A highlight of any trip to a trade fair in Germany was always the Festo stand. They turn engineers loose to build some incredible motion displays. This year at Hannover they constructed an “Incredible Machine.”
The Festo Story
It all began 100 years ago in a workshop in Esslingen am Neckar. Festo founder Gottlieb Stoll asked himself how technology could make work easier. From the initial production of machines for woodworking, the company developed into the production of pneumatic and electrical automation technology for mechanical engineering in a wide range of industries. Today, Festo is one of the world’s leading automation specialists.
To mark the company’s 100th anniversary, Festo has designed an extraordinary application, the Incredible Machine. It is not a specific product, but works on the principle of a Rube Goldberg machine, in which one movement triggers the next. The Incredible Machine demonstrates the history of automation technology from the past to the present and reflects our wide range of competencies and our comprehensive expertise.
The Incredible Machine shows the fascination for motion technologies, be it pneumatic, electric, digital or a combination of these, it presents the most important industries in which Festo operates, it inspires enthusiasm for technology and it provides an outlook on what the future of automation could look like – because inventiveness and a pioneering spirit have been part of our DNA from the very beginning.
Just as a butterfly can trigger a chain of movements by fluttering its wings, sometimes a tiny impulse can bring about significant changes. That is why our eMotionButterfly sets the machine in motion. During this journey, we look back at our history, but above all we are looking forward to the future. A motion impulse runs in 12 modules over a total length of 46 feet, triggering a chain reaction of different motion functions in the machine. More than 1000 Festo products and more than 1.12 miles of tubes and cables are installed in the machine.
Whether pushing, turning, lifting, positioning or relocating workpieces, materials and products during their production process, whether dosing, filling, throttling or pumping liquids and bulk materials in the process industry: motion is involved everywhere in industrial manufacturing processes. As a specialist in automation, Festo has made motion its core business.
The machine is not a purchasable product, but rather an innovation carrier that demonstrates the range of technical solutions in automation technology. Festo also wants to show how important freedom for creativity and inventiveness are to maintain a leading position in global competition. Festo wants to be the best partner for its customers, always at the highest technological level and as a holistic provider of electrical, pneumatic and digital solutions and – as a special USP – the matching training courses from Festo Didactic.
Innovations can solve specific problems and have the potential to change entire sectors and create new industries. The driving forces behind these innovations are the ecosystems of customers and partners who are looking for solutions to their challenges. The journey in the machine leads through specific industries, such as battery production for electric cars, laboratory automation in the life sciences, intralogistics and the semiconductor industry. It delves into the company’s history and ends with insights into the actuator technology of the future. But the momentum continues.
Motion is changing our world and will continue to do so in the future. How this change will unfold over the next 100 years remains to be seen. But one thing is certain: it will be characterized by motion and bold ideas. Through small impulses that can trigger chain reactions and ultimately lead to something big.
This news lies far from my core of experience. I, however, have been impressed with Festo technology ever since my first factory visit probably close to 20 years ago. Just when I begin to believe that innovation is dwindling in this market, a new product arrives.
Festo introduces its new flagship valve terminal, the VTUX. The VTUX can serve as I/O, remote I/O, and decentralized I/O. These compact and rugged IP65/67-rated terminals can be located anywhere on a machine that boosts operational performance and original equipment manufacturer (OEM) installation productivity. VTUX modularity results in less inventory and lower overhead costs.
VTUX is both compact and lightweight, an advantage for end-of-arm tooling and conserving space on a machine or in a control cabinet. The terminal is made from a high-performance polymer so rugged and durable that these units can be placed in welding cells.
The key to the VTUX’s flexibility is its modular design. For high flow rates up to 670 l/min, a high flow sub-base is used and for space saving needs, the compact sub-base. A single valve model can be used for both sub-bases, which simplifies ordering, stocking, and support. High flow and compact sub-basses of one or four valve positions can be mixed and matched on a terminal. VTUX terminals can have up to 128 valves with up to 128 solenoid coils. The VTUX also features vacuum capability.
