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trends
in automation
The Festo customer magazine 1.2012
Cover story
Powering change
Ideas for greater energy effi ciency
Inspiration
Free from resources
Interview with Prof. Dr.-Ing. Egon Müller,
Chemnitz University of Technology
Compass
Environmental fl ight
Solar energy boost, cheaper
batteries on the way
Synergies
Hungary drives ahead
The outlook is good for companies
in the automotive industry

On course for
energy effi ciency
Set your course for maximised
savings potential. On board you’ll
fi nd products and solutions,
intelligent confi guration, tailored
services as well as training
and consulting.
www.festo.com

Rich Huss, President and CEO Festo USA
Time to act
Energy is something we use every minute of every day.
Sometimes we don't give it much thought; other times it may
preoccupy us, whether we are responsible for ensuring its
supply, use it to provide food, to travel places or wonder how to
pay for it. Another reason for concern may be related to global
warming, the environment or health issues associated with
obtaining and using fuel. In short, we are affected by energy,
on whatever level and in whatever big or small way.
Energy usage is also a big concern for factories. For many
energy consumption is the largest contributing factor to
increasing production costs and rising faster than labour costs.
How do we use fuel more effi ciently, how can we prevent losses
in supply systems, what can we do to use less and how can
we make or convert energy-ineffi cient equipment into energyeffi
cient ones? In this issue of trends in automation we focus
on how factories can change the way they manage their energy
requirements to save money and resources.
In an interview with Dr. Mueller we read about his thoughts
on cutting consumption in very interesting ways. These include
considering energy usage right at the design stage, using
software, regulating power requirements to match the fl ux of
slower and busier work times. "Smart" systems can also
help to make better use of natural lighting, air and water by
monitoring and adjusting usage carefully. We also explore
some rather inventive uses of solar power and batteries that
could prove interesting for the future.
The modern world is inextricably linked to energy. As world
population grows and standards of living improve, the topic
of how we source and use energy becomes signifi cant and
could have far-reaching consequences. Not only do we need
to develop clean renewable ways of obtaining energy, we also
need to change our behaviour and fi nd new ways of using it
more effi ciently. We have the tools and the time to act is now.
In this edition of trends in automation you will fi nd plenty of
food for thought and action!
Rich Huss

Photo: GeoEye
Cover story Bird’s eye view of the Gemasolar
solar power plant in Spain: The plant is revolutionising
electricity generation using solar energy
(see back page). This groundbreaking technology
symbolises the dawning of a new era in energy
effi ciency – and is at the heart of several initiatives
in industry and automation technology.
In this issue we look at the objectives, applications
and results of these effi ciency measures.
trends in automation
1.2012
Editorial 3
Panorama 6
Festo worldwide 47
Competition/About this magazine 53
Soft Stop 54
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8
“The best energy effi ciency measure
is, quite simply, to save energy.”
Inspiration
No race for resources
Energy-effi cient production concepts are
preparing companies for tomorrow’s
competition. Prof. Dr.-Ing. Egon Müller
talks about savings potential of up to
50% over the next decade. 8
14
The solar plane “Solar Impulse”
is set to circumnavigate the globe
in two years’ time – with no fuel
and no harmful emissions.
Compass
Batteries move up a gear
Electric cars are becoming more popular,
but expensive batteries take the fun
out of driving. The automation industry
is therefore working on concepts for
low-cost battery production. 12
Sun-fuelled wings
Fuel prices have exploded and rising
costs are having an impact on air
travel. Environmentally-friendly forms
of propulsion are opening up new
perspectives for altitude fl ight with
renewable energy. 14

16
Impulse
Twenty per cent of a car’s
entire energy consumption
over its life cycle comes from
the production process.
Cover story
Powering change
The will is there, but the way is
unclear. When it comes to actual
implementation of energy effi ciency
measures, plant manufacturers
and operators aren’t sure where to
start. Germany is leading the way
with initiatives that are driving
more effi cient use of the earth’s
limited resources. 16
Further related articles
No race for resources 8
Batteries move up a gear 12
Sun-fuelled wings 14
Sunny side up 34
Every gram counts 42
Keeping a clean slate 44
Skin from the factory
Touch, heat, breathing – the skin is our
most important organ. Four Fraunhofer
Institutes have developed a fully automated
process for producing skin equivalents
for medical applications. 22
Telescopic handling in a vacuum
The price war in the solar market shows
no sign Article of slowing cancelled down. at short The notice. sliding fork
is a clean room (data robot not available) with infi nitely variable
telescopic handling that has simplifi
ed processes and reduced costs. 26
34
For Oerlikon Solar, the outlook for thin-fi lm silicon technology
in photovoltaic modules is good.
Synergies
A country on the move
Hungary is a country deeply rooted in
European history. Despite the negative
political headlines, the business outlook
remains promising. 28
Tooth by tooth
Modern transmissions must be able
to withstand extreme loads. Ready-toinstall
pneumatics are making the
production of bevel gears faster and
safer. 32
Sunny side up
Oerlikon Solar is overcoming the
upheaval in the sector with quality and
innovation. Automation technology from
Festo guarantees perfect handling of
large sheets of glass. 34
Terminal intelligence
The valve terminal CPX from Festo works
without an extra controller and performs
the tasks of a PLC for the inspection of
turned parts. 38
1.2012 trends in automation
Contents 4 – 5
Tea time in Buenos Aires
Did you know? Argentina is the
eleventh largest tea producer in the
world. The Festo PrePack Service
ensures fast tea bag production. 40
Every gram counts
Tonnes of waste are produced in tin
plate production. Huber Packaging
Group and Festo Didactic have signifi -
cantly improved material effi ciency
thanks to material fl ow analysis. 42
Keeping a clean slate
The costs for wastewater disposal are
a signifi cant burden for local authorities.
Pneumatic automation has increased
energy efficiency at the wastewater
treatment plant in Sindelfi ngen. 44

Energy excellence
Standing 508 metres tall, the world’s
tallest offi ce building is truly a sight
to behold. In July 2011, the Taipei Financial
Center, Taipei 101, also became the
world’s tallest green building, achieving
Leadership in Energy and Environmental
Design (LEED) Platinum Certification
under “Existing Buildings” for outstanding
energy effi ciency measures.
Over a 20-month period, the offi ce
building underwent a series of optimisation
measures and energy consumption
was signifi cantly reduced. With 101
fl oors above ground and fi ve below
ground level, this “green building” is
now achieving annual energy savings of
10 per cent. Current consumption was
reduced by 4.8 million kilowatt hours,
water consumption was reduced by
28,000 tonnes and there are now 1,261
fewer tonnes of waste produced than
there were before the effi ciency measures
were introduced. Taipei 101’s
energy consumption is now up to 30
per cent lower than that of an average
building, resulting in annual savings
of around 700,000 US dollars.

Phot Pho hot ho o: D DDanie
anie nie i lM l MM.
M M. MM.
Shi Shih

Interview
No race
for resources
Egon Müller is one of the leading experts in innovative production structures and factory
concepts. The Professor of Factory Planning and Factory Management at the Chemnitz
University of Technology believes that savings potential of up to 50% can be realised over
the next decade through environmental production factors. In this interview he explains
the importance of staying out of the race for energy resources.
trends in automation: Professor Müller, you see a savings
potential of between 30% and 50% of the total consumption
of material and energy resources. Is this fi gure not too high?
Prof. Egon Müller: To back up this statement, we need to fi rst
remind ourselves of a well-known principle of physics. Energy
can be transferred between systems, but cannot be created or
destroyed. It can only be converted from one form of energy
into another. Furthermore, energy conversion between different
forms of energy and energy levels must take place in one
direction and cannot be reversed. If you look at a factory as a
“total energy consumption system”, in which a wide variety
of energy conversion processes take place, the potential you
referred to can be achieved systematically. When it comes to
About the person
Prof. Dr.-Ing. Egon Müller
Egon Müller heads the Department of Factory Planning
and Factory Management at the Chemnitz University of
Technology. He and his team of 30 staff members work
on the development of future production structures and
new factory concepts in mechanical and plant engineering
and for the automotive industry and its suppliers.
These include fl exible and versatile factories as well
as non-hierarchical regional production networks.
The department offers extensive expertise in the fi eld
of computer-based factory planning, modelling and
simulation as well as energy-effi cient factory planning.
www.tu-chemnitz.de/mb/fabrplan/englisch
the consumption of material resources, the use of new materials
and their cycles – in other words their reuse – is of major
importance along with new technological methods. For factory
planning and operation, this means generating new concepts
that, for example, bring together mechanical engineering and
process engineering in order to create these cycles.
trends in automation: In your book "Energieeffiziente Fabriken
planen und betreiben" (Planning and Operating Energy-efficient
Factories), you show how the potential for energy savings
can be exploited systematically. What are the key points here?
Müller: I could refer to the necessary holistic approach,
but that wouldn’t be any more useful than merely suggesting
a systematic approach. A factory is fi rst and foremost a group
of people who use the available machines and equipment
to create products from materials. These processes are also
planned by people and are therefore to be anticipated. We
must develop appropriate competencies and train the people
in the factory to realise this potential systematically using the
methods and tools provided. Along with this aspect, a holistic
view of the supply, conversion, transfer, and use of energy
as well as its optimisation in the factory play a key role.
trends in automation: To what extent can energy effi ciency
be made a strategic competitive factor for a company?
Müller: Continuously rising energy prices and the associated
direct cost effect will be a major issue for companies in the
future. Issues surrounding the availability of and access to
energy resources will also become a strategic success factor
for companies. Looking at the forecasts for future energy
demand by energy source and economic area for the period up
to 2030, it is already clear that companies in a position to opt
out of this race for energy resources will have a major competitive
advantage. It is also clear that the best energy effi ciency
measure is, quite simply, to save energy.

