Combining robust design, food-safe materials and adaptive silicone fingers, the HPSX directly addresses long-standing automation challenges where rapid, precise and gentle product handling is essential.

“In developing the HPSX, we refined the gripper’s shape, dimensions and internal geometry to maximise gripping force while minimising air volume,” says Peter Potters, Product Manager at Festo. “This enables faster cycle times and multiple picks per second. At the same time, we selected a silicone material that is soft enough to prevent product damage but firm enough to securely grip objects and withstand high acceleration.”

The new gripper’s design reduces air consumption while maintaining high gripping force, enabling quicker actuation and faster picking cycles. The HPSX has been designed and tested to withstand acceleration forces of up to 15G while handling loads of up to 0.5 kg, ensuring reliable performance even in high-speed applications. This combination of low air volume, strong grip and acceleration resistance delivers both speed and consistency on fast-moving production lines.

Gripper fingers are manufactured from a soft, silicone-based material specifically chosen for its controlled flexibility. This allows the HPSX to conform to delicate, irregularly shaped or hygienically sensitive products without damaging them. The adaptive design eliminates the need for rigid, application-specific tooling, making the HPSX ideal for handling fragile food items, pharmaceutical products and cosmetics.

To meet stringent hygiene requirements, the HPSX features a corrosion-resistant, sanitary design that is easy to clean and maintain. The gripper has an IP69k high-pressure washdown rating and is built to withstand aggressive cleaning processes common in food and pharmaceutical environments. It complies with EC 1935/2004 requirements and uses FDA-compliant, food-grade and metal-detectable materials, ensuring safe operation in regulated production environments.

The HPSX can handle a wide range of product shapes and sizes without requiring a tool change, significantly reducing mechanical changeover time. This flexibility is particularly valuable in applications such as cosmetics kitting, where a single gripper may need to pick and place multiple product types within the same production run. By eliminating the need for frequent gripper swaps, manufacturers benefit from reduced downtime and increased overall equipment effectiveness.

Available in three sizes (40 mm, 70 mm and 100 mm) and in two-, three- and four-finger configurations, the HPSX offers nine variants to suit diverse applications. A universal ISO50 fitting enables straightforward attachment to existing robotic end-of-arm tooling.

In addition, the HPSX integrates seamlessly with Festo’s broader automation portfolio, including controllers, valves and pneumatic systems. Using single source reduces installation and programming complexity by eliminating interface and compatibility issues between components from different suppliers. For OEMs and end users, this translates into faster commissioning, simplified troubleshooting and a single point of contact for service and support – further increasing uptime.

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Building on the highly cost-effective VTUX base system, the latest additions include advanced communication via Festo AP, new smart vacuum and I/O options, and new energy-saving valve functions. Together, these enhancements enable the creation of more compact, responsive and future-ready machines – reducing compressed air consumption, simplifying architectures, and lowering system costs.

The VTUX was initially launched with basic capabilities to meet the broad needs of most volume users of pneumatic solenoid valve manifolds. Since its introduction, there has been a continuous roll-out of new features, making things even easier for users. The basic VTUX valve terminal is carefully cost-optimised through design and manufacture, delivering high flow rates and virtually unlimited modularity.

The valve modules can be arranged freely and are compact and lightweight, saving time, space, and weight in the machine. The ability to ‘split’ manifolds cost-effectively without having to pay for additional fieldbus nodes means designers can arrange their layouts for ease of assembly and simpler maintenance. Crucially, the VTUX minimises piping run lengths, which can improve response times and cycle rates at the same time as reducing wasted ‘dead air’ volumes.

Open communication with Festo AP

However, the greatest benefits result from Festo considering not only how to mount and connect pneumatic solenoid valves across a machine but also the surrounding architecture. VTUX now uses Festo AP (Automation Protocol) to optimise digital communication. This brings flexibility, enables open architectures, and allows seamless integration of electrical and pneumatic automation.

With AP, VTUX becomes part of a digitised automation platform, enabling sensor integration, advanced diagnostics and predictive maintenance through data exchange with the cloud in the Industrial Internet of Things (IIoT). Festo’s CPX-AP-I remote I/O system with IP65/67 protection enables real-time communication via Ethernet-based fieldbus. Seamless connectivity also supports all other technologies, such as IO-Link or direct fieldbus integration. A recent addition is the CTED multi-protocol node, which enables compact, flexible and cost-effective connections directly to all common Industrial Ethernet (fieldbus) hosts.