VTUX offers a platform for fully integrated vacuum solution for configuration of up to sixteen vacuum channels per terminal. The platform enables bidirectional communication from the PLC to the vacuum generator. Vacuum and ejector pulse can be individually controlled. VTUX vacuum delivers high vacuum or large suction volume flows and can be combined with valves. Parameters can be changed via teach-in from the PLC during operation. There is an integrated vacuum sensor for continuous monitoring of actual values and there is a parameter-based air saving function. The system monitors vacuum for early detection of faults or errors during operation.
The electronics side of the terminal offers the same flexibility as the pneumatics side by featuring mix and match modules. For example, users can add multiple analog or digital I/O modules, including I/O-Link. The modular concept continues through to the method of communication between controller and terminal. The choices include the new Festo Automation Platform (AP) for backplane speed communication in all top communication protocols. All AP-based modules appear to the control engineer to be under a single IP address, simplifying commissioning and allowing smaller and less expensive PLCs to be specified. Additional communication modules include IO-Link, AP-I for decentralized I/O, and multipin connector.
VTUX terminals are assembled and tested prior to shipment from the Festo Regional Service Center in Mason, Ohio, which means they are drop-in ready for installation. As a core Festo product, VTUX components are stocked globally for fast, assured replacement and minimum downtime wherever the machine is located. The modular design not only lowers inventory, but also decreases the learning curve, troubleshooting time, and repair. The VTUX offers an outstanding price/performance ratio.
Time to first production. This mantra has stayed with me since the time a company I worked for built automated assembly machines. This story tells of how some new engineering tools from Festo and additional assembly services enabled a company called CODI Manufacturing to meet a customer’s immediate need.
CODI Manufacturing introduced today a compact, flexible 12-cycle-per-minute case packer for small to mid-sized food and beverage companies that achieves an industry leading price/performance ratio.
The company utilized the Festo Handling Guide Online (HGO) engineering tool to design the two-axis handling system, the core of the new machine’s package handling. By having Festo assemble and ship a bolt-in-ready handling system, the company was able to build and commission the new machine in just four weeks.
“This machine is incredibly flexible,” said Jared Jones, Chief Operating Officer, CODI Manufacturing. “All the end user has to do is swap out the gripper head to change the number, type, and size of bottles, cans, jars, or pouches being packed into shipping cases, select a new recipe on the HMI, and start the machine.”
The CODI design features:
Festo’s new multiprotocol CMMT-AS servo drives and matching EMMT-ST one-cable motors
New CPX-AP-A configurable remote I/O terminal
New VTUX valve terminal
A simplified motion series (SMS) low-cost electric-linear actuator
The CDPX IP67 machine mounted HMI
Festo robust linear axes
The Festo CPX-CEC controller with EtherCAT communications for advanced motion control.
Collaboratively, Festo Engineering and CODI developed a pneumatic gripping head that provides feedback on successful gripping of each bottle. “Customers are amazed at the advanced motion automation technology on this machine for the price point,” Jones said. “It’s striking how much state-of-the-art automation is packed into such a small footprint machine.”
CODI Manufacturing had wanted to build a compact case packer for small to mid-sized companies for several years. Recently, CODI was four weeks into an eight-week project when Jones and the customer discussed adding a case packer to the order. “When I mentioned a price, the customer said he’d buy the machine if we could deliver it in four weeks with the rest of his order,” recalled Jones. “I said we’d try.”
The core of the machine would be a two-axis handling system used to grip and lift six bottles off one conveyor and place them into a box on an adjacent conveyor. The CODI team used the Festo HGO engineering tool to specify the system where the axes, servos, motors, mounting plates, and accessories were all properly sized and interoperable. The design session took minutes, saving CODI several days of engineering time.
“One of my lead controls engineers came into my office and said that Festo would supply a bolt-in-ready handling system at basically the same cost as buying and assembling the pieces and parts,” Jones said. “There was simply so little price difference between assembled and unassembled that we went with assembled. We used CAD files from the HGO session to build the frame while we waited for the assembly. Three weeks later, the system arrived. We used eight bolts to attach it to the machine frame. For a multiple-axis system, this was the easiest and fastest assembly and commissioning we’d ever had and the lowest total cost.”
