Automation. Ventura. Fast. Compatible. Transparent. Automation Platform for Machines. AM 768 ENG/

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1 Automation Ventura Fast. Compatible. Transparent. Automation Platform for Machines AM 768 ENG/

2 Transparency across all levels From the control panel all the way to the I/O node The automation platform Ventura from KUHNKE Automation provides a transparent communication structure reaching from the operation and maintenance level over the machine control level all the way down to individual actuators, sensors and drives. It offers a completely homogenous system design based upon internationally accepted industry standards. The primary advantage of the Ventura concept is seamless communication at superior speed in combination with unsurpassed data transparency. Superior speed right where it counts The automation platform Ventura relies on the EtherCAT system bus to provide fast communication between the machine control system and all associated actuators, sensors and drives. EtherCAT is an internationally accepted industry standard, which is known to enable short response times and supports even fast and complex processes. Additionally, it allows seamless integration of the machine control system into an already existing communications infrastructure based on systems, such as PROFIBUS or CANopen. Flexible due to standardization At operation and control level, Ventura uses the Ethernet industry standard. Ethernet and EtherCAT offer inherent compatibility and are therefore an ideal technological basis to guarantee unlimited data transparency from the factory control level all the way to each individual field device. Availability at the highest level Pro-active maintenance is one of the key strategies to ensure maximum availability of modern machines and associated control systems. With its web-based Condition Monitoring System, the automation platform Ventura offers an excellent technology for the continuous monitoring of machines and operating conditions. It puts maintenance personnel into a position to deal with critical conditions long before they result in system failures.

3 Machine-Specific Devices Actuators/ Sensors/Drives Control Operation & Maintenance

4 Consistent system design Technology for seamless interaction The automation platform Ventura is a comprehensive system, comprised of carefully matched hardware and software components. It is based on internationally accepted industry standards to provide maximum flexibility and compatibility. Due to the use of hardware and software products featuring superior functionality, the design concept of Ventura matches a wide range of applications. Consistent modular system design allows individual adaptation to all kinds of requirements. Keeping control at all times At operational level, Microsoft Windows XP is used as the software basis. The use of visualization software with OPC technology allows designing highly intuitive user interfaces featuring innovative operation and display concepts. The KUHNKE software solution ConditionPro continuously collects all relevant process data and analyzes vital operating parameters. It is the technological basis for pro-active maintenance concepts and adds a high level of availability to any machine. Control systems matching any situation With its programming system CoDeSys, Ventura provides a state-of-the-art technology for efficient process control. The spectrum of available solutions includes the Ventura FIO PLC based on an embedded controller, the versatile industry standard PC Ventura IPC and the highly flexible Programmable Automation Controller (PAC) with integrated motion functionality. This allows the design of tailor-made solutions for targeted process control precisely matching any type of application. Controlled action right at the hot spots At field level, the automation platform Ventura includes a wide range of standard actuators, sensors and drives. In addition, KUHNKE Automation is able to develop all kinds of custom-designed solutions, special purpose solutions with built-in intelligence, as well as machine-specific solutions.

5 Ventura Life Control & Visualization Software Ventura Image Drive Control Simulations ConditionPro Maintenance & Analysis Ventura Scout Operation & Control Ventura Touch Operation Operation & Maintenance Ventura IPC Control Ventura Fuxx Pilot CNC Ventura PLC Control FIO PLC Control Ventura Fuxx Drive Control Ventura FIO Fast I/O IP 20, IP 65 Ventura RIO Remote I/O Ventura AS-i AirBox+BitBox Actuators/ Sensors/Drives Ventura Smart Drive Ventura Smart I/Os Ventura Smart Force Ventura Smart Spin Ventura Smart Therm Machine-Specific Devices