1.2012 trends in automation
Inspiration 8 – 9

“The best energy effi ciency measure
is to save energy.”
Egon Müller, Chemnitz University of Technology
trends in automation: To what extent can a factory plan for
and implement energy self-suffi ciency?
Müller: Using a holistic approach, it is feasible for the planning
of new factories and relevant for the planning and realisation
of factory areas or extensions. The energy-effi cient plant extension
project in St. Ingbert/Rohrbach, for which Festo won the
Energy Effi ciency Award 2008, is a good example of the type of
development that has taken place in recent years. Since then,
many technologies and possibilities have undergone further
development and are now available for integration in suitable
planning concepts. This also includes potential that can be realised
through the use of renewable energy.
trends in automation: What sector do you see as the leader
in energy effi ciency and why?
Müller: Based on my own experiences, automotive manufacturers
and their major suppliers are leading the way. The huge
rise in energy costs is by no means the only incentive. Marketing
is another major consideration, as it focuses not only on
the environmentally-friendly and resource-effi cient nature of
the products themselves, but also on their manufacture and,
consequently, the factories in which they are produced. It is
important that the entire product life cycle be taken into account,
particularly the manufacture and use phases.
trends in automation: Is the automotive industry a good
example for other sectors?
Müller: Basically, yes. In some cases the automotive industry
is more than just taking the lead role; the major signifi cance of
the industry means it has a direct infl uence on other sectors.
This applies to mechanical and plant engineering, control and
automation technology as well as electrical engineering and
drive technology.
trends in automation: What energy-effi cient projects is your
institute currently involved in and what conclusions have you
drawn from your research?
Müller: In the cluster of excellence “Energy-effi cient Product
and Process Innovations in Production Engineering” (eniPROD),
we are working on a “Logistics and Factory Planning” subproject,
which aims to develop methods for factory planning
with a focus on energy effi ciency and software systems to support
the planning process. This research has already produced
a conceptual framework for a holistic energy effi ciency model.
With this model, knowledge can be created, prepared and
made available in a systematic manner on the one hand, and
competence development and training can be implemented on
the other. In another research project with a stronger technological
focus, we are working on the measurement and recording
of energy consumption in complex factory structures. Initial
fi ndings in relation to measuring systems and their benefi ts
have already been applied to practical solutions.
trends in automation: What does a busy man such as yourself
like to do in his spare time?
Müller: When I have the time, I like to work on my 1976 vintage
car in my garage. During the summer, when the weather is
good, I enjoy going for drives or taking part in vintage rallies.
I also like to read books about automotive engineering. Issues
such as the historical development of factories create a link
between my work and my spare time.

1.2012 trends in automation
Inspiration 10 – 11

Automation optimises e-mobility
Batteries move up a gear
There are currently 2,300 electric cars on Germany’s roads. This fi gure is set to reach
one million by 2020. The industry is currently dealing with the crucial question of how
to make the leap to low-cost, high-volume battery production. The automation industry
has some answers.
In order to make electromobility more
accessible for the broader market,
the cost of batteries used in electric
vehicles needs to come down. They
are still one of the biggest cost drivers
in electromobility. The problem is that
battery production is still predominantly
a manual process with a large number of
individual steps.
Competence cuts costs
“Between 30 and 40 per cent of the value
added in purely electric vehicles is due to
the battery,” says Michael Karcher, Head
of the industry segment Electronics and
Solar at Festo. “If we are to eventually
have effi cient mass production, we
need to set up technologically fl exible
electrode and cell production for the
manufacture of battery prototypes with
a high degree of standardisation and
automation. This will allow production
costs to be reduced and ensure the quality
of the results.” This demands effective
and reliable automation competence at
all levels. Mechatronic solutions, which
integrate expertise from different areas
of process and factory automation and
transfer it to the latest technologies in
battery production, look promising.
Innovation with mechatronics
“Our customers from the automation industry
have a good understanding of the
automotive sector when it comes to their
current fi eld of activities. However, when
it comes to the optimum conditions for
battery production engineering, they
are more or less starting from scratch,”
says Karcher. In order to fundamentally
Ph Phot hott o o: D
D aiml iiml er A AAG
redefi ne processes you need innovators
like mechatronics engineers and a
willingness on the part of companies to
innovate. This is exactly what happened
in the case of automation system supplier
and plant manufacturer ads-tec. The
company, which is based near Stuttgart,
develops automated production systems
for high-performance lithium-ion energy
storage devices.
Protection of sensitive cells
For the FUEL project initiated by the
Federal Ministry of Education and Research
(BMBF), ads-tec fi rst developed
a production method for automating the
bonding, feeding and handling of cells
on a laboratory scale. According to Head
of Automation Dr. Peter Korff, the aim
was to provide production facilities that
would allow the fast, low-cost production
of cells and battery systems. “Lithiumion
cells are sensitive. We must make
sure that we maintain cell quality during
the process and take care not to damage
or contaminate them, particularly
during handling. Because we have to
create a whole new set of conditions for
the accumulator production technology,
we are open to new solutions and ideas.
For handling the lithium-ion cells, we
worked with Festo to devise a new frontend
solution with an air bearing, which
was previously only used for the solar or
electrical industry,” explains Dr. Korff.
Objects slide evenly
Both the solar and electrical industries
use the air bearing ATBT from Festo for
the contactless transport of sheets of
glass and delicate fi lm. A layer of air on
the fi ne surface allows objects to glide
evenly. For ads-tec, the engineers from
Festo used the so-called reversal effect,
with an extensive vacuum for the handling
of battery packs in the production
system. “With conventional solutions we
could only grip the cells in certain places
using vacuum generators, which meant
that reliable holding of the cell could not
be guaranteed,” says Michael Karcher.
Because the air bearing grips the entire
surface, the bonding process is no longer
prone to failure caused by production.

People want e-mobility
According to a study on electromobility
by TÜV Rheinland, the level of acceptance
for electric cars is growing worldwide.
This applies in particular to the
emerging markets of China and India,
where mobility is also rising. 92% of
people in India and 88% in China are
willing to consider an electric car if buying
a new car within the next fi ve years.
In Germany and the USA, the fi gure is
lower at 57%, with the fi gures for the
UK and France being about the same.
ads-tec production system:
Automated bonding, feeding and
handling of lithium-ion energy
storage devices.
Air bearing ATBT in the bonding
process: Festo also delivers air
supply and air/vacuum preparation
with corresponding valve and
control intelligence depending on
the degree of automation.
1.2012 trends in automation
Compass 12 – 13
Michael Karcher,
Head of industry
segment DE
Electronics and
Solar, Festo
One more question
trends in automation: Solutions with
similar requirements to those of battery
construction already exist in the
manufacture of carbon composites. Is
it possible to transfer this technology?
Michael Karcher: Absolutely, yes.
Lightweight design plays a crucial role
in the production of electric vehicles.
It is a good starting point for our
engineers, who are familiar with the
requirements for handling fl exible
materials in the food and textile
industries. In those environments it
is important to grip bulky materials
carefully, to observe the fi bre orientation
during handling and placement
and to avoid unnecessary stress on
the structures. This expertise can be
applied very effectively to the automation
of battery production.

Energy-effi cient fl ight
Sun-fuelled
wings
Increasing passenger volumes in international air travel
have intensifi ed the search for energy-effi cient drive forms.
Many of the current developments share the same ambitious
goal – to fl y using renewable energy.
Phot P o: SSolar
olar Imp Impulse ulse/Jea /Jean n Re Revill villard ard
The history of fl ight has been
shaped by pioneers such as Otto
Lilienthal, the Glider King, Louis
Blériot, the fi rst man to fl y across
the English Channel, and Amelia Earhart,
the first woman to fly solo across the
Atlantic. Today’s pioneers are working
hard to develop a whole new generation
of energy-effi cient aircraft.
Lightweight aircraft sets milestones
Two of these pioneers are balloonist and
adventurer Bertrand Piccard and his
partner André Borschberg. Their aim is
to circumnavigate the globe in 2014 in
their solar plane “Solar Impulse”, using
only solar energy. The fi rst crucial steps
in the pioneers’ ambitious plan have

Energy effi ciency in its highest
form: With around 12,000 solar
cells, the Solar Impulse HB-SIA
is the fi rst solar aircraft to fl y
day and night without fuel.
already been successfully completed.
In July 2010, Solar Impulse made the
fi rst night fl ight in the history of solar
aviation, lasting 26 hours. In May 2011,
the solar-powered lightweight aircraft
proved its ability for short-haul fl ights
with a 630-kilometre trip from Payerne in
Switzerland to Brussels. For Piccard,
who in 1999 made the fi rst non-stop
round-the-world balloon fl ight, this
represents a major milestone in aviation
history. It was this world record trip that
inspired him to develop Solar Impulse.
After around 20 days of continuous fl ying,
the balloon’s fuel supply almost ran out
shortly before reaching its destination.
With the sun as an inexhaustible energy
source, this should never happen again.
Energy from 12,000 solar cells
For the round-the-world trip in 2014,
Piccard and Borschberg are building a
new machine specially adapted to longhaul
conditions. It will even exceed the
already impressive values achieved
by the current prototype HB-SIA.
The HB-SIA is a cantilever high-wing
aircraft with four electric motors, which
power the twin-bladed propellers at
a speed of 200 to 400 rpm. Current is
supplied by around 12,000 solar cells.
With a wingspan of 64 metres, the Solar
Impulse is almost as wide as an Airbus
A340. Whereas the jet has an average
take-off weight of 300 tonnes, the solar
aircraft weighs 1,600 kilograms at takeoff,
which is not much heavier than an
average-sized car. Solar Impulse reaches
a maximum altitude of 8,500 metres at
an average fl ying speed of 70 kilometres
per hour. Any comfort must take second
place to the required drive energy,
however. Passengers must wear warm
clothing to protect themselves against
the cold.
www.solarimpulse.com
A brave vision
According to aircraft manufacturer EADS, the passenger aircraft of
the future will be battery-powered. EADS presented the “VoltAir”
fully electric drive concept at the Paris Air Show Le Bourget 2011.
This research project brings the vision of a zero-emissions, ultralight
aircraft a step closer to becoming a reality. This could feasibly
happen within the next 20 years. VoltAir passengers will benefi t
from the extremely low noise levels of the engines.
Hybrid takes off
Siemens, Diamond Aircraft and EADS have developed the world’s
fi rst aircraft with serial hybrid electric drive. The new drive train
was tested in the “DA36 E-Star” motor glider. The E-Star uses a serial
hybrid electric drive, which until now was only found in cars. A 70 kW
electric motor from Siemens powers the propeller. The required
electricity is supplied by a small engine with a generator. Fuel
consumption is very low since the combustion engine always runs
with a constant low output of 30 kW. A battery system provides the
increased power required during take-off and climb.
Naturally effi cient
Phot P o o: E EEADS
E ADS
Photo: Siemens
1.2012 trends in automation
Compass 14 – 15
A unique undertaking in distance records starts every year in western
Alaska, when the world’s best long-distance fl ier prepares for
a very special non-stop journey to the other side of the world.
The most resilient bar-tailed godwits can fl y the 11,500 kilometres
from America’s far north to New Zealand in just 10 days without
stopping. This amazing feat is possible thanks to the perfect
combination of bodyweight, aerodynamics and wingspan as well
as an intelligent choice of route.

