Servopneumatics

Mechatronic Motion Solutions

Mechatronic Motion Solutions

from Festo is a worldwide
unique system which comprises
components, modules and software. It combines all types of
pneumatic, servopneumatic and
(electro)mechanical motion,
geared to your task. Irrespective
of the control system you use,
Mechatronic Motion Solutions
provides the appropriate interfaces.

Mechatronic
Guarantees mechanical and electrical compatibility at all levels.
All pneumatic and electric drives
are equipped with suitable interfaces for mechanical, data and
energy transmission, thus ensuring that different technologies
can be combined in one system.
It also enables complex handling
and positioning systems to be
set up easily and safely.

Motion
Stands for the comprehensive,
multi-dimensional portfolio of
linear and rotary drives as well
as a large variety of mechanical
and vacuum grippers. They provide a host of benefits, such as
high speed, precision, etc.

Solutions
Represents the decades of experience Festo has in the field of
handling technology, across all
industries and continents, as
well as its expertise in the development of components and
sophisticated systems. They
range from pre-designed and
calculated components to subsystems and complete systems,
making them the logical answer
to the demand for pre-installed
and customised systems and
solutions.

Products for servopneumatic systems

The Festo product range, from

controllers to drives, makes it
extremely easy to implement
servopneumatic systems. It is
also perfect for integration into
the CPX environment with universal fieldbus connection.

One of the latest intelligent CPX terminal modules:

the positioning module CMAX. With this module,
you can use a wide range of drives such as DGCI,
DNCI and DSMI, as well as control their position
and force.
More information on page 9
Application examples on pages 1619
Brings drives to the right position gently and quickly
and then accelerates even more quickly: the electronic end-position controller CMPX. It is also new
in the CPX terminal and protects the drive and handling unit through gentle pneumatic braking.
More information on page 10
Application examples on pages 1619

The proportional directional control valve VPWP

with integrated pressure sensors doesnt just give
you the best control results; in addition to the sensor data, it also sends diagnostic data to the CMAX
and CMPX.
More information on page 11

Drives with displacement encoder DGCI, DNCI or

DSMI: drives with linear or rotary motion that also
give you the advantages of pneumatics. They offer
dynamic response, force and versatility all with
a positioning accuracy of 0.2 mm!
More information on pages 1215
Note:
For additional information
on our products, visit our
website at
www.festo.com

Good reasons to choose servopneumatics

As the global market leader for

servopneumatic systems, Festo
now presents the third generation of servopneumatic drive systems. This includes groundbreaking innovations such as the proportional directional control valve
VPWP, which will open up new
fields of application and make
familiar solutions even simpler
and more stylish.

Electrical terminal CPX

with positioning module CMAX

Proportional valve
VPWP

Pneumatic linear drive

with integrated displacement
encoder DGCI

Perfectly matched
It goes without saying that the
individual Festo servopneumatic
components are perfectly
matched to each other, whether
they are used as stand-alone
units or together with pneumatic
or electric components. This
makes Festo servopneumatics
an important part of the mechatronics kit.
Versatile positioning of
large loads
Maximum power density in
automation dynamic
response, force and versatility
are guaranteed with servopneumatics based on controlled
pneumatics.
Position control or force control? Why not both? Also with
positioning accuracy of up to
0.2 mm or 5% of the force setpoint value for a wide range
of drives.
Commissioning at the push of
a button
The integration of the position
controller CMAX and the electronic end-position controller
Soft Stop CMPX into the modular electrical terminal CPX
reduces the time and effort
you spend on installation, configuration and commissioning.

When is it right to use servopneumatics? Your application

decides!
Pneumatic, servopneumatic,
electrical or in combination? The
decision is yours. Our expert consultants give you the freedom of
choice, as Festo can provide you
with all three technologies.

This means that you can always

be sure that youre using the best
possible technology.
Servopneumatics is recommended whenever the following criteria and advantages are important
to you:

If you ...
... prefer sturdy, compact,
low-cost solutions
want a repetition accuracy in
the tenth-of-a-millimetre range
want to reduce air consumption by up to 30% in comparison to standard pneumatics
do not require maximum
precision and speeds as priorities but are looking for cost
advantages of up to 50% compared to electrical solutions
and for combining positioning
and force control to enable
new approaches to problem
solving.
place great value on the use
of diagnostics to optimise
machine availability and
reduce downtime. Each device
in the control circuit supplies
differentiated diagnostic data.
already have compressed air
available.

The entire world of servopneumatics at a glance

The range of servopneumatic

products in the modular mechatronic system leaves nothing to
be desired.

