With the 'Motion Terminal', Festo says it has achieved a technological leap forward by merging hardware and software into a digitalized valve. During the three-year development period, an intelligent pneumatic automation platform for Industry 4.0 was created, on the basis of which a wide variety of valve functions can be flexibly programmed and controlled via motion apps.

In total, the Motion Terminal combines the functions of over 50 individual components, which should simplify the engineering process immensely and save on numerous hardware components. In other words: for the first time, the functions of a valve can be changed under software control - without having to change the hardware. According to Festo, the new intelligent technology enables simple directional valve functions through to complex movement tasks that were previously reserved for servopneumatics or electrical automation.

Project manager Dr. Julia Duwe, Head of Future Motion Solutions Management, explains: "From a technological point of view, this completely new platform is a fusion of mechanics, electronics, control technology and software. By selecting various motion apps, the user has the option of recording the status of their system in real time as well as changing its functionality. If the system needs to be adapted to customer requirements, the programmable platform eliminates the need for the machine manufacturer to make time-consuming hardware changes to many individual components - which speeds up the delivery time."

In addition to the controller, on which the motion apps run, the app-controlled valve is located on the terminal, consisting of four 2/2 diaphragm seat valves, which in turn are controlled by four piezo pilot valves. The integrated stroke and pressure sensors ensure optimum control and transparent condition monitoring. The interaction and the design in the form of a bridge circuit, which allows independent ventilation and exhaust, give the valve its flexibility. Last but not least, the terminal provides an input module with up to 16 analog or digital inputs for direct control applications such as 'Soft Stop'.

New functions can be programmed intuitively on the Motion Terminal. Last but not least, the software functionality should enable the machine manufacturer to offer additional services and new business models. The built-in sensor technology provides real-time data from the system operation and provides an insight into the processes within the system. The virtual production history warns of critical wear or deviating parameters, for example. Faults in the complex processes become visible and traceable. The digitized functionality is protected invisibly in a 'black box' instead of being exposed in visible hardware elements - thus ensuring a high level of protection of intellectual property.

The user can access the device directly via Internet technologies. The various motion apps can be configured either via the browser or, as before, via the machine control system. Changes to the production order can be made by changing the app during operation without any changeover effort.

Last but not least, according to Duwe, special apps for the energy-efficient operation of pneumatic applications significantly reduce the energy requirement, and the newly developed piezo valves for controlling the main valve stages also reduce the consumption for pilot control by up to 90% compared to conventional solenoid valves - with a service life of up to 300 million switching cycles. This is complemented by a diagnostic app for locating leaks. Depending on the application, savings in compressed air consumption of up to 70 % are possible compared to standard operation.