6 Hardware, software, support and service From problem to system solution KUHNKE Automation is a system supplier thinking not merely in products, but in complete systems. Comprehensive knowledge about processes and technologies results in integrated solutions. Many years of experience in the fields of actuator, fluid, control and drive technology leads to innovative concepts, which reach way beyond traditional mechatronic solutions. From hardware to system It is one primary competence of KUHNKE Automation to combine a wide range of external and proprietary technologies to a fully integrated custom solution that is precisely tailored to customer-specific requirements. KUHNKE Automation accomplishes this goal by means of the automation platform Ventura with its wide product range, reaching from standard industrial PCs to a variety of control and display technologies, all the way to remote I/Os, drive controls, and drives. Intelligent software design Innovative software solutions from KUHNKE Automation integrate machines and individual hardware components into homogenous systems. They are used to control motions and automatic processes, monitor machine parameters, reduce down times and lead to a maximum level of efficiency and availability. In addition, Ventura Life Protect effectively protects the complete control concept, thereby safeguarding your investment into intellectual property. Support right from the start At KUHNKE Automation, you meet with experienced experts who are skilled to analyze existing situations and identify opportunities to drive performance to the limits. Communicating with them will lead to a wealth of new ideas and solutions based on the latest technologies. The services of KUHNKE Automation include client-specific hardware development, individual software design and tailor-made drive and control technologies.

7 Operating systems, securing processes Operation & Maintenance EtherCAT The real-time alternative of the Ethernet Ventura Life Software to control and visualize processes Ventura Life Protect Protecting know-how and intellectual property Ventura Image Design and simulation of motion processes ConditionPro Providing information for pro-active maintenance Operation & Maintenance

8 The real-time alternative of the Ethernet EtherCAT Operation & Maintenance Modern machine and factory automation solutions are unthinkable without networking. At the control level, Ethernet has established itself as an international industry standard. Connecting actuators, sensors and drives, however, requires a network protocol that offers sufficient data throughput to allow the real-time control of fast processes. At this level, the automation platform Ventura relies on EtherCAT for good reason. The real-time Ethernet EtherCAT is the internationally accepted field bus designed for fast communication of process data in real-time. The open protocol is fully compatible to Ethernet, allowing seamless communication across all levels of an automation system. Extremely short response times and high transmission rates turn EtherCAT into an ideal data expressway for the control of time-critical processes. This means, the bus system is no longer the bottleneck of data transfer, which allows completely new concepts for machine control. Broad range of applications Due to its superior performance, EtherCAT is the ideal field bus system for fast machines, which require the communication of high amounts of data within short intervals. This includes applications for fast collection of measuring data, as well as geographically distributed systems, as they are typical in applications such as logistics, forwarding and building automation. Proven standard hardware EtherCAT does not require any special hardware components inside a personal computer and is open for a variety of protocols. This communications standard can be used in combination with conventional Ethernet components and wiring. There is no need for switches, hubs or high-performance micro controllers. EtherCAT is a standardized communications technology and allows any combination with SERCOS and CANopen drive profiles. Clock rates of more than 10 khz Extremely short response times ( 100ųμs) Ideal for distributed systems Support of all topologies Open for a variety of protocols Standardized communications technology according to IEC, ISO and SEMI Support of all established device profiles

9 Software to control and visualize processes Ventura Life fast response time faster Defined system performance Ventura IPC (delivery incl. software) Single core If a standard industrial PC is used for machine control, Ventura Life becomes the core of the automation platform Ventura. On one side, this intelligent software is used to control all real-time processes, on the other side, it provides an intuitive human-machine interface for process operation and visualization. Basis for fast processes Ventura Life combines fast operation with openness. The software is able to control real-time processes from the CoDeSys Soft PLC all the way to coordinated multi-axis motion control applications. Data communication is realized primarily via the real-time field bus EtherCAT. However, other field bus systems, such as CANopen, PROFIBUS or AS-i, are also possible. Coordination between system worlds Ventura Life connects fast real-time processes on one side with Win32 processes on the other side. For this purpose, the performance advantages of dual-core processors are used by means of parallel processing of Win32 and real-time processes. This ensures maximum advantages as to processing speed and safety. Ventura Life comes as a complete package, including all software modules. Real-time processes Win32 processes Dual core 300 MHz 800 MHz 1000 MHz 1600 MHz C2D Performance Operating and visualizing The HMI solution for operating and visualization of production processes is realized with either Microsoft Windows XP or Microsoft CE. This means, Ventura Life uses visualization packages with OPC interface, while allowing direct interfacing with standard Microsoft applications. Integrated technology protection Optionally, Ventura Life includes a copy protection mechanism to efficiently protect the machine control technologies used. This effectively prevents any unauthorized copying and transferring of the control software. CoDeSys programming system Fast communication via EtherCAT, CANopen, PROFIBUS or AS-i Real-time operating system with task for Microsoft Windows Coordinated multi-axis motion control tasks according to PLCopen specification CNC tasks according to PLCopen specification Copy-protected control software Real-time processes - Real-time OS - Soft PLC - Programming system - CNC functionalities - Copy protection Windows processes - Communication - Windows XPe - HMI applications - Office applications HMI interface based on Microsoft Windows XP embedded Operation & & Maintenance Maintainance