I tend to like the research coming from Interact Analysis. Their methodology appears to be more rigorous than others that come my way. Samantha Mou, Research Analyst based in China, covers Industrial Automation.
This research report covers motion control in the face of high interest rates, elevated inventory, and sluggish demand in 2024.
She continues, “This has been affecting sales of industrial automation components to machine builders (OEMs), including motion control products. Despite this, innovative technologies continue to create new opportunities for motion control, attracting new entrants to the market through product launches or partnerships. In this insight, we will discuss two new growth areas identified from our research and conversations with manufacturers: smart conveyance technology and robots with machine-integrated control.”
Smart conveyance technology
Smart conveyance technology is a multi-carrier transport technology and is available as either linear or planar systems. The market for linear systems has surged over the past three years, with sales revenue growing from $237 million in 2020 to $488 million in 2023. By 2029, sales of linear systems are expected to exceed $1.1 billion, nearly five times the market size in 2020. Planar technology is still in its trial period, generating sales of nearly $20 million in 2023.
Since Interact Analysis began tracking smart conveyance market data in 2020, the food, pharmaceutical and general packaging industries were the main application markets for smart conveyance systems until 2022. However, over the past 2-3 years, the landscape has changed with the rapid penetration of smart conveyance products in the Asian market, and a sharp increase in sales from the battery and electronics industries.
Although new vendors have not acquired meaningful market share, as the supplier base has not yet consolidated, we expect they will increase their presence, especially in their local markets; China, Japan and Europe.
There has been rapid expansion of the supplier base for linear smart conveyance systems, particularly in the Asia Pacific region.
Naturally, rising demand for smart conveyance technology represents a growing market for motion control products, including servo and direct drive technologies. Rather than offering smart conveyance systems in their own portfolio, some vendors are supplying key components to system providers. For example, many automation companies, including Rockwell and Siemens, have partnerships with Planar Motor Inc. (PMI), which makes planar smart conveyance products, to equip PMI systems with servo drives and controllers.
Machine-integrated robots
The term machine-integrated robots refers to robots that are fully integrated into machine control platforms, either by eliminating robot-specific controllers or by retaining robot controllers but integrating the programming platform into the machine systems. The first approach is more common for those machine-integrated robots currently deployed, which include customized robots made by machine builders (OEM-manufactured robots).
In 2023, global machine-integrated robot shipments reached nearly 20,000 units, of which shipments in the Americas, EMEA and Asia-Pacific regions accounted for 31%, 41% and 28% respectively. From 2023 to 2029, the market is projected to grow at a compound annual growth rate (CAGR) of 14.6%. Compared with the standard industrial robot market (with annual shipments of more than 520,000 units), the machine-integrated robot market is currently much smaller but is expected to grow at a faster rate.
The shortage of experienced engineers is one of the major drivers of growth for the machine-integrated robot market. By integrating robot and machine controllers, engineers can control machines and robots in a unified development environment, without using robot programming languages. This helps reduce challenges for both machine builders and end users in finding or training engineers and operators for robotic machines.
New entrants and partnerships are increasing the number of solutions available for machine-integrated robots. Robot manufacturers, machine builders and motion control system suppliers are all actively introducing new products and solutions.
For example, Rockwell Automation partnered with autonox Robotics in 2023, having previously entered a partnership with Atom Robot in late 2022. Now, robot arms from three robot vendors can be directly equipped with Rockwell PLCs. Most recently, Siemens confirmed new cooperation agreements with collaborative robot makers Universal Robots and Jaka, further expanding the range of robots that can be directly programmed on its platform. In the meantime, motion control suppliers also work closely with machine builders to provide solutions for OEM-made robots. For example, SEW offers a “Parallel Arm Kinematics Kit” to OEMs looking to make their own delta robots. In China, many packaging machinery manufacturers exhibited machines with picking robots made in-house at the recent CIIF tradeshow.
Final Thoughts
The surging smart conveyance market and the emergence of machine-integrated robots offers new opportunities to motion control suppliers. Driven by the trends of digitalization, flexibility, and ease-of-use in the manufacturing industry, both technologies are expected to increase their penetration in the machinery industry. Despite current challenges, many suppliers are preparing strategies for the next growth cycle. Companies with competitive products and solutions will gain an advantage when demand inevitably picks up.