Whether the system is central, decentralised, or hybrid, VTUX with Festo AP offers scalable configurations, integrated safety functions, and flexibility for the customer’s machine concept. Consequently, machines communicate more efficiently, grow flexibly, and meet the highest safety standards – from compact single applications to complex networks.

Better end-of-arm performance

The lightweight design of the VTUX means it can be deployed on the front-end unit, a portal, or a robot arm, enabling short and efficient compressed air lines. Innovative new features include optional individual input modules for ultimate flexibility and logical commissioning and diagnostics.

The ability to specify one, several or all slices with a smart vacuum generator further enhances reach and flexibility. This option is particularly attractive in end-of-arm applications where reduced piping and cabling make assembly faster. Fewer snag and wear points, combined with the reduced footprint and moving mass, create significant performance enhancements.

More sustainable operation

Performance and sustainability combine in the new Smart Switch Lite. With this option, a 5/4-way valve on the VTUX valve terminal enables the supply air to be switched off during cylinder movements. This saves energy and optimises the cycle time simultaneously. Despite the supply air being switched off, the cylinder reliably reaches its end position due to the residual expansion energy. In addition, the cylinder chambers can be individually exhausted and blocked, which enables precise control and greater flexibility. Reduced pressure in the end position ensures that the subsequent movement can take place with greater dynamics, enabling faster and more efficient processes.

Commenting on the ongoing development of VTUX functionality, Festo’s GB Product Manager Jonny Mottram said: “VTUX technology is continuously evolving to meet the automation needs of our customers, and we have further exciting new VTUX features planned for 2026. I’d urge machine builders seeking to increase their machines’ performance while reducing costs to make use of the national network of Festo Applications Engineers. Their extensive try-out facilities can significantly reduce the time and risk of changes by thoroughly modelling and testing your solutions.”

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Featuring integrated sensors and precise valve control, the OVEH joins Festo’s growing portfolio of EOAT technologies, which are engineered to meet the evolving demands of modern manufacturing environments.

The OVEH vacuum generator combines a compact design with advanced functionality, making it an ideal choice for a wide range of applications, including handling printed circuit boards, machine loading and unloading, packaging assembly and picking finished items from 3D printers. Its universal robot interface, compliant with ISO 9409-1-50-4-M6, ensures compatibility with a variety of cobots and robots, enabling seamless integration into existing systems.

Peter Potters, Festo’s EOAT Product Manager, explains: “The OVEH vacuum generator represents a significant step forward in EOAT technology. Its compact size, lightweight design and integrated sensors make it a highly dynamic and reliable solution. Offering both high vacuum and high suction volume options, the OVEH provides manufacturers with the flexibility to adapt to diverse applications while maintaining process reliability.”

The OVEH can be configured with a single suction cup or with up to nine suction cups on an adapter plate, offering a wide range of possible gripping positions. This flexibility allows manufacturers to create customised gripper units that can be easily retooled, adapting processes to meet demand. The OVEH’s low height and weight further contribute to its high dynamic response, making it well-suited for applications that require speed and precision.

Safe and reliable operation is assured with an integrated pressure sensor that continuously monitors vacuum levels. This feature is particularly valuable in applications where precision and consistency are critical. The OVEH vacuum generator also includes a valve-controlled ejector pulse, which enhances the secure handling of workpieces and supports efficient operation. Air quality is maintained using integral process air filters and an open silencer to reduce contamination of the suction nozzle.

Another standout feature of the OVEH is its plug-and-work capability. A mechanical robot interface enables quick and easy integration with various cobots, while control can be managed via digital I/O (PNP/NPN) or IO-Link. Clearly designed interfaces simplify the connection of pneumatic tubing and a single electrical connector, reducing setup time and streamlining deployment.

Festo’s OVEH vacuum generator is a testament to the company’s commitment to developing EOAT solutions that empower manufacturers to optimise efficiency, enhance safety, and embrace the possibilities of human-robot collaboration. By combining cutting-edge technology with user-friendly design, the OVEH is poised to become a valuable asset in industries ranging from electronics and packaging to additive manufacturing.

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There are many reasons for the tremendous growth in demand for industrial robots, including labour shortages, rising energy costs and the need for higher flexibility and productivity. These commercial pressures are creating exciting opportunities to push the boundaries of end-of-arm tooling (EOAT) design, taking into account critical factors such as moving mass and surface form and texture, while improving accuracy and safety.