10 Protecting know-how and intellectual property Ventura Life Protect Operation & Maintenance Intelligent protection The software system increasingly determines the total value of modern machines. Therefore, it represents a valuable resource, calling for special protective measures. By means of an intelligent combination of hardware and software, Ventura Life Protect ensures that no unauthorized outsider can get hold of costly intellectual property. Protecting hardware from copying By means of a unique black box design, complex mechanical and electronic functions are combined inside solidly encapsulated hardware components. This effectively prevents any reverse engineering, since any attempt to open such a component inevitably leads to its destruction. Additional means consist of hardware engineering without the use of established standards or the intelligent distribution of functions across multiple decentralized functional modules. Systemized software protection Mechanisms such as One Time Programmable (OTP) effectively prevent any copying or transferring of software and data. However, that is not all: Memory modules automatically block any unauthorized access. Internal programs are equipped with intelligent access control. Software is used in an encrypted form. Protected protocols ensure safe communication between individual components. License keys are generated from system fingerprints. Selected hardware components come with electronic identification tags. Specific agreements for know-how exchange On the basis of clearly defined contractual agreements, KUHNKE Automation ensures uninhibited cooperation between engineering partners and allows intensive know-how exchange while effectively protecting the intellectual property of the respective contract partners. Encapsulated electronics to protect from reverse engineering Integration of software into hardware Hardware components with individual ID tags 10 Generation of license keys from system fingerprints

11 Design and simulation of motion processes Ventura Image Operation & Maintenance Figure: Modelling and visualization of a cutting machine with real Ventura IPC process control The design of mechanical production processes and development of dynamic motion sequences that consider kinematic circumstances, is a highly complex and time-intensive task. Ventura Image allows virtual modeling of electric drives and drastically reduces the time needed from projecting until commissioning. Simulation, interpretation, perfection Ventura Image offers unlimited WYSIWYG for programming of motion control systems. All motions can be simulated right on the monitor to allow repetitive analysis and interpretation until perfection is reached. In addition, alternative drive concepts can be simulated and compared under realistic conditions. This not only reduces the time needed for program development, but also results in perfectly balanced and optimized motion processes. Test run in the virtual world Control programs developed with the help of Ventura Image are already comprehensively tested before they are transferred to the machine. All control functions are perfectly integrated into the respective motion processes. Maximum speed and superior productivity can be ensured way before the machine will produce the first prototype product. Better results in less time By allowing synchronous design of hardware and software, Ventura Life supports simultaneous engineering processes. This considerably speeds up the time needed for product development and results in machines working at full performance right from the start. Due to mixed operation of simulated and actual sensors and actuators via EtherCAT, Ventura Life provides ideal conditions for interactive hardware and software development. On-screen simulation, interpretation and perfecting of machine motions Virtual comparison of different drive concepts Real WYSIWYG environment for programming motion control systems Simultaneous engineering of hardware and software Reduced product development process Simulation models also usable with third-party controls 11