Once motion control systems, robot systems, and logic control systems existed as if on two different planets. Technology developers slowly began integrating motion control into their PLC platforms until today no one would acquire a PLC that cannot integrate motion.
Several years ago Rockwell Automation announced a robot control platform integrated into its control platform. And ABB/B+R and several others. Many robot applications readily lend themselves to integration into overall machine control.
Samantha Mou writes for Interact Analysis, one of the few analyst firms I find interesting. Based in China, she has written a good piece about Siemens’ announcements around Hannover Messe.
Just before Hanover Messe, Siemens announced its cooperation with two collaborative robot vendors, UR and JAKA. This will enable Siemens PLCs to control robots from UR and JAKA through the TIA Portal using the ‘Standard Robot Command Interface (SRCI)’ function. Prior to this, Siemens was already working in cooperation with Comau, Stäubli, Kawasaki and Yaskawa in integrated robot control via SRCI. A series of other leading robot brands, such as ABB, KUKA, FANUC, Epson and Techman, are also scheduled to come on board, and some other well-known Japanese and Chinese suppliers are pending, including Yamaha and Estun.
This will mean that the most influential industrial robot and collaborative robot brands on the market will support integrated robot control, allowing their robots to be controlled by automation systems.
Currently, the integration of industrial or collaborative robots and machines generally uses communication networks. The robot and the machine utilize independent control platforms, and robot controllers are connected to the machine PLC via communication protocols to facilitate machine-robot coordination.
So, how do companies integrate the two?
The concept of machine-integrated robot control emerged in a bid to unify control of machines and robots. There are two main ways of doing this. One is to retain the robot-specific controller hardware. For example, Siemens’ method employs a PLC that supports SRCI functions to translate and merge the robots’ control instructions into the TIA Portal. This enables engineers to use Siemens’ development environment to control robots without using robot programming languages.
Another integration method is to eliminate the robot controller hardware and use an automation controller with motion control functions instead. Robot axes are regarded as components of the machine and can be controlled directly by the machine controller. Notable solutions using this method include Rockwell’s Unified Robot Control, B&R’s Machine-Centric Robotics, Schneider’s PacDrive, and Omron’s NJ501-R controller. In addition to robot mechanics coming from robot manufacturers, there are also many cases where machine builders or integrators build robot mechanics themselves.
Another example of labor shortage.
With the increasing adoption of robots and the continued shortage of experienced engineers, there is strong growth in the market’s interest in integrated robot control. Different types of relevant market players are trying to seize the opportunities and benefits offered by this technology.
This acquisition is a very interesting acquisition from several points-of-view. This shows Siemens commitment to factory automation. It hints at entry into the mobile automated robotic space (see the analysis by Vanessa Lopez, Research Analyst, Interact Analysis at the bottom of the story). Even though I don’t see as much in the US as I once did, Siemens is still one of the most active automation suppliers.
Key points from the news.
Planned acquisition to strengthen Siemens’ position as a leading technology company in the field of factory automation and digitalization
Strategic addition to the Siemens Xcelerator portfolio
A business of ebm-papst, a leading supplier of fans and compact and intelligent mechatronic systems, which employs around 650 people
Major growth opportunities in the field of intelligent, battery-powered drive solutions
Siemens AG has signed an agreement to acquire the industrial drive technology (IDT) business of ebm-papst. The business, which employs around 650 people, includes intelligent, integrated mechatronic systems in the protective extra-low voltage range and innovative motion control systems. These systems are used in free-range driverless transport systems. The planned acquisition will complement the Siemens Xcelerator portfolio and strengthen Siemens’ position as a leading solutions provider for flexible production automation.
Cedrik Neike, member of the Managing Board of Siemens AG and CEO of Digital Industries, said: “Ebm-papst’s innovative portfolio of mechatronic drive systems and its highly qualified people are an excellent fit for Siemens. The acquisition will enable us to tap new business and customer potential in the rapidly growing market for intelligent, battery-powered drive solutions in intralogistics as well as mobile robot solutions.”