Effi ciency initiatives
Powering change
When it comes to actual implementation of energy
effi ciency measures, many plant manufacturers and
operators aren’t sure where to start. Numerous
effi ciency initiatives have been introduced by German
industry to lead the way. They can power change by
helping companies to drive international efforts for
more careful use of the planet’s limited resources.

1.2012 trends in automation
Impulse 16 – 17
Savings potential in
automotive engineering:
Production accounts for
20% of the energy consumed
by a vehicle over
its entire life cycle.

There are no indicators to suggest
a reversal of the trend of rising
energy prices in the medium term.
This is partly due to the huge
growth in demand for energy from emerging
BRIC countries and the fi nite supply
of fossil fuels. The uncertainty as
to whether fossil fuels can ever be fully
replaced by renewable energy sources
is also a contributing factor. The fi gures
speak for themselves. In the past decade,
industrial energy prices have risen
Energy effi ciency@Festo
Every industrial application has its own specifi c requirements
when it comes to technical and fi nancial criteria.
Examples include speed, load capacity, precision,
effi ciency or robustness as well as acquisition costs
(price, commissioning, installation) and operating costs
(maintenance, service life, energy costs). The importance
of energy effi ciency can vary depending on the application.
“The task at hand must be clearly defi ned before
deciding whether to choose electric or pneumatic drive
technology – or a mixture of both,” explains Festo energy
effi ciency expert Dr. Axel-Andreas Gomeringer.
Even a small number of measures can have a positive
effect on energy effi ciency. These include Energy Saving
Services, training courses, air-saving circuits, weight
reduction and energy recovery as well as the correct sizing
of drives or the reduction of leakage, pressure levels,
tube volumes or friction. Customers specify the application
and experts from Festo then check and fi nd the most
effi cient alternative.
The “Energy Effi ciency@Festo” brochure provides a
useful introduction to this topic. Tools for the optimum
confi guration of drives and the new energy effi ciency calculator
are available on the Internet. These allow users to
calculate the costs for compressed air production using
different variables and to determine the savings potential
for compressed air consumption.
www.festo.com/energyeffi ciency
is 1.12-01
Energieeffi zienz@Festo
www.festo.com/trends
by approx. 12.5% year on year. These
costs are therefore rising between two
and four times faster than personnel
costs, which are another key strategic
cost for businesses.
Exploding energy prices
It is surprising that so many companies
do not have a detailed breakdown of
their energy costs. Although most are
aware of the energy costs per year,
energy consumption is rarely documented
Leakage detection with ultrasound detector:
With Festo Energy Saving Services, companies
have energy consumption under control.
with a view to evaluating cost-cutting
measures relative to total expenditure.
It is also common practice to add energy
costs to fi xed costs or variable production
costs rather than to report them individually.
Initiatives such as Green Carbody,
Blue Competence, Energy Efficiency
in Pneumatic and Electric Production
Systems (EnEffAH), the German Electrical
and Electronic Manufacturers’ Association
(ZVEI) and the Society for Measurement
and Automatic Control (VDI/

VDE GMA) as well as the Energy Saving
Services from Festo that are used by
many companies are helping to ensure
that there is more clarity with respect to
energy costs and are thus paving the
way for greater energy effi ciency.
Green Carbody
The production process alone accounts
for 20% of a vehicle’s entire energy
consumption over its lifetime. To reduce
this percentage, 60 companies in Germany
joined forces to create the “Green
Carbody Technologies” innovation
alliance. “The objective of the alliance
is to achieve energy savings of up to 50%
during the automotive production process,”
says Dr. Jan Bredau from Solutions
Product Management at Festo.
In the “planning the effi cient use of compressed
air” subproject, Volkswagen,
Boge Compressors, Festo and the Fraunhofer
Institute for Machine Tools and
Forming Technology (IWU) aim to save
energy in compressed air applications.
Compressed air is used in these systems
primarily for welding tongs, grippers,
toggle lever clamps, pin pulling cylinders
and other cylinders. More is required for
the process, for example during laser
welding.
Analysing compressed air consumption
Energy consumption can be signifi cantly
reduced through detailed analysis of
compressed air consumption in body
construction, better coordination between
the generator and consumer sides,
simulation-based confi guration as well
as energy monitoring and diagnostics.
Consumption data is recorded, solutions
for improving energy effi ciency are determined
and losses due to planning and
operation are identifi ed.
Tools for estimating compressed air consumption
during the planning phase help
to ensure optimum and energy-effi cient
coordination between the generator and
consumer sides in compressed air applications.
“Other automotive manufactur-
“The objective of the alliance is to achieve energy
savings of up to 50% during the automotive
production process.”
Dr. Jan Bredau, Head of Development Systems, Festo
ers have now also expressed an interest
in these successful energy-saving tools,”
explains Werner Reichelt, Head of Automotive
Management at Festo.
50% less energy
Electric motors account for around 70%
of all industrial energy requirements.
However, there is no reliable differentiation
for the energy consumption of electric
motors in handling technology, nor is
there precise data for the distribution of
compressed air technology.
The experts working on the joint project
“Energy Effi ciency in Pneumatic and
Electric Production Systems” (EnEffAH)
expect savings of up to 50% for electric
motors and compressed air systems.
Supported by the Federal government,
EnEffAH is drafting energy-saving concepts
and plant optimisation procedures
for pneumatic and electrically driven
handling systems with companies such
as Kaeser Kompressoren, Cooper Tools
and Festo as well as institutes of the University
of Stuttgart and the Fraunhofer
Institute.
Blue Competence of the VDMA
The “Blue Competence” sustainability
initiative of the VDMA has already led to
signifi cant improvements in effi ciency
in plant construction and engineering.
Compared with the level of consumption
in 2000, the products manufactured
by the mechanical and plant engineering
industry today are already allowing
energy savings to be achieved which are
equivalent to the electricity demand of
all 48 million households in Germany,
Austria and Switzerland.
According to the VDMA, the use of innovative
machinery and plants will allow
these savings to be doubled in ten years.
The various trade associations of the
VDMA want to use Blue Competence to
raise public awareness of energy effi -
ciency and to highlight the savings being
achieved by the technology leaders in
industry.
1.2012 trends in automation
Impulse 18 – 19
The effi ciency initiatives introduced by
German industry are being used both
individually and collectively to identify
savings potential. They can help companies
to drive sustainable business practices
and effi cient use of resources. The
net result is an investment that is good
for the environment and the company
balance sheet.
www.eneffah.de
www.bluecompetence.net
www.vdi.eu
How does Festo
contribute to energy
effi ciency?
Festo experts give
their opinion …

Everyone must play a part
Energy effi ciency is more than just a concept. It must be an
integral part of a company’s mission and vision. It affects every
single employee in the company – whether they are in research
and development, production, service or consulting. Here,
Festo employees from different departments provide some
insights.
With Festo Energy Saving Services, we are
providing our customers with the tools
to permanently reduce their energy consumption –
from compressed air production through to
application with professional analyses and
optimisation concepts. The amortisation
periods for our projects are no more than
two years, and are often less than one year.
Our customers in the process industries
are also looking for energy-effi cient
solutions. A recent example is the wastewater
treatment plant in Sindelfi ngen, which is now
much more energy-effi cient thanks to conversion
to pneumatic automation solutions from
Festo. Our customer has achieved electrical
energy savings in the region of
10% for the operation of large pumps.
Dr. Eckhard Roos,
Head of Process Application
Management
Energy effi ciency has become an essential
part of any production and assembly operation.
All of our plants worldwide are working hard
to deliver energy effi ciency – starting at the factory
and plant planning stage. The result is factories in
which we consistently monitor our consumption
data with an energy monitoring system or generate
energy using sunlight. By taking such steps we are
gradually becoming less vulnerable to the
effects of rising energy prices.
Sven Lensdorf,
Head of Service Management
Christian Leonhard,
Head of Global Factories

At a time when energy prices are so
high, successful facility management
without giving consideration to energy
effi ciency is simply unthinkable. Solar cooling
and the consistent use of compressor
waste heat with adsorption chillers, the
use of geothermal cooling and the deployment
of highly effi cient components are the
cornerstones of our strategy for making our
buildings energy-effi cient. In Esslingen-
Berkheim alone, we are saving enough
energy to supply power to 370 homes.
Bernd Bruy,
Head of Technical Building
Engineering
Dr. Axel-Andreas Gomeringer,
Head of Innovation and Technology
Management
So how much do machine and plant
engineering users actually save by
implementing energy effi ciency measures?
What savings are achieved by the individual
measures? The team of energy effi ciency
consultants at Festo has calculated the
savings for a large number of applications in
fi elds as diverse as body-in-white, food
production, small parts assembly, electronics
and process automation so that we can give
our customers concrete and reliable fi gures.
Our customers in the Netherlands
also value our support in the area of
energy effi ciency. Our training and consulting
initiatives are helping many users to unlock
the savings potential that lies hidden in
their systems. This is not a phenomenon that
is unique to my Dutch customers, however.
General Managers of other Festo national
companies are noticing a similar trend.
Thomas Pehrson,
General Manager Festo Netherlands
1.2012 trends in automation
Impulse 20 – 21

A world fi rst: The modular system
for the fully automated in vitro
production of skin models at
Fraunhofer IPA, Stuttgart.