12 Providing information for pro-active maintenance ConditionPro Operation & Maintenance Faced with today s global market environment, continuous productivity improvements are one vital competitive advantage for any machine manufacturer. Pro-active maintenance is one key enabling factor to minimize downtimes and replace them by scheduled maintenance intervals. ConditionPro provides vital information for such pro-active maintenance concepts, contributing considerably to the availability and productivity of the machine. Specific knowledge for targeted reactions ConditionPro uses real-time communication via the EtherCAT field bus for continuous monitoring of characteristics such as rotation, speed, temperature, humidity, vibrations or dirt accumulation. This allows visualization of exactly those machine parameters, which point out excessive wear or other problem sources at an early stage. Identifying and evaluating trends The development of individual parameters can be monitored by means of visually presented historical curves. Combining targeted trend analysis with parameters, such as environmental influences, allow the analysis of developments in order to predict the remaining time until a specific value will reach a critical threshold. Based on this knowledge, needed maintenance work can be scheduled and the required spare parts can be provided on time. Unexpected machine downtimes are reduced to an absolute minimum, while the availability of the machine is maintained. Acting instead of reacting As soon as a monitored process parameter falls below a pre-defined threshold, ConditionPro automatically issues an acoustic and visual alarm signal. In addition, service technicians can be informed about this detection of a critical condition via SMS or , in order to guarantee fast reactions to solve the related problem. The system also displays all vital information, in order to support fast problem analysis and targeted troubleshooting. Continuous monitoring of vital machine parameters Automatic reaction as soon as a critical threshold is reached Acoustic and visual alarm Information via SMS and/or Early detection of critical trends 12 Targeted de-escalation management

13 Intelligent process control Control Ventura IPC with touch screen Operating, controlling and displaying functions Control Ventura Fuxx Motion control for fast commissioning Ventura FIO PLC Decentralized compact and intelligent control 13

14 Operating, controlling and displaying functions Ventura IPC with touch screen Control The Ventura industrial PC is a solution for machine control, based upon generally accepted industry standards. It fits into any switching cabinet and can be adapted to a wide range of different tasks. Due to its rugged design, it provides reliable operation even under adverse operating conditions. Rugged design principle The Ventura IPC combines compact design with vital characteristics for demanding industrial applications. Since it does not have any moving parts, it is completely free from mechanical wear. It features a highly effective passive cooling system, which does not require any fan. The use of CF memory cards instead of a hard disk contributes to the core benefits of the system: speed, safety and flexibility. Communicative in multiple ways One vital aspect of the Ventura IPC is its versatile interface concept. All actuators, sensors and drives of the machine can be connected via a variety of field bus systems, such as CANopen, PROFIBUS, AS-i or EtherCAT. Ethernet allows easy communication with other enterprise communication systems. In addition, the Ventura IPC features standard COM and USB interfaces, as well as DVI for the connection of a touch screen. Operating by touching A touch screen is used as the primary user interface of the Ventura IPC. It is not only far more rugged than any conventional keyboard. It also supports intuitive control concepts, which require little training while guaranteeing safe and accurate machine operation. Clock speed 800 MHz to 1.6 GHz User interface: touch screen Video interface: DVI Touch screen interface: USB Front side protection rating: IP 65 Power supply: 24 V DC 14 EtherCAT: 2 terminals