IDT products are intelligent, integrated mechatronic systems, which support the automation and digitalization of production processes. This acquisition will be a strong addition to the Siemens Xcelerator portfolio. Through their use in mobile robots and driverless transport vehicles as well as in the automation of auxiliary processes, such as the retooling of modern production machines, they are an important lever for greater flexibility and productivity. For this reason, high market growth is expected in this market segment.
The transaction is to be completed by mid-2025, subject to the necessary foreign trade and merger control approvals. The IDT business of ebm-papst is located in St. Georgen and Lauf an der Pegnitz, Germany, and in Oradea, Romania. The parties have agreed not to disclose the purchase price.
“The acquisition by Siemens is a strategically significant step for us. What our industrial drive technology (IDT) business had lacked until now was a global sales organization for maximum growth. Siemens is a long-standing customer and a company with strong international market penetration and an extensive customer base. The integration that has now been agreed upon will give our IDT business global market access. It will open up new horizons for innovation and further growth,” added Dr. Klaus Geißdörfer, CEO of the ebm-papst Group. “We’ll use the proceeds from the sale of the IDT business to further expand our Air Technology and Heating Technology divisions, to further strengthen our three regions – Europe, Asia and the Americas – and to invest in future fields of our product portfolio, such as digitalization and sustainability.”
Interact Analysis take
Siemens’ recent acquisition takes advantage of surging market
VANESSA LOPEZ, Research Analyst, Interact Analysis
If you’ve been following manufacturing news, Siemens has been making big waves in its divestitures and acquisitions over the last few years. Most recently, it divested several business units worth nearly €3 billion into the newly formed Innomotics, which is currently up for sale.
On March 21st, Siemens announced yet another acquisition. In a press release, the company unveiled its plans to acquire ebm-papst’s industrial drive technology (IDT) business. What makes this move most interesting is the acquisition of ebm-papst’s ultra-low voltage motor offering. In a report published by Interact Analysis in late 2023, we found the market for these products is growing strongly, particularly in applications relating to conveying and mobile robotics.
From a product perspective, ebm-papst’s portfolio is a valuable addition to Siemens’ portfolio. While Siemens has been active in the ultra-low voltage drive market, it previously lacked a complimentary motor offering. ebm-papst, with over $50 million in sales, ranks 13th in the global market. The majority of its revenue comes from the EMEA region, where it holds 10th position in the regional market. Siemens’ acquisition of ebm-papst’s IDT division opens up wider global market access for these products, leveraging Siemens’ extensive global sales channels.
While this could include many pieces of equipment, we believe the primary target is mobile robot applications.
Mobile robots are experiencing early-stage growth. As predominantly battery-powered solutions, these robots typically utilize either 24v or 48v DC motors (what we term ultra-low voltage motors). The demand for ultra-low voltage drives and motors is therefore reflecting this upward trajectory. According to Interact Analysis’ ultra-low voltage drives report, revenues are projected to grow at a CAGR of 25.9%, reaching $3.1 billion by 2027. Similarly, ultra-low voltage motors, extensively utilized in mobile robots, are expected to witness substantial revenue growth, reaching $6.5 billion by 2027, as indicated in Interact Analysis’ ultra-low voltage motors report. This surge in demand can be attributed primarily to the burgeoning adoption of mobile robots, particularly in warehouse automation applications.
Also notable is the rapid growth seen by roller conveyors in both segments of the ultra-low voltage markets under discussion. These products are highly compact and often operate at either 12V or 24V, making them an ideal application for ultra-low voltage motors. Moreover, most conveyor manufacturers purchase motors rather than manufacturing them in-house. Our conversations with ultra-low voltage motor vendors consistently highlighted roller conveyors as a significant area of interest for future growth. Interact Analysis estimates this market will nearly double by 2030.
The accelerated surge in warehouse automation, including the adoption of mobile robots and roller conveyors, presents substantial avenues for Siemens to expand its footprint and secure market share. By strategically aligning itself to meet the escalating demand for ultra-low voltage drives and integrated motor solutions, Siemens is poised to benefit from this surging market. Therefore, we consider Siemens’ acquisition of ebm-papst’s industrial drive technology business as a pivotal and forward-looking investment.