EOAT evolution

Traditionally, a vacuum generated by pumps or venturi nozzles and applied via flexible cups or porous plates has been used for most pick-and-place applications, with specialist Bernoulli non-contact grippers being specified for very delicate substrates. Mechanical grippers have emerged as an alternative. Usually two- or three-fingered, these devices move in a parallel or angled motion with the fingers and mechanically squeeze or engage with the profile of the component to be moved.

Vacuum-based EOAT has evolved to offer vacuum generators that are weight and cost optimised, and which can be mounted on highly dynamic robotic arms close to the vacuum cups, enabling faster evacuation times and increased operating cycles. Improvements in pneumatic valve technology, such as Festo’s VTUX valve terminal, are part of this evolution. The VTUX valve terminal addresses both the mechanics/pneumatics and the electrical connectivity requirements within a single platform. It enables a mix of standard valves and vacuum slices, or 100% vacuum, for reduced installation space and costs.

Developments in mechanical grippers have driven the technology in two directions. Design reviews have removed material, not only reducing cost but, more importantly, reducing moving mass. Higher technology grippers offer more flexible control over position and force using fieldbus protocols. One example is the Festo HEPP electric gripper, which features an integrated motor controller for easy integration into control architecture (Profinet, Ethernet/IP, Ethercat). This powerful electric gripper is also highly flexible, offering precise control of positioning stroke, speed, acceleration and gripping force.

Another development in robotic end-effectors is the evolution of soft grippers or fingers. Festo has demonstrated several solutions for flexible grippers inspired by nature that wrap around the product more dextrously. These range from flexible gripper fingers that mount onto standard mechanical grippers or wholly soft devices more akin to a gecko’s tongue or an octopus’s tentacle. Compliant materials allow these grippers to adapt to non-uniform and differing work pieces, enabling reliable handling of complex components using automated systems.

A major influence on EOAT development is the desire for greater human-robot collaboration. ISO/TS 15066 provides guidelines for designing and implementing collaborative workspaces, focusing on risk assessment and control. It includes advice on limiting robot power and force, monitoring speed and separation, and implementing safety measures to protect workers from potential hazards.

It uses four levels to define the human-robot relationship. Level 1 (Coexistence) sees humans and robots operating in the same workspace, but without direct interaction. For example, a human might be working on one part of an assembly line while a robot works on another, without physical contact. Level 2 enables humans and robots to share a workspace, but not at the same time. Level 3 sees some cooperation, with humans and robots working on different tasks with some degree of interaction. Level 4 defines requirements for full collaboration, where humans and robots work together on the same task or product simultaneously, with a high degree of interaction and communication.

Level 4 requires sophisticated robot systems with advanced sensing, control and communication capabilities to ensure safety and coordination. In addition, grippers must limit the gripping force per jaw as well as meet compatible gripper and finger design.

Ease of deployment

While EOAT design is becoming increasingly sophisticated, automation manufacturers are working hard to ensure that the technology remains quick and simple to specify and deploy.

For example, the ability to optimise the sizing of mechanical or vacuum-based grippers is critical to energy-efficient operations. Over-sizing end-of-arm components not only costs more but results in considerably higher lifetime operating costs, which outweigh the purchase price many times over. Software that guides selection and considers all the key application criteria provides system designers and machine builders with assurance that the correct parts have been calculated and the right safety factor applied without waste.

For end-users, flexibility and responsiveness to fluctuations in demand are key considerations. But when the objects to be picked vary, it is challenging to provide a ‘one-size-fits-all’ gripper. Festo has developed a standalone software package called GripperAI that works with a vision system and deep learning algorithms to support blind bin picking operations. It determines the best gripper to use on a multi-headed tool, enabling fast, reliable, object-dependent gripper selection.

Gripped and sorted

The Würth Group, the global market leader in the development, manufacture and sale of assembly and fastening materials, was among the first to put Festo’s GripperAI software to the test. Würth wanted to comprehensively test the software at the Reinhold Würth Innovation Centre Curio, discuss it with employees and, if everything proved successful, implement it in its logistics centres worldwide.

The logistics centre at Würth’s headquarters in Künzelsau, Germany, includes final packaging stations where a wide variety of products arrive in trays on sorter conveyors. Employees remove the objects from the trays and pack them into shipping cartons. Würth has around 1,000,000 products in its portfolio – from small and light products to very heavy parts. Working with heavy parts is particularly demanding for the employees. As the proposed alternative to manual handling, the GripperAI needed to instruct a robot to handle parts weighing up to 20 kilograms.