15 Motion control for fast commissioning Ventura Fuxx Torque, speed, position control Flying saw Cam function Electronic gear Fuxx Pilot Ventura IPC motion software Speed and angle synchronization Technology functions Fuxx Control Drive controller Control Curve plotting function NC functions Fuxx Drive Electric drives Ventura Fuxx is a drive solution consisting of perfectly matched components. It centers on the motion software Ventura Fuxx Pilot. Fuxx Control describes the drive control matching the system, while Fuxx Drive stands for the respective electric drives. Seamless interaction of these components result in a perfectly matched hardware and software concept, which not only simplifies programming, but also results in a considerable reduction of the time needed for commissioning. Accepted standards applied intelligently Ventura Fuxx Pilot is based on the hardwareindependent programming system CoDeSys, designed to develop drive control applications under Microsoft Windows according to IEC The software uses real-time communication via EtherCAT or other standard field bus systems, such as SERCOS, CANopen or PROFIBUS. It can also be integrated into existing drive control concepts. Faster programming and commissioning Ventura Fuxx allows the easy design even of demanding, multi-axis drive control functions without the need of detailed expert knowledge. It is based upon a library of pre-defined motions, which can be modified easily. The system automatically guides the user through all development steps in order to support fast commissioning. Intuitively easy and visually simple The main argument speaking for the Ventura Fuxx Servo Commander is a high level of user convenience. All control parameters, such as speed, current, torque, as well as error messages and status indications are displayed in an easy-to-understand way, while functional structures are visualized by means of graphics. Oscilloscope functions provide vital information. A context sensitive help function results in a fast learning curve and offers assistance at any time. Precisely matched hardware and software CoDeSys motion programming system under Microsoft Windows Design process without expert knowledge Fast programming and commissioning Consistent field bus protocols: SERCOS, CANopen, PROFIBUS, EtherCAT Integration into existing motion control concepts 15

16 Decentralized compact and intelligent control Ventura FIO PLC Control The automation platform Ventura was developed primarily for close-to-the-machine applications. One interesting solution is the direct combination of a controller and multiple I/O modules. All components are designed for direct rail mounting and are directly connected mechanically and electrically. The resulting solution is a highly versatile control system with consistent EtherCAT communication and a variety of interfaces to the outside world. Highly compact decentralized intelligence The Ventura FIO PLC is programmed via CoDeSys. It features 8 MB system memory and a Flash EPROM with a capacity of 2 or 8 MB to store the control software. As far as mechanic properties and form factor are concerned, it matches the FIO I/O modules, which can be attached directly to form a mechanically and electrically homogenous unit. EtherCAT all the way to each I/O module The Ventura FIO PLC acts like an EtherCAT master and sends EtherCAT telegrams to write output data and read input data. Doing so, the EtherCAT protocol is used all the way to each individual I/O terminal, resulting in a fully consistent and uniform communications concept. Built-in communications options The Ventura FIO PLC is able to exchange data with other systems via industrial Ethernet. In addition, the module features a built-in SD card slot for example to allow local storage of process data. Control programs can be exchanged directly via the USB port. Three additional digital inputs allow realizing fastest possible reactions on specific process events. Directly attachable FIO modules EtherCAT protocol all the way to each I/O module 1,000 I/O signals within 30 μs Optimum solution for decentralized control concepts 16 Ethernet interface to communicate with external systems

17 Components right where the action is Actuators/Sensors/Drives Ventura Fuxx Drive Control Intelligent decentralized drive concept Ventura FIO Compact I/O modules and EtherCAT couplers Ventura AS-i Industrial PC with integrated AS-i master Actuators/ Sensors/Drives 17

18 Intelligent decentralized drive concept Ventura Fuxx Drive Control Actuators/ Sensors/Drives Just like the corresponding software system, the Ventura Fuxx hardware also features a high level of consistency throughout. One core element in this respect is the servo positioner Fuxx Control. They are designed to cope even with demanding applications, requiring high precision at high speeds and contribute considerably to the superior performance of the Ventura Fuxx servo drives. Hardware and software in perfect interaction The consistent system design of Ventura Fuxx Drive Control is based on the seamless interaction between hardware and software. The highly intuitive concept of the motion software Ventura Fuxx Pilot is perfectly tailored to the servo positioners Fuxx Control. This results in fast and easy programming of dynamic, multi-axis machine motions which will work right from the start, because all components are perfectly matched. Controller with integrated intelligence The servo positioner is mounted directly onto the electric drive. It can be used for the synchronized multi-axis control of torque, speed or position. It is activated via the field bus or a serial RS232 interface. Both interfaces also allow easy programming and diagnosis. More intelligence for less installation effort Due to their external location, the servo positioners Ventura Fuxx Control save valuable space in the switching cabinet. In addition, this concept considerably reduces the wiring effort, since connecting the switching cabinet requires only one cable connection. The complete drive technology is based on a plug-and-play principle for fast installation and commissioning. Compact design Minimum wiring effort Plug-and-play drive technology Perfect interaction of hardware and software 18 Fast programming, installation and commissioning

