, detected by a sensor and if necessary rotated through 180 degrees. The swing tops are then transported in the correct position as far as the assembling unit.

The tripod-based system solution from Festo is highly dynamic thanks to its light- Practical and trendy: swing tops weight design, requires little space and saves energy. The handling unit together are gaining in popularity worldwide. with the camera, lighting and motion controller was configured specifically for this application and delivered to the machine ready to install.

www.ams-getraenketechnik.at Germany/International Communication at all levels OPC Day Europe hosted by Festo

From 14 to 15 May 2014, Festo hosted the OPC Day Europe 2014 at its Esslingen location. 190 participants from 16 countries learned about the latest developments in OPC-UA technology and took advantage of the opportunity for a professional exchange of ideas. Exhibitions and presentations by experts provided participants with the latest, up-to-date knowledge. Dr. Michael Hoffmeister, Festo Product and Application Trends, explained how OPC-UA has the potential to bring about a sus- tained improvement in the integration of machines and production systems. Manufacturers like Festo will be able to use OPC-UA to come up with new offerings for their customers. This was also emphasised by his colleague Steffen Schmidt, Head of Control Technology Design and Equipment Engineering for Electrics. Once a number of systems have been equipped with OPC-UA technology, the next logical step will be to standardise the content of the transmitted data such as time stamps, machine states, electricity consumption values and process data.

OPC-UA is a software interface standard designed to facilitate the exchange of data between automation systems and with all systems within a company. It will run on any operating system, regardless of manufacturer or platform, and can be integrated into existing systems. The OPC Foundation is a non-profit organisation with more than 450 members worldwide.

www.opcfoundation.org

“IT meets Automation”: this was the motto for this year's OPC Day Europe, which took Photo : © OPC Foundation place at Festo in Esslingen.

Colombia Anniversary 25 years of Festo Colombia

The national Festo company in Colombia celebrated its 25th anniversary in March this year, throwing a huge party to mark the occasion. This was matched by the opening ceremony for the World Skills Americas, which took place in Bogotá, where visitors and participants were able to watch the Festo AirPenguin fly.

The first production plant opened in 1989 in the capital city of Bogotá in the heart of Colombia. This was followed by more and more sales offices. Today, a total of 67 people are employed in Bogotá and the eight sales offices.

A successful team: the employees in Bogotá celebrate their anniversary. 2.2014 trends in automation Festo worldwide 44 – 45

Switzerland About this

The DRRD overcomes the moment of magazine inertia of the massive substructure with high dynamic response and force thanks to its sturdy bearing. trends in automation 2.2014 December 2014

Publisher Festo AG & Co. KG Ruiter Strasse 82 D-73734 Esslingen, Germany Tel. ++49 (0) 711 347 11 11 Fax ++49 (0) 711 347 20 71 [email protected]

Project management Silke Gartenmeier, Customer Magazine Tel. ++49 (0) 711 347 3902 [email protected]

Responsible for content Guido Purper, Head of Market Communication It ’s all about inertia [email protected] Reliable machining of con-rods Ralf Sohn, Head of Direct Marketing [email protected]

The components used for high-speed grinding must be very powerful Please note and durable. Swiss company Linear Abrasive SA therefore uses the All terms such as customer, user, semi-rotary drive with piston DRRD from Festo for its automated high- specialist or technical consultant speed grinding machines. The machines work on various connecting refer to both men and women. rods from three sides, with the infeed and output of the workpieces fully automated. Copyright 2014 Festo AG & Co. KG In the past, the ingress of cutting and grinding oil regularly resulted All rights reserved. in premature failure of the drives. Using the DRRD made the process more stable. After more than six months of continuous use in three- All images, graphics and texts are shift operation, the semi-rotary drive with piston from Festo shows no protected by copyright law or other signs of fatigue despite being exposed to aggressive oils. The innova- intellectual property rights. Any tive bearing concept of the DRRD makes it sturdy and stable, allowing reproduction, modification or use in it to handle the large moments of inertia without any problem. other print or electronic publications is prohibited without the express As well as high repetition accuracy, which didn’t require readjustment consent of Festo AG & Co. KG. even after assembly, the DRRD is also distinguished by its speed. It effortlessly surpasses the required 5.8 s cycle time for machining each connecting rod. www.festo.com/facebook www.linear.ch www.festo.com/twitter

www.festo.com/youtube

www.festo.com/linkedin 2.2014 trends in automation Soft stop 46

Have you tweeted yet today, Nicole?

Yes, I have. Live from the international press conference currently taking place at Festo. I’ve been working in the area of social media at Festo for the past two years and am responsible for the Twitter feed. The posts that I put up every day are called “tweets”, which is of course based on the name “Twitter”.

Over 240 million people and businesses worldwide use Twitter. We have posted more than 1,300 tweets since we joined Twitter in 2012. Tweets must be no more than 140 characters long, which means that I need to get to the point quickly.

Twitter is an ideal platform for Festo to announce and report straight away on events or to provide information about new products or Bionics and Future Concepts projects. You can also add links to photos and videos to tweets. This is a quick and easy way for me to provide journalists with important information. It is also an excellent means of networking with partners, customers and suppliers. We constantly supply our community of followers with news about what is happening at our partners or vice versa. That is how we feed off and build on each other’s tweets and ideas. This spontaneous, often quite personal method of sharing information also brings people together online.

Twitter is just one of many social media channels used by Festo. I often work together with my colleagues who look after Facebook, YouTube, Xing and Linkedin when working on specific campaigns. We discuss our campaign strategies in a weekly editorial meeting. I enjoy working in a team when developing and implementing ideas. Together we can open many doors for a specific topic. Check out our Twitter page and see for yourself! Setting your sights high? Want to achieve more? We show you new ways forward.

Waves from stone

Located on the slopes of the Coyote Buttes near the northern border of Arizona in the United States of America, the fascinating sandstone rock formation known as “The Wave” reveals the natural wonders that can be formed by the wind and weather over millions of years. Once lakeland, then desert dunes, then seabed and finally petrified into desert sandstone, the rock monument looks back on an eventful history. This is evident in the myriad of red, orange and light brown layers and curves. The different colours are caused by variations in the minerals contained in the stone. Incidentally, anyone hoping to experience “The Wave” should give themselves plenty of time and ideally apply online in advance. This is because access to the fragile sandstone formation is limited to 20 visitors a day.

Festo AG & Co. KG

P.O. Box D-73726 Esslingen Phone +49 711 347-0 Fax +49 711 347-2144 [email protected] www.festo.com