Over two years, Festo built a copy of Würth’s sorter conveyors in its own research and development laboratory to develop the various capabilities of the robot: object-dependent gripper selection, gripping any objects from the trays, packing shipping cartons, and handling the cartons and trays. The robot cell is equipped with a special tool station, allowing the robot to use various suction cups and grippers. GripperAI determines which tool is most suitable depending on the type of object, its shape and surface finish. An integrated camera in the robot recognises the various objects, enabling precise selection. The Festo GripperAI solution can grip almost anything that is presented to it, for which the gripper and robot are designed. The grippers specially developed for this project set new standards in robot technology, while the suction cups come from Festo’s existing portfolio.

The customised AI robot solution enables Würth to handle heavy parts and other objects efficiently, which significantly reduces the workload for employees and increases operational efficiency. Importantly, it requires no teaching or training before deployment. It also works with any robot and vision system.

The robot cell has been in use at Würth since spring 2023 and can serve all the intended lanes. Further development work and optimisation steps have already been defined, such as higher speed, better packing, and optimisation of the overall process. Würth is convinced that this project will significantly improve their logistics processes, facilitate further growth, and support their employees.

Whether your application demands higher precision, faster cycle times, more flexibility, gentler touch, or lower costs, continuing new developments in EOAT mean there is likely to be a tool to meet your needs.

As the range of mechanical and vacuum EOAT options expands, correct selection will be even more important in delivering safe, efficient and optimised robotic solutions. Festo’s team of Grip-It application engineers supports customers by providing practical application advice and guidance, backed by powerful software tools and the well-equipped Customer Application Centre for proof-of-concept trials and backup to theoretical calculations. Online software sizing tools are also invaluable, allowing specifiers to simulate different gripping solutions before they buy.

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Guest speakers included John Pearce, CEO, Made in Britain, Ben Blackledge, CEO, Worldskills UK, Professor Mike Wilson, Chief Automation Officer, Manufacturing Technology Centre, and Dr Sebastian Beck, Festo Board Member for Finance and HR. Key themes included the importance of innovation and collaboration, attracting new talent and skills development, and investment in automation in the context of British manufacturing and the global economy.

Stay competitive, stay accountable

Swapnil Khedekar, Head of Operations Festo GB, set the tone for the day. “Today is not just about reminding ourselves where we’ve come from, but to look ahead. We have not reached the finishing line, we are celebrating a milestone on a much longer journey.”

Swapnil then highlighted the values that underpin Festo’s business ethos. “Innovation is the way we stay competitive, sustainability is the way we stay accountable,” he said. Summarising the company’s long-term approach, Swapnil concluded: “As a family company, Festo thinks in generations, not in quarters.”

Responsible manufacturing

John Pearce, CEO, Made in Britain, expanded on the themes of collaboration, innovation and sustainability, explaining the contribution that British manufacturing makes to the national economy.

“At Made in Britain, we bear witness to the passion and resilience of the UK manufacturing sector. Manufacturing companies carrying the coveted British Trademark now contribute around £20 billion to the British economy, which is great news for customers wanting products that are made well and delivered promptly by people you can trust.”

John emphasised the importance of forming robust, local supply chains, particularly in the context of global disruptions. “Making locally, sourcing locally, is responsible manufacturing. It is also common sense in these uncertain times, rather than any rejection of globalisation. Responsible manufacturing protects the future, supports growth, and safeguards resources.”

He concluded: “Festo leads by example. They are successful manufacturers because they have ambition, resilience, longevity, and a strong commitment to the future.”

Developing skills

Securing the future of manufacturing through developing the skills required to implement new automation solutions was addressed by Ben Blackledge, CEO, WorldSkills UK, an organisation delivering skills excellence across the UK, helping young people thrive and employers grow. Ben underlined the chasm between the expectations of a younger, tech-savvy generation and what manufacturers say they need:

“From our research, 63 percent of manufacturers are telling us that young people don’t have the right skills they need to support their businesses, and yet 50 percent of those same manufacturers don’t feel they are able to engage with any educators or skills providers. This disconnect is then compounded by the fact that 83 percent of young people feel they face a significant barrier to pursuing a career in manufacturing.”