Automated tissue engineering
Skin from
the factory
1.2012 trends in automation
Impulse 22 – 23
Until now, the production of biological tissue equivalents
required expensive manual work and special laboratories.
Four Fraunhofer Institutes have together developed the fi rst
fully automated, sterile system for producing tissue faster
and in larger quantities.

The skin is the most important
organ in the human body. The
production of tissue models
for testing medical treatments
is therefore very complex. Until now,
skin equivalents for transplants or for
verifying the compatibility of active
ingredients in medicines, cosmetics and
chemicals were only produced manually
on a laboratory scale. Culturing took
a whole six weeks. Using this method,
it was generally not possible to produce
more than 2,000 pieces of skin per
month, each measuring a square centimetre.
This is certainly not the case in
the new “Tissue Factory” at the BioPoLiS
bioproduction laboratory of Fraunhofer
IPA. It is the world’s fi rst facility with fully
automated in vitro production, producing
up to 5,000 thumbnail-sized skin models
per month.
Seamless automation
The facility for the production of skin
equivalents is a fl agship project in the
area of bioproduction, which is the symbiosis
of biology and automation technology.
The interdisciplinary cooperation
between biologists and engineers led to
an unprecedented degree of automation
in tissue engineering. The seamless automation
of all process steps facilitated
the introduction of new production and
fi nancial standards such as reproducible
quality, throughput and cost optimisation
in skin model construction.
Faster production
To produce around 5,000 skin models
per month, biological requirements with
regard to the sterility of all processes
and the handling of cells must be met.
This involves a multi-stage process
in which the skin samples are fi rst
sterilised, transported to the system by
robot, broken down, isolated and cultivated
in a special culture medium under
constant ambient conditions. The cells
are then grown in a 3D gel matrix in two
layers. The skin equivalent is ready for
use after just three weeks. In accordance
with the principles of hygienic design,
the developers of the tissue factory
aimed for a continuous process chain.
Cell extraction and proliferation as well
as three dimensional tissue formation
are carried out in a seamless sequence
in a single system. The process incorporates
more than 100 Festo components,
including compressed air preparation,
sensors, cylinders, electric axes, servo
and stepper motors as well as fastswitching
valves and the valve series
VUVG. The majority of these components
are found in the cell extraction
process. Where the products are part
of the production space, clean room
components are used. The decapper
operates as a complete system and is
responsible for unscrewing lids.
Future-proof
The bioproduction of tissue engineering
products is already a hugely important
area in biotechnology. It allows tissue to
be produced in larger quantities and thus
represents a major step forward in cell
research. This new technology paves the
way for an end to animal testing of products
to check the skin tolerance level.
In regenerative medicine, skin equivalents
are helping an increasing number of people,
for example with wounds that are
not healing properly. In future, scientists

want to do much more than just produce
tissue. The automated technology needs
to be further developed over the coming
years so that other products such as cartilage
can be produced automatically.
www.festo.co.uk/laboratory
Phot Photos: os: Frau raunhof nh er/R er er/R er/Rafa afa afael l Kr Krötz
Bioproduction par excellence:
The new tissue factory produces
up to 2.5 times more human tissue
equivalent than before.
Automated tissue growth:
Components from Festo in the cell
extraction module, developed
by Fraunhofer IPT.
1.2012 trends in automation
Impulse 24 – 25
“The automated
process is much
easier to reproduce
than manual work.
The quality of skin
produced with the
tissue factory is
therefore much higher.”
Andreas Traube, Group Leader Bioproduction,
Fraunhofer Institute for Manufacturing Engineering
and Automation (IPA), Stuttgart

Article cancelled

at short notice.
1.2012 trends in automation
Impulse 26 – 27

Automation technology in Hungary
A country
on the move
In the summer of 1989, Hungary was the fi rst central European
country to open its strictly guarded borders. Just three months
later came the fall of the Berlin Wall. Today, Hungary is proud
to be a member of the European Union. Situated on the banks
of the Danube, Hungary has developed into a major hub for the
automotive industry and is a key location for Festo.

1.2012 trends in automation
Synergies 28 – 29
Architectural masterpiece:
The Chain Bridge in Budapest is
the oldest and best known of the
nine bridges crossing the Danube
in Budapest.

Having once led the way in the development of the
free-market economy in Central and Eastern Europe,
Hungary was hit badly by the global economic crisis
in 2008 and 2009. The high public defi cit and levels
of personal debt brought economic growth to a standstill in
2010. However, Hungary managed to weather the storm and
is now on the road to recovery. A clear indicator of this are the
high levels of investment by international groups of companies
from the vehicle manufacturing and plant construction sectors.
They are opening up new horizons for the country, with its wide
lowland plains along the banks of the Danube.
Bridge to the East
No other country in Central Europe is so closely intertwined
with other economies as Hungary. It generates 70 per cent of
its national product through exports. Numerous international
fi rms, most of them from Germany, invested around 60 billion
euros in recent years and currently provide almost four out of
Festo Hungary
Between 1979 and 1990, Festo was involved in a joint
venture that developed and manufactured air preparation
units for compressed air preparation. In 1991, the automation
specialist then opened its own plant. Today, it is
the central location for the manufacture of air preparation
and vacuum technology products in the Festo global
manufacturing network. With a workforce approaching
800, it is set to become the fourth largest Festo plant in
2012 thanks to the huge rise in worldwide demand for
components for compressed air preparation, such as the
MS series and safety valves. Also located on the same
site is the Hungarian local sales company, which boasts an
impressive client list including Audi, Daimler, Opel and GE.
Festo in Budapest: Local sales company for the Hungarian
market and the central plant for compressed air preparation.
Booming MS series: Countless variants – manufactured according to the
modular system – are made to order for customers all over the world.
Barnabás Bertalan,
General Manager of
Festo AM, the manufacturing
company in
Hungary
“We redesigned the plant
so that we can respond quickly
and flexibly to changes in
the market.”
every ten jobs in the private sector. Hungary’s central location
and its close cultural and linguistic links with Germany and
Austria are crucial factors for many German-speaking companies
when choosing locations. The Land of the Magyar, as
Hungary describes itself, acts as a bridge to the former Eastern
Bloc countries. It offers high levels of productivity and a welleducated
and motivated workforce, many of whom speak
German and English fluently. German companies in the
automotive and plant construction sectors have taken advantage
of the favourable investment climate, transforming this
small country of just under 10 million inhabitants into one of
Europe’s key centres of industry in recent years. Both sectors
together currently account for more than half of the country’s
industrial production.
“Vorsprung durch Technik”
The Audi plant in the western Hungarian city of Györ is legendary.
Located halfway between Vienna and Budapest, it produced its
20 millionth engine in April 2011. Audi Hungária has been part
of the Volkswagen Group’s manufacturing network since 1993
and is the second largest company in Hungary. Automation
technology from Festo has been there right from the very start
and today ensures that the assembly plants operate effi ciently.
Audi Hungária employs more than 6,000 people and develops
and produces engines for Audi AG and other makes in the Volkswagen
Group. Every day, the plant produces 6,900 diesel and
petrol engines with between four and twelve cylinders. The
Audi TT Coupé and Roadster models as well as the A3 Cabriolet
are also assembled here. The company plans to expand the
assembly plant to incorporate the entire vehicle manufacturing
process – including press shop, body construction and paint
shop – by 2013. At around 900 million euros, this represents
the largest single investment in Hungary to date. When completed,
the plant will be capable of producing 125,000 vehicles
every year, as compared with 38,000 in 2010. Audi will create
a further 1,800 jobs in the process. Combined with the new
distribution and supplier facilities, this will lead to the creation
of a total of 15,000 jobs for the people of Györ.
On the road to success
Other car makes are also discovering the potential for development
that exists in Hungary’s lowlands. Daimler AG has
invested 800 million euros in the construction of a car plant in
the southern Hungarian city of Kecskemét. Series production
of the A-Class and B-Class is scheduled to begin here in 2012.

