Handling equipment without a control cabinet – virtual start-up

The high-speed handling system with CPX and the integrated EMCA drive with 100 picks a minute enables free movements in space. The CPX automation platform integrates the complete electropneumatic control chain via a CODESYS control system: from the on/off signal, to simple electrical and pneumatic movements, through to the transformation of the tripod models with calibration option.

The CPX takes care of the controls. Originally designed as a valve terminal with remote I/O, it now also enables the local automation in the machine. Together with the electric EMCA drive, the tripod manages completely without a control cabinet for the first time.

The tripod is used to make the connection from the real system to the virtual world and to illustrate the virtual start-up process using CIROS. The CIROS simulation developed by Festo Didactic adopts the tripod as a model from the CAD system. Virtual components are gradually being replaced by real ones in the development process. That improves the quality, shortens the start-up time and shows the way for Industry 4.0. In future, AML (Automation Markup Language) is expected to become the standard for these simulations as a data exchange format for Industry 4.0.

Research Experimental Factory (REF)

The Research Experimental Factory (REF) is a production facility developed by the research department for researching, developing and testing pilot applications for Industry 4.0. The REF represents a production environment that is close to reality, as could be found at many of Festo’s customers: a complete production line is set up from the component to the MES system. Real products are processed with realistic cycle times. Besides Festo components, third party products are also integrated, which enables the interaction between components from different manufacturers to be tested.

Products, for example new drives, grippers or entire handling systems, can be integrated in the REF and tested in exactly the same way as cross-product automation and software concepts.

The modular composition of the REF enables new production stations to be docked via an electromechanical plug-and-produce interface. This facilitates and speeds up the start-up process and makes the production facility adaptable.

Flexible and adaptable assembly

At the Scharnhausen Technology Plant, a facility is being developed to produce a wide variety of valves in small to medium quantities. The research department is helping to plan this – particularly with regard to the control architecture and the implementation of the adaptability principles. For this purpose, process stations are being developed that are able to fulfil tasks such as screwing, pressing in, greasing or feeding independent of the product.

These developments are being prepared and tested at the Research Experimental Factory (REF). The knowledge acquired there will be transferred to the Scharnhausen Technology Plant.

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