Ben sees closer collaboration as the key to resolving the skills gap and securing the future of British manufacturing. He also believes there must be a renewed focus on how skills are taught for the UK to be internationally competitive. “This means embedding world-class standards at the very core of how we train, develop, and empower the next generation. Our partnership with Festo is key to this, and through the WorldSkills UK competition programmes, we are working together to deliver the high-quality skills that employers need to grow.”

Investment in automation

Skills shortages and an aging workforce are challenges that automation can solve, according to Professor Mike Wilson, Chief Automation Officer, Manufacturing Technology Centre. He emphasised the transformative potential of automation as a means to revitalise productivity and stimulate growth, drive innovation and efficiency, and encourage a more dynamic and progressive approach to change.

“We must invest in more automation if we want to retain our competitive edge,” he told the audience. “Britain is still the world’s 12th largest economy, but we only average 119 robots per 10,000 employees. We must treble this figure just to stand still, let alone catch up with countries like the U.S. and Denmark. If we matched the levels of automation that exist in our competing countries, we could increase UK productivity by 22 percent.”

According to Professor Wilson, ease of use and deployment – through cobots, visualisation tools, software and out-of-box solutions – is already encouraging greater deployment of automation, particularly among SMEs. Machine learning and AI will be key to making automation adoption even simpler in future.

He urged the audience: “Give staff the tools to do their job efficiently – sweat the assets, not the people. Thanks to companies like Festo, we have the technology. The banks are willing to provide finance and we have support via 100 percent capital allowance and R&D tax credits.”

The future of automation

Festo’s Dr Sebastian Beck then explained how the company’s original motto, “one mission, many hands”, had set the foundation for a business based on teamwork and collaboration. He traced Festo’s early interest in internationalisation and enthusiasm for technology that resulted in the development of many unique automation solutions, from a semi-automated cylinder-valve combination in 1955, through to modern valve terminals, electric automation and the adoption of piezo technology to improve energy efficiency. He then announced that Festo is close to launching its next innovation, an open architecture automation platform.

Concluding the day, Swapnil Khedekar said: “Festo is focused on making customers’ lives easier. We continue to develop automation solutions that are sustainable, energy efficient and reduce time to market. We remain committed to getting closer to our customers through investment in local manufacturing facilities, collaborative, partnership working, and encouraging lifelong learning – this is what moves us forward.”

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With its constant determination to make people’s work easier and thus increase efficiency, Festo has shaped an entire era of industrial production, and is now celebrating its 100^th anniversary.

From the very beginning, Festo has focused on innovation, responsibility, and the future. And it is the people who still make all the difference. “Festo is the work of many hands” – this saying of the company’s founder Gottlieb Stoll is still the guiding principle for management and staff worldwide.

In 1925, he and Albert Fezer founded the company Fezer and Stoll for woodworking machines in Esslingen am Neckar. Albert Fezer left the company shortly afterwards, and Gottlieb Stoll continued to run the company on his own.

The second generation of owners laid the foundation for the company as it is now. Dr. h. c. Kurt Stoll brought the idea of pneumatics from the USA to Germany in 1950 and, as a pioneer in his father’s company, developed it further. This marked the start of pneumatics at Festo and paved the way for its use in factory automation.

Internationalisation played a vital role in the ongoing development of Festo. Dr. Wilfried Stoll concentrated on developing the international markets and establishing national companies.

In 2000, the owners separated the power tools division from the rest of the company and established it as an independent company under the name Festool.

Education as a key theme for customers and employees

Lifelong learning is firmly rooted in the corporate culture at Festo. This is because successful companies need people who understand, develop, and can apply technologies. Training and developing competencies are thus fundamental success factors for a flourishing workforce. That is why Festo Didactic was established as a worldwide, independent division as early as 1965.

The inventive spirit of Dr. Wilfried Stoll and Dr. h. c. Kurt Stoll, their holistic thinking and approach, and their positive customer-oriented perspective have had a lasting impact on the company. Today, Festo is one of the leading automation companies worldwide and, with Festo Didactic, the world market leader in technical education and training.

Festo says “Thank you”

Thomas Böck, Member of the Management Board, Festo, said: “In 2025, we want to say thank you to our customers, partners, and employees and celebrate this unforgettable anniversary with them.”

Anniversary activities will take place throughout the year, both in Germany and in the more than 60 Festo companies worldwide – with “thank you” parties for employees, school days for the young talents of tomorrow, customer events, and press events. For representatives of the press and visitors who are enthusiastic about technology, the world’s leading industrial fair, the Hannover Messe, will have a special highlight in store.