19 Compact I/O modules and EtherCAT couplers Ventura FIO Actuators/ Sensors/Drives A growing number of functions that need to be controlled and increasingly complex machine functionality also increases the number of I/O signals that need to be connected to the control system. The I/O modules Ventura FIO are the vital link between machine and control system and seamlessly integrate into the automation platform Ventura. They feature a high number of contacts at minimum space and offer a wealth of intelligent details. Communicative at the highest level Each individual module provides up to 32 I/O points. All process signals are connected via multipin connectors. This not only simplifies installation, but also allows wiring independently from the modules. Custom-configuration to match any need Optionally, all input and output functions can be configured freely. This not only simplifies installation, but also provides maximum flexibility. It is even possible to realize application-specific configurations, made up of any combination of digital and analogue input and output signals. When speed meets safety Ventura FIO I/O modules are resistant against interferences and available with protection IP 20. In addition, special models for customer-specific applications are available. The EtherCAT field bus reaches all the way to the individual I/O module. The technical concept allows addressing of up to 1,000 input and output signals within 30 μs. High contact density with up to 32 I/O points per module Interference resistance according to Zone B IP 20 protection EtherCAT field bus all the way to the I/O module Up to 1,000 I/Os within 30 μs Custom-designed configurations 19

20 Industrial PC with integrated AS-i master Ventura AS-i Actuators/ Sensors/Drives Machine control concepts based on an industrial PC combine proven standard technologies with a high level of flexibility and an intuitive user interface. The IPC Ventura AS-i offers a fully integrated AS-i network and therefore does not require any separate gateways. This means, it is possible to control machine functions without any complex and costly detours. Cost-efficient and easy Due to its integrated AS-i master 2.1/3.0, the IPC Ventura AS-i is also ideal for small machine configurations, which primarily require easy installation at a superior price-to-performance ratio. This solution provides all standard services, including direct access to analogue values and detailed analysis functions. Operating by touching A modern touch screen is used as interface between the operator and the industrial PC Ventura AS-i. It is an up-to-date medium to visualize processes and display process data while offering an optimum basis for intuitive machine operation without the need of an additional keyboard. Touch screen user interface Integrated AS-i master Up to 62 AS-i slaves 248 digital inputs 186 digital outputs 124 analogue values 20 Potential separated network with 2-pin screw terminal

21 Product solutions with built-in experience Machine-Specific Devices Ventura Smart Drive Drive technology for special applications Ventura Smart Therm Measuring and controlling temperatures Ventura Smart Spin Heater control with built-in intelligence Ventura Smart Force Precisely controlled pressure Ventura Smart I/Os Compact I/O modules with IP 65 protection Machine-Specific Devices 21

22 Drive technology for special applications Ventura Smart Drive Figure: Motorized linear positioning cylinder with absolute displacement sensor Machine-Specific Devices If specialists join their efforts and experts are forming an interdisciplinary team, the result will be a superior solution that points the way into the future. One typical example of such expert interaction is Ventura Smart Drive. It demonstrates how KUHNKE Automation is able to support companies in the field of machine engineering by the development of intelligent drive solutions backed by many years of experience. Interaction of selected technologies Each machine is characterized by individual requirements, calling for a tailor-made drive technology. Electric drives of the Ventura Smart Drive series combine proven technologies with the highest level of flexibility. They are based on a modular concept, which can be matched precisely to any individual application. A typical problem... Here is one example to illustrate the superior flexibility of Ventura Smart Drive: In the course of designing a machine for producing tablets, the product development team required an electric drive with optimized control and a transmission to match precisely defined performance characteristics. The available space was extremely limited. Connection of the drive to the control system of the machine was to be realized via a field bus system.... and a tailor-made solution KUHNKE Automation solved the space problem by suggesting an EC drive in combination with an especially tuned transmission and a modified position controller. All hardware and software components were perfectly matched in order to provide a fully integrated system with seamless interaction. 22 Wiring effort in the switching cabinet reduced by up to 90 % Wiring effort inside the machine reduced by about 50 % Energy consumption reduced by up to 30 % Switching cabinet design independent from the number of servo axis