Coordinating level

Coordinating system

Control level
Control system

Position controller
CMAX

Controller

Integrated
controller
FED-CEC

Integrated
controller
CECX

PLC
(ABB, Allen-Bradley,
Rockwell, Siemens
etc.)

Field level

End-position controller
CMPX

Proportional
valve VPWP

Actuation

Sensor interface
CASM

Front unit

Servopneumatic

Pneumatic

Electric

Drives

Linear drives with

displacement encoder
DNCI

Grippers

DGCI

Vacuum

Axis controller
SPC200

End-position
controller
SPC11

Ethernet

Axis interface
CPX-CMMX

CPX-CEC

Fieldbus

Robotic
controller
CMXR

Ethernet
(Profinet
Ethernet/IP
EtherCat
TCP)

FHPP
Festo Handling and
Positioning Profile
CoDeSys
provided by Festo
FST 4
Festo Software Tool

Axis interface
SPC-AIF

AS-interface

Proportional valves
MPYE

Swivel modules with

displacement encoder

Fieldbus
(Profibus,
Interbus,
DeviceNet,
CANopen,
CC-Link)
FCT
Festo
Configuration
Tool

DSMI-B

Rotary drives

Vision systems

PositioningDrives
Design and calculation software for
electric drives

Excellence in servopneumatics through innovative products

Maximum power density with

innovative servopneumatics
As the leading provider of
automation technology, Festo
sets high standards for itself,
especially when it comes to the
product portfolio. Thats why our
research and development
experts have been able to consistently expand our range of
servopneumatic components
over the past few years. Three
factors in particular are evidence
of this:
The most powerful, reliable
and energy-efficient servopneumatics on the market
Complete range of servopneumatic products: turning, gripping, linear motion, control
all from a single source
Reasonable prices not just for
the products themselves, but
also when the overall life cycle
costs are taken into account
The following pages contain
more details about our range
of servopneumatic products.

Servopneumatic positioning module CPX-CMAX-C1-1

One of a kind: The new positioning module CMAX is one of a

kind. It is designed for simple
servopneumatic control of various pneumatic drive families,
linear or rotational.The CMAX is
a positioning and force control
module of the electrical
terminal CPX.

Multi-purpose
Positioning technology using
servopneumatics is particularly
useful when compact, low-cost
solutions are required for moving loads typically in excess of
5 kg and accuracy within a few
tenths of a millimetre is sufficient.
Benefits
Positioning and force control in
one work step
Compact, low-cost positioning
system for sturdy applications
Fast processes/high productivity thanks to the FCT software
tool for simple commissioning
with auto-identification and
comprehensive diagnostics

Technical data
Moving loads

Modbus TCP
Activation via control block CPXCEC-C1 and all fieldbuses available in CPX.

horizontal [kg]
vertical
[kg]
Regulated force at 6 bar
[N]
Positioning accuracy
[mm]
Travel speed
[m/s]
Max. 3
Acceleration
[m/s2]

1-300
1-100
30-2700
0.2
Max. 30

Electronic end-position controller Soft Stop CPX-CMPX-C-1-H1

With CMPX, the unique Smart
Soft Stop principle is finding its
own way into the world of the
modular electrical terminal CPX.

The electronic end-position control enables a cycle time reduction of about 30%, with virtually
vibration-free travel to the
mechanical end positions.
Smart Soft Stop enables highly
dynamic movement of loads up
to 300 kg.

Benefits
Approx. 30% shorter travel
times and 30% less air consumption than equivalent
standard pneumatic solutions
Increased cylinder service life
No vibrations when returning
to the end positions
Suitable for use with all fieldbuses/Ethernet and CEC available in CPX
Easy commissioning, Festo
plug and work
New functions
Digital data handling
Pressure sensors provide
reliable downtime control
Two mid-positions can be
flexibly adjusted using the
fieldbus
Brake output on proportional
valve VPWP

Key features
Moving loads

1 ... 300 kg horizontal

1 ... 100 kg vertical
Actuation
Via all fieldbuses available in CPX
Front End Controller FEC and CEC-C1
Mid-positions
Up to two freely programmable mid-positions,
also via the fieldbus
Accuracy 0.25 % of the displacement encoder
length, and no less than 2 mm
Downtime monitoring via pressure sensors
in the valve
Reliable in combination with the brake
function
Max. line length between the controller and the drive: 30 m
Fast, vibration-free travel between two fixed stops

10

Proportional directional control valve VPWP for servopneumatics

Teamwork for maximum servopneumatic productivity: the proportional directional control
valve VPWP with integrated, digital, serial interface for the servopneumatic positioning system
CPX-CMAX and end-position
controller CPX-CPMX Soft Stop.
With the proportional directional
control valve, the force control
function is now also available for
the position controller CMAX.
Integrated pressure sensors constantly monitor the pressure in
the chambers of the connected
drive and give you an edge in
diagnostics and condition monitoring, as the fully
digitised valves supply the controller not only with the sensor
data, but also with valuable
diagnostic values regarding their
own operating status. Total
process reliability!