“The project is still top secret. What we can say is that it showcases our wide range of skills, our broad expertise, our passion for innovation, and our aspiration to make the impossible possible,” says Thomas Böck.

The anniversary as a definitive boost for the future

The Hannover Messe will be a strong start, and that momentum will continue throughout the year. There will be, for example, worldwide “Innovation Days”, where Festo will use a new format to share future trends, technologies, and innovations with customers and partners. “In our anniversary year, we are very much looking to the future since we see it as our responsibility to use our innovations in automation and technical education to help solve the most pressing challenges facing industry and society, and to play a key role in driving industrial transformation as a solution provider,” says Thomas Böck.

In the future, topics such as digitalisation, artificial intelligence, biologisation, and the circular economy will give automation a new boost and, in addition, inspire future generations. Festo will be making a considerable contribution to moving these developments forward.

Responsibility as a continuous guiding principle

The anniversary will also be the kick-off for an ongoing company-wide initiative to strengthen Festo’s guiding principle of social responsibility for sustainable development. “Our Corporate Citizenship Program underscores our belief that companies should not only pursue economic goals, but also play a significant part in society,” says Thomas Böck. As part of the program, all 20,000 employees worldwide can spend one day working on a charitable initiative.

Thomas Böck adds: “This anniversary is not only a cause for celebration, but also a reminder of what is possible with solidarity, trust, passion, quality, and innovation. Together, we look ahead with confidence to a promising future.”

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Its compact design and ability to handle complex movements precisely make the HEPP particularly suited to applications in the electronics and small parts industry, laboratory automation and special machine building.

The powerful and versatile HEPP is available in three different sizes with a gripping force of up to 400N and a stroke up to 56mm. The motor, encoder and controller are integrated into a single component, making the HEPP a very compact solution by removing the need for an external controller in the panel. This is even more critical for EOAT (End of Arm Tooling) on cartesian and 6 axis robots, as only the power supply and communication cable need to be routed through the energy chain.

The HEPP can be adjusted for a wide range of workpieces, both in terms of size and type of material as well as gripping force, to ensure the workpiece is handled correctly. To achieve high gripping forces within a compact unit, Festo has used a precise counter-rotating spindle that can manage the high stress from the feeder forces. This spindle also maintains process positioning reliability of less than 0.02 mm during endurance testing.

The HEPP is also a great solution for handling a workpiece in an e-stop condition due to the integrated holding brake on the motor. If the power supply fails, the tried-and-tested integrated holding brake will hold the gripper fingers in position to prevent the workpiece from being dropped and damaged.

Connectivity meets simplicity

The HEPP electric gripper makes connectivity simple. Users can choose between EtherCAT, PROFINET, EtherNet/IP and Modbus protocols to integrate the HEPP seamlessly into the system environment of their PLC. Necessary function blocks are also provided – at no extra cost – for integration in Festo, Siemens, Beckhoff, Rockwell and Omron environments.

Setting up the HEPP is equally simple: just input the parameters for position, stroke, speed, acceleration or gripping force. With this information and the dynamic electric motor, it is easy to adjust HEPP to specific applications. The motion response and how workpieces are handled can also be defined as required, including for complex production processes.

Integrating the HEPP follows exactly the same process as Festo’s industry leading CMMT range of Servo Controllers, ensuring that a standardised approach to programming of a complete automation solution can be achieved, which optimises programming and commissioning time.

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The Festo Learning Experience (Festo LX) digital learning portal holistically links theoretical learning content with hardware and software solutions from Festo Didactic, allowing theoretical knowledge to be tested directly in practice. In this way, Festo LX enables learners to develop the necessary skills for employment in the high-tech industry of today and tomorrow.

Learners acquire solid basic skills with the SkillsConveyor. The newest member of Festo Didactic’s learning system family, SkillsConveyor, is a transfer belt learning system that can be used to learn various automation technology skills and abilities. This multi-talent supports basic training for various job profiles, like mechatronics or electronics technicians. Learners start with the basics and are accompanied by the multimedia learning content and videos on Festo LX as they progress to more senior roles.

For example, the new MPS 404-K learning factory has been created as part of a university collaboration; in particular as a platform for ‘Industrial Engineering’ degree programs. It focuses on productivity, efficiency, and profitability. Through the complementary courses on Festo LX, learners gain deep insights into economic topics in the production environment and understand how production processes work in reality – from the sensor to the cloud to the SAP system.