23 Measuring and controlling temperatures Ventura Smart Therm In situations where precisely defined thermal conditions are the issue, Ventura Smart Therm is exactly the right solution. This intelligent module for performance control and temperature measurement is perfectly designed up to the minutest detail. It is about 30 % more cost efficient than comparable solutions and saves 80 % of the costs normally needed for wiring. Heating under total control Ventura Smart Therm allows the definition and control of the performance settings of up to nine heating devices. For this purpose, it features 10 A TRIACs for each device, which are designed for a heating power of up to 2 kw. The complete system is protected by continuous current control and additional fuses. Extendable functions and expandable interfaces Ventura Smart Therm presents itself communicative and versatile. It allows the connection of digital I/O signals as well as other control elements and offers additional digital outputs for valves and various actuators. Communication with the machine control system can be realized via different field bus systems. Expansion slots allow the integration of additional applications. 30 % lower component costs 80 % less installation effort Control of up to 9 heating elements Power range up to 2,000 watts J/K thermo elements Alternatively: resistance thermometer PT 100 Fast installation via standard socket Comprehensive digital I/O interfaces Variety of interfaces Machine-Specific 23 Devices

24 Heater control with built-in intelligence Ventura Smart Spin Machine-Specific Devices Especially in terms of speed and efficiency, modern machines need to live up to high expectations. The emphasis is therefore on solutions that continually drive performance while resulting in evident cost advantages. Ventura Smart Spin was designed exactly with these goals in mind. It represents a drive control solution with exactly the functionality needed for any specific application. Saving costs by combining and integrating The integrated machine control module is highly flexible and can be tailored precisely to individual requirements. It combines a variety of functions in one unit, always offering exactly the functionality needed for the respective machine. This not only cuts costs to an absolute minimum, but also reduces the efforts needed for spare part storage and logistics. Very special requirements... One typical example of the efficient use of Ventura Smart Spin is the heating control of a rotating godet. The client required a heating control with integrated temperature monitoring and wireless data communication.... and a tailor-made solution The solution consisted of a temperature control system with eight independent temperature zones, which was exactly tailored to the specific requirements. Transmission of the measured temperature values was realized via a CAN bus. All remaining data communication was realized via various field bus systems. 24 Component costs reduced by 20 % No fan (no dirt accumulation) Weight and needed space reduced by 30 % Only one system supplier Backward compatibility Lower handling costs Improved quality

25 Precisely controlled pressure Ventura Smart Force Using solenoids as actuators is usually limited to simple applications requiring only on/off switching. Ventura Smart Force, however, opens up completely new application ranges for solenoid actuators. This positioning solenoid is the first actuator of its kind to allow exact positioning without the need of a motor drive. Innovation based on experience The positioning solenoid Ventura Smart Force is the result of many decades of experience and an innovative product, developed at the R&D center of KUHNKE Automation. Mechanical basis is a modified heavy duty solenoid combined with an inductive distance sensor precisely tailored to this application. Precision up to a fraction of a millimeter The application range of Ventura Smart Force includes all applications requiring exact positioning in combination with a simple and rugged technology. This positioning solenoid allows exact positioning up to a tenth of a millimeter across the entire stroke. New solutions for common problems A typical application of the positioning solenoid Ventura Smart Force is the exact positioning of work pieces with precisely defined pressure while considering different thicknesses of the material. Alternative applications might be situations requiring a precisely defined travel range of the piston, which is maintained independently from the resulting pressure. Machine-Specific Devices Excellent price-to-performance ratio Powerful due to electronic control Inductive distance sensor Piston travel range 10 mm Positioning precision 1/10 mm Variety of field bus systems possible 25