General Motors is spending 500 million euros on the expansion
of the Opel engine works in Szentgotthárd on the Slovenian-
Austrian border. In 2010 alone, Suzuki Hungária produced
170,000 vehicles in its plant in Esztergom, north of Budapest.
According to Germany Trade and Invest (GTAI), the economic
development agency of the Federal Republic of Germany
(www.gtai.de), Bosch and Knorr-Bremse are two of the biggest
automotive suppliers operating in Hungary, with both companies
continuously putting in large sums of money. Continental
Temic, Schaeffl er and ZF are also active in Hungary. Most suppliers
have their own local development operations. Alcoa,
Delphi, Lear, Luk, Magna-Steyr and Philips are getting in on
the act too. As part of the Daimler investment, a number of
suppliers will be setting up operations directly at the new site
in Kecskemét. The automotive industry and plant construction
sector have recognised the potential of a motivated workforce
combined with favourable economic conditions. International
groups of companies are relying on the high levels of productivity
in the Hungarian economy to help them to return to stable
growth. Hungary is a small country with big opportunities.
Quality from Hungary: Not only does the engine
for the Audi TT come from Hungary, fi nal assembly
of the vehicle also takes place here.
Imposing landmark: The 268-metre long parliament building in Budapest.
“Our market share
of 50% shows that
we are a strong and
reliable partner for
our customers.”
Model plant Audi Hungária: From 2013, up to
125,000 vehicles per year will roll off the assembly
line in the 35,000 m 2 hall.
1.2012 trends in automation
Synergies 30 – 31
Marton Szövényi-Lux,
General Manager of
Festo Hungary

Milling of bevel gears
Tooth by tooth
Modern transmissions for cars and commercial vehicles
must be able to withstand extreme loads and at the same
time run quietly. This applies in particular to the spiral bevel
gears used in drive systems, which must redirect the torque
from the drive shaft by 90° to the axle shafts. In modern
production machines, ready-to-install pneumatics from
Festo deliver increased safety and shorter assembly times.
Tool and product:
Cutter head with
spiral-cut bevel gear.
High-quality spiral-cut bevel gears
combine maximum load capacity
with a low noise level and a high
degree of efficiency. Like many
components in the automotive industry,
they are subject to demands for reduced
weight combined with the smallest possible
dimensions. Ever smaller bevel gears
must guarantee the low-noise transmission
of ever larger torques over hundreds
of thousands of kilometres. Specialists
in the area of bevel gear machine building
like Klingelnberg GmbH depend on
sophisticated production processes in
order to guarantee maximum precision
of the processing machine.
Smooth processes
The manufacturing process in machines
for bevel gear production begins with the
setup process for the clamping device
and the tool as well as the setup of automatic
workpiece loading. The bevel gears
are milled using cutter heads, which cut
out the tooth gaps in the dry-cutting
process. The bevel gears are then hardened
and ground fl at and rounded. The
hard tooth fl anks are ground or lapped
depending on their purpose. Two hard
fi nishing processes give the tooth fl anks
the properties needed for a long service
life, low noise and energy effi ciency.
Large parts of the systems, which can
be as big as a bus, are operated and controlled
pneumatically at 6 bar. Time plays
a hugely important role in the production

process. That is why the company puts
its trust in ready-to-install pneumatics
from Festo.
Fine-tuning of valves
A central element is the ISO valve terminal
VTSA. It is extremely compact and
highly effi cient thanks to its integrated
pneumatic function and a mix of four
valve sizes. To meet the specifi c safety
requirements of the bevel gear milling
machines C29 and C50, the VTSA had
to undergo some fi ne-tuning. To protect
workers against accidental start-up when
working with large moving loads in the
danger area, such as the cutter head,
the valve functions for manual commissioning
of the system were disabled for
these areas. During maintenance and
setup processes, the electrical voltage
and the auxiliary pilot air of the pneumatic
connection are switched off.
Ready-to-install pneumatics
In addition to improving safety, the
ready-to-install pneumatic solution with
the valve terminal VTSA offers signifi -
cant time savings during assembly. The
pre-assembled unit is easily put together
and commissioned by the employees at
Klingelnberg. Work that once took several
days is now done in just a few hours.
The ready-to-install solution from Festo
was installed in more than 30 machines.
All in all, the short installation time of
just seven weeks per machine provides
a decisive advantage.
www.festo.com/catalog/vtsa
is 1.12-02
Valve terminal
www.festo.com/trends
Klingelnberg GmbH
Peterstraße 45
D-42499 Hückeswagen, Germany
www.klingelnberg.de
Area of business:
Development and manufacture
of machines for the production of
spiral-cut bevel gears, measuring
devices for axially symmetrical
objects of all types, and the production
of high-precision gear components
made to customers’ orders
1.2012 trends in automation
Synergies 32 – 33
Global precision:
Klingelnberg supplies
manufacturing machines
to customers all over the
world.
Improved safety for employees:
The function for
manual commissioning was
disabled in some areas of
the valve terminal VTSA.
Saves valuable time:
Ready-to-install pneumatics
from Festo with the valve
terminal VTSA.

Photos: Oerlikon Solar ar
New technologies in thin-fi lm photovoltaics
Sunny side up
For Oerlikon Solar, the outlook for thin-fi lm silicon technology in photovoltaic
modules is good. “We expect continued double-digit growth in the market,” says
Michael Clauss, Product Development Manager of the Swiss company.
Automation technology from Festo ensures secure handling of the large glass sheets.

Sunny outlook:
Thin-fi lm photovoltaics
at grid parity costs.
1.2012 trends in automation
Synergies 34 – 35
Swiss company Oerlikon Solar
owes its confi dence not only to
the continued growth of renewable
energy, but also to its new
TCO deposition system, a solution that it
believes the market has been waiting for.
TCO stands for “transparent conductive
oxide”. The deposition system applies
transparent, conductive zinc oxide layers
on large glass sheets in six process
chambers. These layers act as electrical
contacts in the fi nished photovoltaic
module. Before deposition, the glass is
heated from room temperature to 200 °C
in just 20 seconds. “The art is in creating
an even temperature on the entire surface
of the glass. This allows us to deposit
homogeneous layers,” explains Clauss.
Gentle movement
The sheets of glass to be coated are
transported to the process chambers on
rollers. A pneumatic cylinder from Festo
moves small metal pins, which raise the
glass to various heights for deposition.
The servopneumatic proportional valve
MPYE controls all of the cylinders of
the chambers, regulates the speed and
approaches the various positions gently.
The pneumatic cylinder is a temperatureresistant
special design based on the
compact cylinder ADN.
Impressive lift
When the deposition process is completed,
the glass moves to the exit lock.
It is then returned from the vacuum back
into the atmosphere. An automated lift
moves the sheets to the next process
step. The lift incorporates pneumatic
axes DGC from Festo, while the axis ELGR
ensures constant speed. “The Festo
products used helped us to keep the
system costs down,” explains Clauss.
“A converter with electric motor would
have been far more expensive.”

The new TCO deposition system applies electrically
conductive, transparent coatings made from zinc oxide.
Energy used effi ciently
The TCO deposition system is part of the ThinFab production line.
According to Oerlikon Solar, it allows production of renewable energy at
grid parity costs for the fi rst time. The future certainly looks bright for
Oerlikon Solar with its silicon-based thin-film technology. The energy
amortisation period is just under a year. A fi nished module consequently
only needs to be used for less than one year for all the energy costs of the
production process to be recouped. Wafer-based modules, on the other
hand, require two to three years.
In Oerlikon Solar’s view, the zinc oxide-based method is also better than
other thin-fi lm technologies, which use scarce and therefore expensive raw
materials such as tellurium (cadmium telluride) or indium (CIS/CIGS) and can
be problematic when it comes to disposal due to the toxicity of cadmium as
a raw material.
Thin fi lm outperforms wafer
In an analysis conducted in 2010 by French investment bank BNP Paribas,
thin-fi lm photovoltaics were rated as a lower-cost technology compared with
crystalline, wafer-based photovoltaics. It takes just a year for an investment
in thin-fi lm technology to be amortised, as compared to between two and
three years for wafer-based systems.
The energy yield is higher and thin-fi lm modules generate more energy than
wafer-based modules when there is less solar radiation. The performance of
wafer-based modules deteriorates at high temperatures, but remains virtually
constant in the case of thin-fi lm modules. Production costs for thin-fi lm
modules are also lower in comparison with wafers.
The pneumatic components make the
lift easy to adjust. The toothed belt
axis for the guide is a ready-to-install
unit for quick and simple construction.
The axis has already successfully proven
its reliability with a tested service life of
5,000 km.
Nitrogen instead of compressed air
A unique feature of the system is the
open-loop and closed-loop control medium
of the pneumatic system. Instead
of using compressed air, Oerlikon Solar
operates the TCO system with pure nitrogen.
“We can thus keep the vacuum and
gas supply system free of contamination,”
says Clauss. “The pneumatic components,
such as the MS series service units, tubing
and fi ttings, also perform well with
pure nitrogen.”
Also included is the fast and dynamic
fl ow sensor for liquids SFAW. It measures
the fl ow rate, consumption and temperature
of the water cooling in the system
chambers. What makes this solution
really clever is the ability of the sensor
to control the volume of cooling water as
required. More cooling water is supplied
when temperatures in a process chamber
are high and less when they are lower.
The Festo sensor thus contributes to the
effi cient use of energy and has permanently
reduced the operating costs of
the system.