Multi-sensor control
Integrated pressure sensors and
cascade control for optimum,
high-precision control results
and sturdy characteristics. Optimum positioning characteristics
with speed and acceleration
ramps.
Additional function
Digital switching output for
controlling
A shut-off valve or
A switching valve for a clamping unit
Further advantages
Durable: adaptive selftuning control algorithm
Quicker to install: plug and
work with auto-identification
More productive: comprehensive diagnostic capabilities

11

Design options
The design of the displacement
encoder differs depending on
its function, use and location.
Measuring absolute values,
incremental and contactless or
potentiometric (e.g. for retrofitting) each option has its
own strengths.

CPX terminal
CMAX or CMPX
DGCI

Linear motion
Rodless drive DGCI with recirculating ball bearing guide and
contactless displacement
encoder for measuring absolute
values.
Advantage: the drive can be
directly connected to CMAX or
CPX without an extra interface,
providing plug and work with
auto-identification.

VPWP

Compressed air

CPX terminal
CMAX or CMPX

DNCI

VPWP

Compressed air
CASM

12

Linear motion
Standard cylinder DNCI to ISO
15552 with contactless displacement encoder and additional sensor interface CASM.
As a signal converter, the sensor
interface CASM establishes the
connection between the incremental displacement encoder
with potentiometer and
the proportional valve VPWP.
This digitised bus transmission
is very secure.

Linear motion
Standard cylinder DNC to ISO
15552 with external displacement encoder/potentiometer.
One design for all standard
cylinders.

CPX terminal
CMAX or CMPX

e.g. DNC

VPWP

Compressed air

e.g. MLO-POT-...-LWG
CASM

Rotary motion
Semi-rotary drive DSMI and sensor interface CASM.

CPX terminal
CMAX or CMPX

VPWP
CASM

Compressed air

DSMI

13

Drives and displacement encoders

With the combination of highpower drives and an integrated
displacement encoder, it is possible to use the dynamic
response, force and flexibility of
pneumatics for many positioning
tasks with a positioning accuracy of up to 0.2 mm. Linear and
rotary motion is possible servopneumatics can be used to
actuate a great variety of pneumatic drives.

Advantages built in:

integrated displacement
encoder
Compact and flexible, with no
inconvenient external attachments
Long service life thanks to the
wear-resistant contactless displacement encoder
Simple installation and assembly thanks to mounting accessories from the corresponding
cylinder module.

14

Standard cylinder DNCI

Technical data
Diameter: 32, 40, 50 and 63 mm
Stroke length: 10 ... 750 ... 2000 mm
Max. force: 430 ... 1680 N
Suitable for CMAX, CMPX and as a measurement
cylinder
Key features
With contactless displacement encoder for
incremental measurement
Wide range of piston rod variants
Standard cylinder to ISO 15552
Optimum performance with guide and
clamping unit

Linear drive DGCI

Technical data
Diameter: 18 63 mm
Stroke length: 100 2000 mm
Max. force: 120 ... 1680 N
Suitable for CMAX and CMPX
Key features
With guide
With contactless displacement encoder for
absolute measurement
Based on linear drive DGC
Supply ports optionally on end face or front
Wide range of options for mounting on
drive units
System product for handling and assembly
technology

Semi-rotary drive DSMI

Technical data
Diameter: 25, 40 and 63 mm
Swivel angle: 0 ... 270 swivel angle
Mass moment of inertia up to 6000 kg/cm
Suitable for CMAX and CMPX
Key features
Based on swivel module DSM
Built-in rotary encoder
Compact design
Wide choice of mounting options

Displacement encoder MLO

Technical data
Stroke: profile 225 ... 2,000 mm,
connecting rod 100 ... 750 mm
Measuring principle: potentiometric,
contacting and measuring absolute values
Suitable for CMAX and CMPX
Key features
Function: analogue
System product for positioning applications
and Smart Soft Stop (SPC10/SPC11)
Version: profile or connecting rod
Low-cost
Ideal for retrofitting

15

Pressing unit for sawing wooden planks

The task
Wooden planks of different
thicknesses are sawn into slats
of different widths using highspeed saws. During the sawing
process, each plank is pressed
down by three rollers (m = 80 kg)
and moves at 3 m/s. The contact
pressure can be adjusted
according to the type of wood.

