System diagnostics

System Diagnostics

Unlike traditional component based diagnostics, System Diagnostics obtains information from various sensors which are distributed across the machine, and provides diagnostic information with regard to the complete health status of the pneumatic system. The sensor information is collected by a central controller and interpreted. With communication software the diagnostic information is provided to a network, a human machine interface (HMI, PC) or to another control device. System diagnostics provides full condition monitoring down to the specific component, enabling easy troubleshooting and fault identification for the whole pneumatic motion system.

On these same lines, Festo has recently introduced the GFDM Energy Monitoring Package. This package is aimed at monitoring a system's pressure, flow and air consumption parameters using sensors and this information is fed to a diagnostic controller which stores this information obtained during "ideal" conditions and uses it to monitor the system thereafter. Immediate visualization is available on an operator panel or a decentralized PC. The aim is to save the customer $$$ in electricity costs used to manufacture compressed air.

In addition to this standard product, advanced system diagnostics can also be performed using sensors and Programmable Logic Controllers (PLC's). Sensor information is collected into the PLC, processed by pre-programmed diagnostic algorithms and the result can be displayed on an operator panel or a laptop running SCADA software. Real-time parameter monitoring becomes easy for the customer along with setting of thresholds to monitor certain critical process parameters.


Festo performs such customized projects using its CPX range of programmable logic controllers, HMI's (FED) and electronic sensors:


CPX I/O Terminal

  • Large choice of fieldbus protocols
  • Embedded controller enables decentralized or stand-alone control
  • Variable connection technologies
  • Compact for direct mounting, with a high protection classification
  • Complete diagnostics for error detection

Proximity Sensors

  • Threaded barrel and rectangular designs
  • Solid state (NPN, PNP)
  • Analog, reduction factor 1, corrosion resistant versions
  • High switching distance

Optical Sensors

  • Diffuse, retro-reflective and through beam designs
  • Polymer or glass fiber-optic cables
  • Laser types for displacement and long distances
  • Teach-in, color sensing, background suppression

Pressure/Vacuum Sensors

  • Programmable and configurable
  • LCD Displays and high contrast LEDs
  • Relative, relative x 2, and differential pressure sensing
  • Adjustable hysteresis, analog and digital outputs



Flow Sensors

  • Measure flow and consumption
  • Wide measuring range of flow
  • Integrated or remote display
  • Ultrafast response times and high accuracy

Actuator Feedback

  • Quick installation in profile barrel slot
  • End of stroke and displacement types
  • High reliability and service life
  • For slotted, round, and tie rod cylinders

Intelligent Compact Vision System

  • Ethernet, CAN, and digital I/O interface
  • CMOS image sensor with max. 640 x 480 pixel, grayscale
  • 185 fps (VGA) – 2000 fps (640 x 40 pixel)
  • Recording time at max. speed/resolution 3s -10s
  • IP 65/67
  • Small dimensions and low weight (160 g)

Electronic HMI's

  • Touch-screen color displays
  • Easy commissioning with text and graphics
  • Serial and Ethernet Compatibility
  • Robust design for use in harsh environments

Energy Monitoring Package GFDM

  • Constant monitoring of flow, pressure and air consumption
  • Intuitive teach-in and automatic reference data acquisition
  • Trend information
  • Centralized or decentralized visualization
  • Easy installation in new or existing pneumatic applications

An example of system diagnostics visualized on a PC:

System Information

The diagnostic information regarding health status of the pneumatic system can be visualized using an OPC client like RSView.