The lift on the exit lock incorporates pneumatic axes DGC.
The low-cost axis ELGR ensures constant speed.
100 football pitches
The new TCO system represents a major
leap forward compared with its predecessor:
“With the second generation we
have almost doubled the annual capacity.
It coats 300,000 sheets of glass every
year. This corresponds to around 100
football pitches,” explains Clauss. The
maintenance and cleaning intervals have
been extended by 75%. As each cleaning
process means half a day of downtime,
customers of Oerlikon Solar are thus able
to signifi cantly improve their productivity.
“The productivity increases have been
eagerly awaited by the manufacturers
of thin-fi lm modules,” says Clauss. But
this is by no means the end of the Swiss
company’s achievements. Oerlikon Solar
Effi ciently tempered: The fl ow sensor SFAW controls
the amount of cooling water as required.
“In a project as challenging as the TCO deposition
system, choosing the right automation partner is
important. They must understand our requirements
and contribute their own ideas.”
Michael Clauss, Product Development Manager, Oerlikon Solar
has broken the world record for the lowest
module production costs with € 0.5
per Watt peak and stabilised effi ciency
of 11.9% in the champion laboratory cell
with thin-fi lm silicon technology.
www.festo.com/catalog/elgr
www.festo.com/catalog/dgc
is 1.12-03 | is 1.12-04
Toothed belt axis ELGR | DGC axis
www.festo.com/trends
1.2012 trends in automation
Synergies 36 – 37
Oerlikon Solar Ltd.
Hauptstraße 1a
CH-9477 Trübbach, Switzerland
www.oerlikon.com/solar
Area of business: Development
and manufacture of tried and
tested systems and turnkey
production lines for the
production of environmentallyfriendly
thin-fi lm solar modules

Valve terminal replaces PLC
Terminal intelligence
Until a few years ago, manual and visual random sample inspections of industrial
components were often suffi cient. However, as technology has advanced, so too have
the requirements with respect to technical solutions – and system controllers. In a machine
for the visual inspection of turned parts the valve terminal CPX from Festo now performs
the tasks of the PLC.
One hundred per cent test quality
based on one hundred per
cent process quality – not to
mention extremely compact
and with no additional system controller.
In the specially constructed system for
the testing of precision turned parts, the
Festo valve terminal CPX-CEC-C1 handles
all of the functions of a complete PLC.
It controls pneumatic and electric axes
and positions the turned parts correctly
so that a full surface inspection
can be carried out using a camera.
This complete solution from Festo is a
high-performance unit consisting of the
intelligent valve terminal CPX, controller
CMMS, camera SBO and the servo motor
EMMS with slide EGSL. Their interaction
allows very fast and precise testing of
the turned parts in a three-second cycle.
Perfect mirror image
Before the visual inspection, the turned
part is fi rst cleaned using a brush and
vacuum. A conical, tapered mirror then
travels through the inside of the part to
be inspected and sends the image information
to the camera. The movement is
performed by a mini slide EGSL, actuated
by a servo motor EMMS. If faults such
as cracks or grooves are found, the intelligent
valve terminal issues the command
to reject the part at the end of the
inspection process.
Effi ciency thanks to a complete solution
The subsequent external inspection is
carried out using a conical mirror. The
component is drawn in through an opening
in the mirror, which opens out at the
top, by EMMS and EGSL. A red LED ring
light provides optimum contrast for the
camera at the top. The inspection system
also detects the position of the turned
part, which was originally fed unoriented
from the screw conveyor. In the next
and fi nal step, the machine separates
the good parts from the faulty parts.
The lack of an additional PLC offers
advantages with regard to development,
commissioning and maintenance. This
innovative, complete system solution
from Festo for the inspection of turned
parts is based on a standardised control
concept. On the valve terminal CPX-CEC-
C1, the individual components demonstrate
their unique characteristics such
as high performance, excellent fl exibility
and durability. In addition, as the control
components come from a single source,
programming times are shorter and
service is fast and reliable.
www.festo.com/catalog/cpx
www.festo.com/catalog/cmms
www.festo.com/catalog/sbo
is 1.12-05 | is 1.12-06 |
is 1.12-07
Compact Vision Systems|
Valve terminal CPX | Motors and controllers
www.festo.com/trends

Cleanliness
is everything:
A conventional
spout brush
removes chips
from the turned
parts.
State-of-theart
technology
against a traditional
backdrop:
System for
inspecting the
surface of turned
parts using the
latest technology
from Festo.
Twice the
reliability:
Two controllers
CMMS monitor
and control the
electric drives.
1.2012 trends in automation
Synergies 38 – 39
Critical eye:
The pin-shaped
mirror supplies
the inside view
of the turned
part to the camera
positioned
underneath.
Intelligent
control:
The terminal CPX
with CEC-C1 handles
the tasks of
the PLC.

Rapid construction of packaging machines
Tea time in
Buenos Aires
Argentina is not only one of the largest
beef producers, it also ranks eleventh
in the global tea production industry.
The Festo PrePack service ensures the
rapid construction of machines for
packing tea bags.

Even Argentina, known for its timeconsuming
mate tea ceremonies,
today loves a quick cup of tea
in between times. Particularly
in cities the tea is mainly made using
bags. The tea suppliers must look sharp
to meet the needs of about 41 million
inhabitants for the precious leaves while
ensuring that the full aroma is retained.
MAI S.A. packaging machines ensure
that this happens as quickly as possible.
The EC12/T, for example, fi lls tea bags,
attaches a string and a label to the small,
cushion-shaped bags and seals them so
that the aroma stays fresh.
Supplied ready to install
MAI opted for the PrePack service to
ensure the rapid assembly and maintenance
of the EC12/T. The Argentinian
company receives the required set of
components, such as the standard
cylinders DNC and cylinders DSNU,
solenoid valves MFH, tubing and other
accessories using a single part number
and in one single packaging unit. This
means the required component is immediately
available for production in
the shortest time possible.
Reduced errors
Leonardo Ionkoff, Customer Solutions
Developer at Festo Argentina, describes
the response to PrePack: “Customers are
absolutely thrilled because our service
offers numerous advantages. It is ideal
for standardised machines and provides
better, faster stock control to identify
errors in assembly or component confi
guration. Our customer’s productivity
is considerably improved.”
With Festo’s easy assembly service concept,
which includes the PrePack service,
the time taken to receive and store goods
is signifi cantly reduced. Thus the Pre-
Pack service now makes the production
process easier and constantly improves
cost control. PrePack has been used in
Argentina for about three years.
www.maisa.com.ar
www.festo.com/catalog/dnc
1.2012 trends in automation
Synergies 40 – 41
Standard cylinder
DNC: The clever
design reduces space
requirements by up
to 11% compared with
ordinary standard
cylinders.
Festo standardised
components: Quick
delivery means the
customer no longer
has to store parts.
Assembled quickly
with PrePack: The
EC12/T tea bag packaging
machine of MAI
S.A., Argentina.

Improved material effi ciency for packaging
Every gram counts
The amount of waste produced in the manufacture of a single
unit of tin packaging is no more than a few grams. However,
when multiplying this by millions of units, it amounts to a considerable
volume of valuable metal. Huber Packaging Group and
Festo Didactic together managed to signifi cantly improve material
effi ciency by conducting detailed material fl ow analyses.
Lever lid cans or canisters are rarely
regarded as valuable objects. They
are mostly just a means to an end,
such as for transporting and storing
products. Once the paint, oil, cheese,
beer or pickles have been used up, the
packaging has fulfi lled its purpose and is
recycled. However, it should be remembered
that behind every item of metal
packaging lies an extensive and complex
production process, which demands the
highest levels of quality and effi ciency.
Millions of euros worth of materials
In order to be better able to meet
demands for greater material effi ciency,
Huber Packaging Group GmbH participated
in the VerMat programme of the
German Materials Effi ciency Agency
(demea) at two of its plants. The aim
of the “Analysis of start-up and quality
losses in component manufacturing”
project was to identify potential for more
economical use of tin and chrome plate
and thus to make the company’s business
processes more effi cient. It proved
to be an extremely worthwhile exercise.
Huber Packaging Group processes tens
of thousands of tonnes of tin plate to
create metal packaging every year. This
corresponds to a material value of tens
of millions of euros.
Putting processes to the test
The manufacture of tin packaging produces
a certain amount of waste from
cuttings and rejects. To reduce these
losses, Huber Packaging Group under-
took a detailed analysis of its production
processes with Festo Didactic GmbH
& Co. KG Denkendorf. Every lid, every
base, every ring that did not meet the
strict quality requirements was analysed.
Were quality characteristics not met?
If so, which ones? What were the reasons
for poor quality and how could the problem
be rectifi ed?
Over 100 tonnes saved
Material fl ow analyses on selected production
systems provided the basis for
a sustainable improvement in effi ciency.
These analyses recorded the input
material, the quantities and the weight
of the good parts as well as the waste
produced. The latter was further quantifi
ed to produce a summary in which

the roots of the errors and their effects
were evaluated. This detailed approach
proved to be extremely successful in
the case of Huber Packaging Group, as
the material losses had many different
causes. Potential savings of well over
100 tonnes of tin and chrome plate per
year were identifi ed on the basis of rela-
“We were surprised at just
how much material we were
able to save.”
Wolfgang Merkle, Head of INDUSTRIAL,
Huber Packaging Group
tively low levels of investment. For Huber
Packaging Group, the decision to work
with Festo Didactic has really paid off.
All these small improvement measures
have together helped the company to
make signifi cant changes.
www.festo-didactic.com
1.2012 trends in automation
Synergies 42 – 43
Huber Packaging
Group GmbH
Otto-Meister-Straße 2
D-74613 Öhringen, Germany
www.huber-packaging.com
Area of business:
Manufacture of tin plate metal
packaging for chemical products,
dyes, paint, foodstuffs and party
kegs for the beverage industry

Automation of wastewater treatment plants
Keeping a
clean slate
The energy consumption of wastewater treatment
plants has a major impact on local authority budgets,
accounting for up to 20% of energy costs. A modernisation
project at the wastewater treatment plant in
Sindelfi ngen shows how pneumatic automation can
bring about a sustainable increase in effi ciency.
According to the study “Enhanced
energy effi ciency in wastewater
treatment plants” published by
the Federal Environment Agency
(UBA), German wastewater treatment
plants consumed 4,400 GWh/a of electricity
in 2006. Aerators, large pumping
stations and stirrers as well as sludge
treatment in particular require large
amounts of energy. Only around one fi fth
of the entire current consumption is covered
by the wastewater treatment plants
themselves through the generation of
power from biogas.
Extremely resilient
Experts believe that enormous potential
can be unlocked through the reduction
of current consumption and the genera-

tion of power by the plants themselves.
Process engineering optimisations such
as energy-effi cient design and regulation
of the ventilation or the use of highly effi -
cient pump impellers also have a positive
effect on plant operation. Pneumatic
automation solutions are an economical
alternative. Process valves in wastewater
treatment plants are often actuated
infrequently or have long periods when
they are not used at all. This leads to the
formation of deposits and caking and
thus to increased breakaway torques or
forces. Pneumatic actuators can overcome
this problem simply by increasing the air
pressure. They cope well with loads without
getting damaged and are not affected
by differences in temperature, contamination
and humidity. Pneumatic actuators
only require electricity for regulating
and generating compressed air and act
directly on the shut-off valve.
Lower costs
Pneumatic components are resistant
to continuous loads and maintenancefree
over their entire service life. They
are very easy to install and are cheaper
than comparable electrical solutions,
particularly when implementing complete
system solutions. Pneumatic
components are also very impressive
when it comes to safety. Compressed
air continues to be available even
during a power failure. An air reservoir
is always available along with a compressor
for generation and preparation
purposes.
1.2012 trends in automation
Synergies 44 – 45
Energy-effi cient:
The trickling fi lter system at
the Sindelfi ngen wastewater
treatment plant.