Interrelationships between technology and business thus become easier to understand and can be experienced in practice in a learning factory with a realistic infrastructure. Using the appropriate courses on Festo LX, future industrial engineers acquire skills in essential key areas such as data acquisition, automated manufacturing or IoT applications. A key advantage is that those who want to learn remotely from their educational location, away from a real learning factory, can enjoy the benefits of digitalisation and carry out the learning paths using the digital twin of the system.

The learning scenarios are related to real applications of human-machine interaction in the industry. For example, workpieces are recognised by AI algorithms, fed into the production process by the cobot or handed directly to a worker as a sample for quality control. The learning solution is easy to operate and is therefore ideal for vocational schools, training companies or research projects.

Virtual Reality Learning makes it possible to learn skills that are difficult or impossible to teach using conventional learning formats. This teaching method encourages learning by exploring and experiencing. It means that self-directed learners can experiment freely, make mistakes, and gain practical experience. In the future, Virtual Reality Learning will be available on the Festo LX digital learning portal in combination with other digital learning offerings and physical learning systems.

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The company has joined forces with other international automation partners and the Industrial Digital Twin Association because standardisation is what machine and system builders expect. The advantages offered by digital twins was very effectively demonstrated by a collaboratively built machine for a labelling application at the Hannover Fair.

Digital twins can be used in many places in engineering, depending on the application. “Machine and system builders will demand digital twins so that they can develop their machines and systems faster and make fewer mistakes during the process,” explains Gerhard Borho, member of the management board for digitalisation at Festo. Step by step, the principle of ‘digital first’ continues to advance. Components and machines are developed virtually as much as possible before the hardware is produced; this also applies to testing and system integration. Similar developments can be seen in factory planning.

Shorter development times require further simultaneous engineering by the machine builders. Digital twins therefore need to precisely replicate the capabilities of the components, if necessary, down to the physical behaviour. This significantly shortens customers’ project timelines and increases productivity. Even before a machine developer has assembled the machine hardware, they can simulate it, test it, and make adjustments. For example, they can design and program optimum, efficient handling systems using the virtual model. That is how errors can be detected and corrected at an early stage, which significantly contributes to efficient and stable operation later.

Digital twins of automation components are much more than just 3D models that move virtually. They are digital representations that provide all kinds of information about the components, including a clear description of their capabilities, the documentation, the behaviour – for example, simulation of their kinematics and kinetics – and the communication with them, including the role they play in the machine.

Focus on the entire life cycle

The Industry 4.0 machine architecture is based entirely on digital twins. Thanks to their standardised communication interfaces, they make life easier for our customers throughout virtually the entire lifecycle of a machine: from virtual commissioning and control of the machine to data acquisition and the resulting value-added services such as maintenance or diagnostics. Behavioural models of pneumatic functions were used to virtually commission the labelling machine mentioned earlier. The reduced need for searching in catalogues, on support portals or for preparing machine documentation provides further time savings.

Until now, there was a multitude of data for each automation component in different formats such as CAD, PDF or even paper manuals. Data management was therefore cumbersome and difficult to access throughout the entire lifecycle of an automation product. This lack of digital continuity also made it difficult to fully network all objects. Festo is therefore working on seamless and consistent communication technology such as OPC-UA. Ultimately, the administration shell is used as a central source of information to utilise digital twins throughout a component’s service life.

Digital twins make things easier right from the planning stage and the preparation of concrete proposals. “Intelligent algorithms can be used to design and configure optimum and, at the same time, energy-efficient components,” adds the Borho.

Advantages during commissioning

A virtual model allows the developer to test whether the slide can be moved, for example, and view the process data from the displacement encoder or the signal from the end position sensors. If the developer wants to create control sequences for the machine, they can easily be created using the components’ functions such as extend, rotate, or grip.

Other value-added services can also be implemented on the basis of digital twins. The condition monitoring function generates a message when, for example, operating components are approaching the end of their service life. The machine’s digital twin could then automatically order spare parts. If at that point there are newer models for the components being replaced, the customer can use the virtual environment to first test how the new components interact before ordering them.

Condition monitoring can also be used in conjunction with the simulation models of the digital twins to create predictive maintenance plans. Furthermore, customers can use the digital twins to develop and test subsequent changes, optimisations, or reconfigurations on the virtual model before these are implemented on the machine, which speeds up the process.