26 Compact I/O modules with IP 65 protection Ventura Smart I/Os Machine-Specific Devices 26 Compact machine design with short distances and reduced complexity does not need any extensive wiring and leads to cost savings that contribute to the overall efficiency and competitiveness of the manufacturing process. The custom-designed EtherCAT I/O modules Ventura FIO IP 65 from KUHNKE Automation allow direct integration into the machine and require neither a separate switching cabinet nor any protective housing. Rated protection from water The special hose-proof design of the Ventura FIO IP 65 modules confirms to protection IP 65. This means, all electric components are effectively protected against flowing water (such as the jet of water emitted by a nozzle), meaning that it can be mounted on any suitable mounting plate directly inside the machine. Increased flexibility for individual solutions Ventura FIO IP 65 modules are ideal for realizing application-specific I/O configurations. They allow the connection of sensors with minimum wiring efforts. Digital and analogue I/Os can be operated in mixed mode. Reduced wiring and shorter cables lead to increased resistance against electromagnetic interferences. In addition, these modules offer increased flexibility as far as the placement options of actuators and sensors are concerned. Direct, simple and cost-efficient The I/O modules of the Ventura FIO IP 65 series save valuable space inside the switching cabinet and do not require any additional housing to offer IP 65 rated protection. In addition, they are designed for easy mounting and offer fast plug-and-play installation to reduce installation efforts and save costs. Hose-proof protection according to IP 65 No protective housing required No space in a switching cabinet required Reduced wiring efforts Plug-and-play installation Application-specific I/O configuration Integrated digital and analogue I/Os EtherCAT interface

27 KUHNKE Systempartnership + Electronics Solenoid Technology Solenoid Technology Electronics Fluid Technology + Solenoid Technology Electronics + Fluid Technology Fluid Technology The Technology Company KUHNKE develops, manufactures and distributes, through its individual companies, customer-specific products such as electronic, solenoid and pneumatic components, as well as services for the automotive, machine building and medical equipment industries. KUHNKE is first choice if you are looking for integrated solutions. When challenges are to be solved in areas such as fluidic control engineering, low electrical power consumption, reliable drive and control technology even in tough ambient conditions, saving space, low operating noise or trouble-free product lifetime, KUHNKE can develop innovative products for you. Mechanical solutions derived from fluid or solenoid technology can be combined with electronics to complete function units. So we create competitive advantages for you. With KUHNKE know-how and the KUHNKE range of services you can also achieve considerable cost and logistics benefits. 27

28 Kuhnke Automation GmbH & Co. KG Lütjenburger Straße 101 D Malente Sites Headquarters: Malente, Germany Phone +49(0)4523/ Fax +49(0)4523/ Internet A company of the Kuhnke AG Production plants: Germany, Italy, Romania Subsidiaries and sales partners: Austria, Belgium, Bulgaria, Croatia, Czech Republic, Finland, France, Germany, Greece, Great Britain, Hungary, Ireland, Italy, Moldova, Netherlands, Norway, Poland, Portugal, Romania, Serbia, Slovenia, Sweden, Switzerland, Spain, Turkey, Ukraine Morocco, South Africa, Tunisia Brazil, Canada, Chile, Columbia, El Salvador, Mexico, Peru, USA, Venezuela China, India, Indonesia, Malaysia, Philippines, Singapore, South Korea, Taiwan, Thailand Australia 01/01/09 DW Printed in Germany by KUHNKE, Bad Malente-Gremsmühlen KUHNKE TECHNOLOGIES This document is directed primarily to specialists involved in the conception, design and construction of machines. It does not indicate any information about availability of products. The technical specifications stated herein are only of descriptive nature and do not represent a guarantee as to the ability or usability of a product in a legal sense. Such specific assurances are subject to individual contractual agreements. We do not accept any claims for compensation of damages for whatever reason, unless substantial proof of intention or gross negligence is provided. Complete or partial reproduction of this document requires the written consent of the author. All rights concerning changes, omissions and misconceptions are reserved. Microsoft Windows and the Windows logo are registered trademarks of Microsoft Corporation in the USA and other countries. EtherCAT is a registered trademark and patented technology, licensed from Beckhoff Automation GmbH, Germany. Additional information on the PLCopen organization can be found at