Clearly laid out
and space-saving:
The pumping station
after conversion.
Clean and safe
solution: Pneumatic
slide valve instead of
non-return valve.
Decentralised solution
The wastewater treatment plant in
Sindelfi ngen, near Stuttgart, treats
wastewater for 250,000 inhabitants.
This plant is an impressive example of
the benefi ts of a pneumatic automation
solution. The process valves with their
pneumatic valve actuators DLP and DRD
from Festo are distributed throughout
the entire plant, sometimes in locations
that are not easily accessible. Instead of
actuation using individual pilot valves,
a decentralised solution was chosen in
which the actuators are connected to
the control system using valve terminals
type CPX/MPA. With this system solution,
there is just one clearly defi ned
and standardised interface from the
valve terminal to the fi eldbus. The modular
electrical terminal CPX in combination
with the valve terminals MPA increase
system availability. The maintenance
and diagnostic capabilities also play
a role. An electronic component allows
for valve-specifi c diagnostics for each
coil. It monitors coil current, undervoltage
and short circuits and detects line
interrupts. The integrated diagnostics
memory stores the messages with
a timestamp.
Measurable environmental protection
The central pumping station of the
Sindelfi ngen wastewater treatment plant
is now extremely energy-effi cient. There
are six centrifugal pumps in the pump
cellar – each with a power consumption
of 90 kW and a delivery rate of up to
500 l/s at a delivery height of 8 to 9 m.
Before the modernisation, the non-return
valves had to be kept open at all times.
However, this reduced the delivery rate
by up to 10%. Now the new pneumatic
automation of the existing knife gate
valves has fully replaced the functionality
of all non-return valves and thus
increased operational reliability. The
Sindelfi ngen wastewater treatment plant
now achieves the same pump delivery
rate as before with signifi cantly lower
energy consumption.
Savings of 89,469 kWh or € 11,300 are
made every year. This corresponds to a
total saving of 2% of the total demand for
electricity for the Sindelfi ngen wastewater
treatment plant. The pumping station
is now more clearly laid out and the
plant requires less space. The noise level
has also been reduced considerably.
Because the shut-off valves close tightly,
there are no more undetected leaks.
Thanks to the pneumatic solutions from
Festo, the plant operator has managed
to significantly increase the fatigue
resistance, service life and energy
effi ciency with an amortisation period
of less than a year.
www.festo.com/catalog/cpx
www.festo.com/catalog/dlp
is 1.12-08
Partners for automation in water
technology
www.festo.com/trends

Russia
Mobile
customer service
Festo Expotainer hits the road in Russia
As part of a unique campaign, Festo brought the latest developments
in pneumatics and electric drive technology directly to
the world’s largest industrialised country. The Festo Expotainer
took to the road in Russia for the fi rst time in June 2011. On a
tour that covered more than 8,000 km, the mobile technology
showroom visited St. Petersburg, Moscow and 13 other cities.
Over the course of four weeks, 36 tonnes of state-of-the-art
automation technology rolled its way across the vast Russian
landscape. Around 800 visitors showed up to see 14 dynamic
applications featuring pneumatic and electric drives as well
as the latest control and sensor technology. The cleverly
designed 50 m² exhibition space also had wall displays featuring
product examples and video presentations about the world of
Festo technology.
The Festo Expotainer was, as always, an amazing experience
for everyone who came to see it – young talent interested in
a career in technology, customers and interested companies
alike. It was like a mobile bridge bringing innovations to
various regions throughout the country, even the more remote
ones. Such outstanding success deserves to be repeated,
and so in 2012 the Festo Expotainer will spend an entire eight
weeks on the road in Russia.
1.2012 trends in automation
Festo worldwide 46 – 47
The Festo truck travelled around 8,000 kilometres on its tour of Russia.
The Festo Expotainer visited 15 cities, starting with St. Petersburg.
Around 800 visitors got a chance to see the mobile technology showroom.

Germany
Winners of the German Future Award 2010
with Prof. Dr. Wolfgang M. Heckl, Director General
of the Deutsches Museum (centre), and Petra Maria Jung,
Offi ce of the Federal President.
Germany
Festo training and consulting: By industry for industry.
The Bionic Handling
Assistant exhibit:
The gripper fi ngers are
equipped with pressure
sensors, making
it possible for the assistant
to grip objects
more or less fi rmly as
required.
Hall of Fame
Bionic Handling Assistant in the
Deutsches Museum, Munich
On 15 September 2011, the winner of the German Future Award
2010 earned a place in the “Hall of Fame” at the Deutsches
Museum, thus joining the ranks of other major technological
innovations.
“We’re proud to make the Bionic Handling Assistent accessible
to large numbers of people at the Deutsches Museum.
We’re very pleased to be able to demonstrate to visitors the
magnitude of the technological breakthrough which has been
achieved by this project,” remarked award winner Dr. Peter
Post from Festo at the ceremonial unveiling of the exhibition
model. With the help of four sub-modules, visitors will
experience exactly what it is that distinguishes the innovation
developed by Festo and Fraunhofer, and be able to see the
“trunk” of the Handling Assistant in action.
The Bionic Handling Assistant is a pliant gripper arm whose
structure and overall mode of operation are based on those of
the elephant’s trunk. Its highly fl exible nature makes it suitable
for industrial and household applications allowing for safe
interaction between people and technology.
www.deutsches-museum.de/ausstellungen/
neue-technologien/zukunftspreis
Change that works
New courses for 2012
Companies can only respond successfully to changing market
requirements if they engage in a process of continuous selfanalysis
and are in a position to adapt accordingly. The Change
Management course faces up to this challenge and answers
questions on supporting factors, mechanisms, tools and alternatives
for successful change.
The long-term success of process optimisation is determined
by its implementation. There are often problems when it comes
to consistent control, effective problem solving and the need
for guidance at grass-roots level. The Shopfl oor Management
course paves the way for achieving sustainability.
Start date for both courses: May 2012
For more information, call ++49 (0) 800 / 337 86 82
(no charge for calls from German landlines) or visit www.festo-tac.de

Germany
Welding whizz
Soft Stop saves valuable time
Highly dynamic: Sliding platform of the bielomatik machine.
Precision and high speed infl uence the thermal bonding of
plastic parts for car engines and exhaust systems. In a process
lasting less than a minute, half shells are rubbed together at
180 Hz and then welded at 220 °C. Thanks to servopneumatics
from Festo, the process is now even faster. bielomatik Leuze
GmbH + Co. KG can extend and retract the sliding platform of
a welding system 30% faster than before. This was made possible
with the electronic end-position controller Soft Stop from
Festo, which works without a shock absorber. The controller
Engine part made
from polyamide:
The half shells
are welded together
in just 55 seconds.
ensures smooth deceleration of the linear drive and prevents
wear as a result of impact on the cushioning components.
The Festo Soft Stop solution is thus much more effi cient and
extends the service life of the system. The robot that was
previously responsible only for feeding parts is now able to
perform additional tasks.
www.bielomatik.com
1.2012 trends in automation
Festo worldwide 48 – 49

Hungary
Magic squares: Electric drive technology from Festo produces cubes for “CubiCup”.
Precision, short cycle and retooling times: Electric axes, motors
and controllers from Festo.
The magic pyramid
Effortlessly precise electric drives
30 years ago, the Rubik’s cube had taken the world by storm.
In the spirit of this much-loved puzzle, the Hungarian company
Cubi Team Kft. developed the strategy game “CubiCup”, in
which two players create a pyramid from 56 wooden cubes.
To ensure that the cubes fi t together perfectly, the edge length
of 17 mm must be cut to within an accuracy of one tenth of a
millimetre. This is done using electric axes and controllers from
Festo, which ensure absolute precision in the automated, highly
effi cient system. Apart from the quality of the end product,
the automation solution guarantees short cycle and retooling
times for different toys. A production changeover requires
only a change in program along with the replacement of a few
components, inserts and tools.
Enjoy a challenge?
Answer our quiz on page 53 and you could
win the “CubiCup” strategy game.