Together with other component suppliers, Festo has incorporated the digital twins of its electric and pneumatic automation products into a use case that gives machine and system builders the opportunity to discover the advantages of the digital twins live in the engineering tools from Siemens.

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The recent pandemic taught us that rapid and reliable tests at low cost are key to future prevention and control of transmissible diseases. High throughput testing for many upper respiratory tract pathogens is now possible, using automation technology.

Fast MDx is the first fully automated, high-throughput, near-patient testing system. It can detect many pathogens with unrivalled speed without the need for expensive biosecure laboratories. Developed by London-based social enterprise company Fast MDx, the eponymous testing system cuts the typical 24 to 48 hour waiting time to just one to two hours.

“The Fast MDx test platform is mobile and can be used anywhere,” explains Richard Lewis, founder and CEO of Fast MDx. “Only one technician is required to operate it, rather than the five normally needed in a central laboratory to process up to 1,000 patient samples in an 8-hour shift.”

Thanks mainly to economies of scale, Fast MDx is the first system in the world to make molecular testing and diagnostics accessible everywhere, not just in more affluent countries. It will be launched in June 2023 with a multiplexed, CE-IVDr-approved test for the most common respiratory pathogens: influenza A, influenza B, RSV A, RSV B and Covid-19. The company will be expanding the range of tests in 2023/24 to include tests for infections such as C-Diff and MRSA, as well as for sepsis, which kills about 11 million people worldwide every year. It is also the perfect system for conducting genomic testing, which informs doctors what screening tests to request based on their patients’ own DNA, in order to detect hereditary diseases at an early stage.

Automation reduces errors

The Fast MDx platform relies on automation technology from Festo for pipetting and dispensing. Included in the system are Festo handling gantries with electric axes, heat sealing from Kbiosystems and Fast MDx’s patented, ultra-fast qPCR thermal cycler, the NGX2.

During sample preparation, Festo’s EXCM planar surface gantry operates in the X and Y planes. The 92 patient samples are scanned using Festo’s optical sensors to track and confirm that all the samples are present. The automated pipetting system, consisting of the Festo DHOE pipetting head and the DHAO disposable syringe ejector, is mounted on the planar surface gantry in the Z direction. The pipetting head can accurately dispense volumes in the range of 10 µl and the pipetting speed can be adjusted to dispense up to 10 ml/s.

The master mix is prepared, placed in the microtiter plate and then the samples are added. The disposable tip pierces the Fast MDx’s Pathtube cap, and aspirates and pipettes each patient sample into the master mix in one of the microtiter plate wells. Piercing the Pathtube cap saves a lot of time and money, as no conventional opening and closing systems are needed, and eliminates the human handling errors that so often occur when manually pipetting hundreds of samples into tubes.

A separate Festo handling system uses an EHPS-16 electric gripper to pick up the filled microtiter plate and place it in the heat sealer. The sealed plate is then placed in the RT block, which triggers the conversion of the RNA, if present, into complementary DNA (cDNA). Finally, the plate is placed in the NGX2 qPCR thermal cycler, where the PCR reaction takes place and the cDNA is amplified. The NGX2 uses an ultrafast fluorescence detection system to determine whether the cDNA sequence of the pathogen of interest is present in any of the patient samples. The Biosero software used on the platform integrates and controls all the modules and makes operating it very easy.

To avoid having to use an external pneumatic supply, the Fast MDx test platform uses Festo’s PGVA pressure and vacuum generator, which produces a pressure or vacuum of ±0.5 bar using a 24-volt power supply. The PGVA integrates a mini compressor, air filter unit, reservoir and electronic pressure and vacuum control in a very small space, providing a totally self-contained solution for liquid handling in laboratory automation.

Special machine manufacturer, Applied Automation, is responsible for assembling the complete test system including safety, risk analysis and CE marking.

“Thanks to the close cooperation between Fast MDx and Festo, we were able to build the first prototypes quickly and efficiently, despite the extremely high degree of complexity,” says Lewis. “We were able to combine Fast MDx’s extensive expertise in qPCR thermal cycling with Festo’s proven 3D gantries, controllers and pipetting systems.”

Tamara Seivwright-Blake, project engineer at Festo GB says “I’ve enjoyed working on such a socially conscious project bringing together and coordinating the different parties involved and continuously developing and refining the platform.”

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