The solution
A proportional directional control valve VPWP-6 on each standard cylinder DNCI-100-100 controls the movement of the contact rollers. The core of the control unit is made up of a CPX terminal with a local CPX-FEC, a
Profibus interface, three CMAX
modules and an I/O module.

Once the plank has gone

through the machine, the contact rollers must return to their
initial position without coming
into contact with the conveyor.

New for CMAX: the combinable

record switch unit. This ensures
reliable switching through different operating statuses. The unit
switches between position control and force control on an
event-controlled basis.
The CPX-FEC controls the CMAX
modules via I/O and fieldbus.

The data for the plank that is

being fed into the machine are
transmitted to the system by
the fieldbus.

16

The advantages
The stand-alone solution
independently controls the
pressing process
Fast and flexible
A system for position and
force control, freely programmable
Safety functions integrated
into the system: emergency
off and Board fed in signal
for locking the system
Clear error diagnostics

Areas of application
The full potential of servopneumatics comes to the fore
in the following fields:
Production engineering,
e.g. flexible and controlled
pressing of workpieces with
a defined force
Packaging technology, e.g.
repositioning goods from a
conveyor belt to a packaging unit
Conveying technology, e.g.
in pushing and sorting
functions
Dosing technology, e.g. in
volume filler systems
Test engineering, e.g. for
positioning the test
equipment

17

Filling in a matter of seconds

The task
The bags must be filled with 50
to 150 ml in just a few seconds.
The outlet port of the dosing
valve must be flexibly adjustable
between 0 and 100%. A precision of 0.5 mm is sufficient for
this task. Another important
requirment is that the filling
liquid must not be heated up
by the drive.

The solution
Four standard cylinders, each
with a valve VPWP, control the
filling process. A CPX terminal
with a Profibus interface and
four CMAX modules controls the
four axes. The positioning stroke
of the cylinder is set via the
fieldbus, independently of the
volumes to be filled.
In order to protect the cylinders
against the cleaning agents,
each one is individually encapsulated. The valve terminals and
proportional valves are mounted
in areas of the machine that are
shielded from splash-water.

18

The advantages
Flexible dosing of a wide range
of media
High cycle rate
Each filling cylinder can be
controlled individually
Compact design
Uses the existing CPX terminal
Great value solution
No temperature rise
Can be controlled directly via
the PLC
No programming required

Safety Your requirements in focus

The aim of the risk assessment
is, amongst other things, to
determine the hazardous situation and then estimate the risks.
This applies to the entire life
cycle of a machine.

For operation, this is generally

split into four modes:
Basic setting/rest
Normal operation
Set-up and service operation
Emergency operation
The necessary safety functions
can be derived from these operating modes:

An example: Reversing at
reduced speed and with dualchannel protection against
unexpected restarting.

Tamper-proof, prevention
of unexpected start-up

Stopping, holding
or blocking a
movement

Pressurising

Maintaining pressure

Reducing speed

Switching to unpowered

Reversing a
movement

Pressure and force

reduction

Exhausting

Note:
You can find more details in
our safety brochure, available
in PDF format from the download area
www.festo.com
19

Festo worldwide

Australia
Festo Pty. Ltd.
Head Office (Melbourne)
179-187 Browns Road, P.O. Box 261
Noble Park Vic. 3174
Call Toll Free 1300 88 96 96
Fax Toll Free 1300 88 95 95
Tel. ++ 61(0)3/97 95 95 55, Fax 97 95 97 87
E-mail: info_au@festo.com.au
Austria
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Linzer Strae 227
1140 Wien
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E-mail: automation@festo.at