Greece
Booster boxes
Pneumatics increase the degree of automation
Fruit and vegetables look much more appetising and natural
in wooden boxes. As a packaging material, wood does have
some advantages over cardboard and plastic. This natural
material has the benefi t of being very strong at a low unladen
weight, which remains constant during transport in refrigerated
containers, even when subjected to variable ambient
conditions such as air humidity, for example. That is why Greek
fi rm NOURIS M. SONS O.E. has been specialising in machines
for the manufacture of wooden boxes for packaging fruit and
vegetables for many years.
The degree of automation was increased gradually through
the use of pneumatic components. They provide quick and
accurate movement and ensure production capacities of up
to 4,500 boxes per second. A recent addition is the Festo fi lter
regulator MSB6-1/2. It features an integrated lock that makes
oil supply easier. The new design with pressure gauge guarantees
reliable operation of the service unit combination.
In addition, valves from the MFH series, cylinders type DNC and
ADVU components contribute to ensuring maximum reliability
for the Greek company.
www.nouris.gr
China
Festo continues to expand
Expansion of the plant in Jinan
The economic boom in China has led to greater demand for
automation technology. Production tends to be based in the
region for the region. Refl ecting this trend, Festo opened new
production and logistics facilities at its Jinan plant on 21 March.
This expansion will ensure that regional market demand in
High-speed production: Automation technology from Festo
proves its strength.
China can continue to be met in the coming years.
Jinan is served by the high-speed rail link between
Beijing and Shanghai and is therefore an ideal location
for future production growth.
Festo in Shanghai: In addition to the Festo company founded in 1993 there are branches in a further 33 cities in China.
1.2012 trends in automation
Festo worldwide 50 – 51

Germany International
Hanover Fair 2012
Ideas for automation
Visitors to the Festo stand in Hall 15 from 23 to 27
April will be presented with information and ideas
for automation on ten different topics. In the area of
energy effi ciency, for example, the savings potential
that can be realised will be demonstrated using
typical industrial applications. One of the highlights
on show will be the MS series service units with
their scalable mix of sizes and condition monitoring.
Vision controlled motion will focus on technically
and economically optimised solutions in a
wide range of industrial sectors. And on the topic
of safety know-how we will demonstrate pneumatic
and electrical safety functions in the overall mechatronic
concept.
The heavy-duty electric axis EGC-HD, the low-cost
electric piston rod cylinder EPCO and the pneumatic
cylinder series with self-adjusting end-position
cushioning will be premiered. As part of the Bionic
Learning Network, Festo is developing new technologies
for automation. Example: Gecko – technology
inspired by nature with suction cup-like elements.
www.festo.de/hannovermesse
Festo
Technology Days
May to November 2012
Festo Learning Centre Saarland 08/05 – 10/05
Sales offi ce Chemnitz 05/06 – 06/06
Sales offi ce Berlin 07/06
Sales offi ce Regensburg 17/07 – 18/07
Sales offi ce Bielefeld 25/09
Sales offi ce Bielefeld in Bonn 26/09
Sales offi ce Neuss 27/09
Sales offi ce Lüdenscheid November
For more information, see www.festo.de/technologietage
International
Twitter and Facebook
Festo is expanding its Social Media presence
Following the huge success of the YouTube channels, Festo is
joining Twitter and Facebook in time for the Hanover Fair 2012.
From the end of April, you’ll be able to access information
about the company, its innovations, new products as well as
career and education opportunities. You can also keep up-todate
with news on events and trade fairs. Come and join us!
We look forward to getting to know you.
Festo at trade fairs
and conferences
April to November 2012
Analytica, Munich 17/04 – 20/04
Pump & Valves 2012, Antwerp, Belgium 18/04 – 19/04
Hanover Fair 23/04 – 27/04
IFAT ENTSORGA, Munich 07/05 – 11/05
TeroTech 2012, Celje, Slovenia 15/05 – 18/05
Automatica, Munich 22/05 – 25/05
Achema, Frankfurt 18/06 – 22/06
MSR Spezialmesse Rheinland, Leverkusen 27/06
Sindex, Berne, Switzerland 04/09 – 06/09
MSR Spezialmesse Südwest, Ludwigshafen 19/09
IAA Commercial Vehicles, Hanover 20/09 – 27/09
PVSEC 2012, Frankfurt 25/09 – 28/09
Aadeca 2012, Buenos Aires, Argentina 03/10 – 05/10
Motek, Stuttgart 08/10 – 11/10
Scanautomatic 2012, Göteborg, Sweden 09/10 – 11/10
Science Days 2012, Rust 11/10 – 13/10
Schüttgut Dortmund 07/11 – 08/11
Vision Stuttgart 06/11 – 08/11
FoodTech 2012, Herning, Denmark 13/11 – 15/11
SPS/IPC/DRIVES, Nuremberg 27/11 – 29/11
Valve World, Düsseldorf 27/11 – 29/11
For more information, see www.festo.de/messen
Hanover Fair 2012: Exhibitors
from all over the world will be
demonstrating innovations
and solutions based around
the theme “Technology meets
progress”. Festo will be there
in Hall 15, Stand D07.
Automatica, the international trade fair
for automation and mechatronics in Munich.
Visit Festo in Hall A2, Stand 311.
www.festo.com/facebook
www.festo.com/youtube
www.festo.com/twitter

Fill up with solar energy About this
magazine
This issue focuses on energy effi ciency
and energy saving measures. Now you
can produce your own energy even when
out hiking. The solar rucksack powers
portable devices such as a smartphone,
digital camera or GPS. Even laptops and
tablet PCs will hold their charge.
So what are you waiting for? Let’s go!
1 st prize:
Solar rucksack
2 nd to 4 th prizes:
Energy meter
5 th to 20 th prizes:
Festo “CubiCup” (see page 50)
Submit the correct answers to the
questions below at www.festo.de/trends
by 15 May 2012 to be entered into the
draw. Only one entry per person is
permitted. There is no right of appeal
and no cash alternatives are available.
Festo employees and their families are
excluded from participating.
The winners will be announced on the
Festo homepage and in the next issue
of this magazine. Best of luck!
1. The EGSL is a…? (page 38)
2. What type of cylinder are DNC and DSNU? (page 41)
3. In which Hungarian city does Festo produce components for
compressed air preparation? (page 30)
“trends in automation 2.2011” winners
1 st prize: GEO Themenlexikon: Mr. Opitz,
GKN Sinter Metals Components GmbH,
Bonn
2 nd – 4 th prizes: Trivial Pursuit Wetten
& Gewinnen: Mr. Pirner, Gerresheimer
Werkzeug- und Automatisierungs-technik
GmbH, Wackersdorf; Mr. Heidtmann,
Aspen Bad Oldesloe GmbH, Bad Oldesloe;
Mr. Feil, Dr. Schneider Kunststoffwerke
GmbH, Kronach
5 th – 6 th prizes: Zeit – Wissen magazine:
Mr. Dolzer, Josef Rettenmaier & Söhne,
Rosenberg; Mr. Fitzner, BK Giulini GmbH,
Ludwigshafen
4. What secures the bonding process without failures caused by production? (page 12)
5. Which media does the fl ow sensor SFAW control? (page 37)
6. What is the name of the telescopic handling unit that transports solar
cells? (page 26)
1.2012 trends in automation
Festo worldwide/Competition 52 – 53
trends in automation 1.2012
April 2012
Print run
35,000 copies
Publication dates
Several times a year
Cost: € 3
Publisher
Festo AG & Co. KG
Ruiter Straße 82
D-73734 Esslingen, Germany
Tel. ++49 (0) 711 347 0
Fax ++49 (0) 711 347 20 71
infoservice@festo.com
Project management
Silke Gartenmeier, Customer Magazine
Tel. ++49 (0) 711 347 39 02
gtm@de.festo.com
Responsible for content
Dirk Ebertz,
Head of Marketing Instruments
dbrt@de.festo.com
Ralf Sohn, Head of Direct Marketing
rso@de.festo.com
Please note
All terms such as customer, user,
specialist or technical consultant refer
to both men and women.
Copyright 2012 Festo AG & Co. KG
All rights reserved.
All images, graphics and texts are protected
by copyright law or other intellectual
property rights. Any reproduction,
modifi cation or use in other print
or electronic publications is prohibited
without the express consent of Festo
AG & Co. KG.

Are you
on target,
Mrs. Klesmann?
My work as an engineer in the Standard
Design department requires creativity
and concentration. The same can be
said of fi eld archery, which is a personal
passion of mine. I consider inner calm along with the
knowledge that I have acquired over the years to be the
key to my success. However, there’s no way of guaranteeing
that I’ll hit the target every time – either in archery or in
3D model design. There are simply too many variables to
be taken into account.
In fi eld archery, you can spend up to seven hours on a
course stretching over several kilometres and may fi nd
yourself having to assess the conditions as many as
24 times. How far away is the target? How does the
terrain affect the path of the arrow? What are the wind
and weather conditions like? And, most importantly,
what is my physical and mental state? Even with 15
years of experience, two German Championship titles
and fi fth place in the European Championships under
my belt, there is absolutely no guarantee of success.
With each target, the adaptation and optimisation
process begins anew.
My work with 3D models is very similar, in that I must try
to understand the product, the manufacturing process
and the application process. Even the smallest deviation
or minimal change in dimensions can have major consequences
– both positive and negative. You have to know
the product features and be able to think beyond the
current situation and to look at it from a different
perspective in order to identify new possibilities. Just
like on a fi eld archery course, you often have to approach
your target slowly and gradually in order to hit the mark.
1.2012 trends in automation
Soft Stop 54

Highly modular
Ideal for special purpose machine
construction – valve terminal MPA-L.
Simply choose the combination of individual
components you need and then add or
remove components as required.
www.festo.com

Photo: Torresol Energy
Powering change
The Gemasolar solar power plant in Andalucia, with its
140-metre high concrete tower and a fi eld containing 2,650
heliostats, is powering change. What makes this power
plant revolutionary is not the heliostats or the central receiver,
but the way in which energy is stored – fl owing through the
receiver and fi lling the tanks, which are 14 metres high and
36 metres wide, located at the base of the tower.
Until now, solar technologies were restricted by the fact that
they normally only generate electricity during sunlight hours.
Gemasolar is the fi rst large-scale solar power plant to use
molten salt as a heat storage system. When heated to
565 degrees Celsius, it can provide electricity for 15 hours.
Gemasolar can therefore supply power round the clock
and not just when the sun is shining.
The Spanish solar power plant is just one example of the intelligent
use of energy. Industry initiatives such as Green Carbody
or Blue Competence are setting the standard for greater
energy effi ciency worldwide.
Festo Corporation
395 Moreland Road
P.O. Box 18023
Hauppauge, NY 11788
Phone 1.800.99.FESTO
Fax 1.800.96.FESTO
customer.service@us.festo.com
www.festo.com/us