Festo’s AI-enabled monitoring and predictive maintenance system AX Motion Insights Pneumatic is a cost-effective, easy-to-use solution for preventing unscheduled machine downtime by monitoring pneumatic cylinders for wear and anomalies. This AI-based industrial app ensures operations are more reliable, efficient, and ultimately more profitable.
The system uses AI to detect anomalies in the behavior of pneumatic drives and cylinders without the need for additional sensors. It provides a “health score” as a “risk of failure” indicator for each cylinder. Connectivity is achieved via a PLC function block. The system is compatible with actuators from different manufacturers and has specific connectivity details for Siemens, Rockwell, and Beckhoff controllers.
Jonas Schimmele, Business Driver Digital Business, Festo, said the app does not require additional sensors because the system leverages existing PLC signals and actuator end-position sensors already present in most machines. “No extra hardware is needed beyond the connectivity function block for PLC integration,” Schimmele said. “AI models analyze motion profiles, timing, and stroke completion data to detect deviations from learned baselines.”
The system measures signal edges of valves and limit switches, as well as looks for behavioral anomalies in motion profiles, Schimmele noted. These are captured via PLC data streams and processed by AI models to assign a “Health Score” for each cylinder, indicating risk of failure. Continuous monitoring enables trend analysis and anomaly detection.
Motion Insights Pneumatic enables maintenance teams to schedule tasks in advance, significantly reducing the risk of unexpected downtime. The platform offers the flexibility of on-premises computing, giving end users full control over their data and deployment. This is an open system and works with both Festo and third-party components. The AX platform features ease of use and seamless integration, opening the door for customers to embrace AI, data-driven solutions, and digital transformation.
“Predictive maintenance for pneumatics existed in basic forms (manual trend analysis and extra sensors), but AI makes it far more feasible, scalable and user-friendly,” Schimmele said. “Festo combines decades of mechanical expertise with machine learning to create standardized, plug-and-work apps that learn normal operating behavior and detect anomalies automatically.”
A critical element of Motion Insights Pneumatic is its integration with Festo’s Smartenance maintenance management system. Motion Insights Pneumatic works in tandem with Smartenance; the Insights app identifies when maintenance is needed, and Smartenance manages the resulting tasks. The integration of the two creates a cohesive, end-to-end workflow that ensures predictive insights are not just seen but also efficiently acted upon.
Motion Insights Pneumatic is easy to set up and use. The “plug-and-play” aspect of this app, combined with its user-friendly interface and standardized AI models, makes the technology more accessible than otherwise possible. This is beneficial for original equipment manufacturers (oems) and end-use companies that are just beginning their digital journey, as it lowers the barrier to entry and brings the benefits of AI without requiring deep data-science expertise. OEMs and end users simply download the app, install it, and integrate it themselves.
“This approach removes the need for deep data-science skills and accelerates adoption — no data scientist needed, quick installation, and low investment risk,” Schimmele said. “It’s ready for large-scale rollouts as you do not need to adapt to every single asset.”
Festo AX Motion Insights Pneumatic joins the Festo AX Motion Insights Electric app, which focuses on electric components, and Festo AX Data Access, which makes operation technology (ot) data available for information technology (it) analysis. These apps can be used singly or in combination. Other similar tech includes energy monitoring (AX Energy Insights), as well as vacuum generation, Schimmele said, forming a complete digital ecosystem for predictive maintenance and efficiency.
CODI Manufacturing, Littleton, Colorado, recently installed all three on its new, compact gantry palletizer to give customers the ultimate in uptime and insights into operational efficiency.
The solution is broadly applicable, Schimmele said, noting a few key uses could include the following:
- Automotive (body shop clamps, paint shop actuators)
- Food & Packaging (format adaption, packaging motion)
- ELA & Battery (tension control actuators)
- Machine tools (tool door actuation)
“Essentially, any system with linear motion critical for process performance, multiple pneumatic cylinders, and high uptime requirements benefits from predictive insights,” he said.
As for how it impacts system life, Schimmele said that industry benchmarks indicate that there is between a 5–20% productivity loss linked to component failure. AX aims to eliminate this. Festo highlights its quick turnaround on ROI by focusing on 5–10% critical cylinders. “While exact numbers depend on the application, predictive maintenance typically reduces unplanned downtime by 20% and can extend component life significantly by preventing catastrophic failures,” he said. “Festo reports improved OEE (Overall Equipment Effectiveness), reduced maintenance costs, and longer service life for pneumatic systems when using AX Motion Insights.”
The apps can be deployed on-premises using standard hardware and container technology such as Docker. Containerization allows the apps to be deployed flexibly on various computing environments, including industrial PCs, virtual machines, servers, and edge devices. Insights Electric and Pneumatic are purchased on a subscription basis, while “time-limited” options (3 and 5 years) will be released at the end of 2025. Data Access is purchased under a perpetual license.
Festo AX apps run on customer infrastructure (on edge, on-premises, in customer cloud instances) using container technology (e.g., Docker), giving full control over data. Common industrial protocols like OPC-UA and MQTT are supported for secure integration. Schimmele said that cybersecurity best practices such as network segmentation, encrypted communication, and role-based access are recommended. The app is not cloud dependent unless chosen by the user.
Through Festo App World, customers can select a license package based on the number of cylinders they want to monitor. Unlike competitors that might offer a single software tool, Festo AX apps are a seamless part of a complete one-stop-shop automation solution, including its electrical and pneumatic components. This simplifies integration and offers a single point of contact for support.
Finally, as concerns grow for energy usage by AI technologies, Schimmele highlights the energy savings that can be achieved through the app. “AI itself has minimal energy impact compared to the savings achieved,” he said. “By detecting wear early, it prevents inefficient cylinder operation. Combined with Festo AX Energy Insights, users can monitor compressed air consumption and detect leaks, which can reduce pneumatic energy losses by up to 50%. So, while AI requires computing resources, the net effect is lower compressed air usage and improved energy efficiency.”
Festo
festo.com