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01511 Vantaa
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5300 Explorer Drive
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India
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237B,
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Iran
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Teheran 1581975411
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Teheran 1389793761
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Malaysia
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Mexico
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Schieweg 62
2627 AN Delft
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E-mail: info@festo.nl
New Zealand
Festo Limited
20 Fisher Crescent
MT. Wellington
Auckland NZ
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Festo Automation Ltd.
Motorways Centre, First Floor, Block C
Alausa, Ikeja,
Lagos, NIGERIA
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Avenida Granvia, 159
Distrito Econmico Granvia L'H
08908 Hospitalet de Llobregat, Barcelona
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200 21 Malm
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Moosmattstrasse 24
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Taiwan
Festo Co., Ltd.
Head Office
24450, No. 9, Kung 8th Road,
Linkou 2nd Industrial Zone
Linkou Hsiang, Taipei Hsien,
Taiwan, R.O.C.
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Ukraine
Festo Ukraina
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ul. Borisoglebskaya, 11
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Israel
Festo Pneumatic Israel Ltd.
P.O. Box 1076, Ha'atzma'ut Road 48
Yehud 56100
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Romania
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010217 Bucuresti
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Czech Republic
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147 00 Praha 4
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Fax ++420 241 77 33 84
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Italy
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Russia
OOO Festo-RF
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119607 Moskow
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Denmark
Festo A/S
Islevdalvej 180
2610 Rdovre
Tel. ++45 70 21 10 90, Fax ++45 44 88 81 10
E-mail: info_dk@festo.com

Japan
Festo K.K.
1-26-10 Hayabuchi, Tsuzuki-ku
Yokohama 224-0025
Tel. ++81 (0)45/593 56 10, Fax 593 56 78
E-mail: info_jp@festo.com

Singapore
Festo Pte. Ltd.
6 Kian Teck Way
Singapore 628754
Tel. ++65/62 64 01 52, Fax 62 61 10 26
E-mail: info@sg.festo.com

Estonia
Festo OY AB Eesti Filiaal
Laki 11B
12915 Tallinn
Tel. ++372 666 15 60, Fax ++372 666 15 61
E-mail: info_ee@festo.com

Korea South
Festo Korea Co., Ltd.
470-1 Gasan-dong, Geumcheon-gu
Seoul #153-803
Tel. ++82 (0)2/850 71 14, Fax 864 70 40
E-mail: info_kr@festo.com

Slovakia
Festo spol. s r.o.
Gavlovicov ul. 1
83103 Bratislava 3
Tel. ++421 (0)2/49 10 49 10, Fax 49 10 49 11
E-mail: info_sk@festo.com

Croatia
Festo d.o.o.
Nova Cesta 181
10000 Zagreb
Tel. ++385 (0)1/619 19 69, Fax 619 18 18
E-mail: info_hr@festo.com

South Africa
Festo (Pty) Ltd.
22-26 Electron Avenue, P.O. Box 255
Isando 1600
Tel. ++27 (0)11/971 55 00, Fax 974 21 57
E-mail: info_za@festo.com

Norway
Festo AS
Ole Deviks vei 2
0666 Oslo
Tel. ++47 22 72 89 50, Fax ++47 22 72 89 51
E-mail: info_no@festo.com

Ireland
Festo Limited
Unit 5 Sandyford Park
Sandyford Industrial Estate
Dublin 18
Tel. ++ 353(0)1/295 49 55, Fax 295 56 80
E-mail: info_ie@festo.com

Colombia
Festo Ltda.
Avenida El Dorado No. 98-43
Bogot
Tel. ++57 (0)1/404 80 88, Fax 404 81 01
E-mail: festo@festo.com.co

Slovenia
Festo d.o.o. Ljubljana
IC Trzin, Blatnica 8
1236 Trzin
Tel. ++386 (0)1/530 21 00, Fax 530 21 25
E-mail: info_si@festo.com

United Kingdom
Festo Limited
Applied Automation Centre, Caswell Road
Brackmills Trading Estate
Northampton NN4 7PY
Tel. ++44 (0)1604/66 70 00, Fax 66 70 01
E-mail: info_gb@festo.com
United States
Festo Corporation (New York)
395 Moreland Road, P.O. Box 18023
Hauppauge, N.Y. 11788
Call Toll-free 800/993 3786
Fax Toll-free 800/963 3786
Tel. ++ 1(0)314/770 01 12, Fax 770 16 84
E-mail: customer.service@us.festo.com
Venezuela
Festo C.A.
Av. 23, Esquina calle 71, No. 22-62
Maracaibo, Edo. Zulia
Tel. ++58 (0)261/759 09 44, Fax 759 04 55
E-mail: festo@festo.com.ve
Vietnam
Festo Co., Ltd (Cong Ty Tnhh Festo)
No. 206 Tran Nao Street
Ward Binh An, District 2
Ho Chi Minh City, Vietnam
Tel. +84 (0)8/740 69 09, Fax 740 69 10
E-mail: info_vn@festo.com

135004 en 2010/04

Argentina
Festo S.A.
Edison 2392
(B1640 HRV) Martinez
Prov. Buenos Aires
Tel. ++54 (0)11/47 17 82 00, Fax 47 17 82 82
E-mail: info@ar.festo.com