Festo ElectroPneumatics Workbook Advanced Level TP202 44 2005

Electropneumatics Advanced Level

Workbook TP 202

CD-ROM included

Festo Didactic 541091 en

Intended use

The Festo Didactic Learning system has been developed and produced solely for vocational and further training in the field of automation and technology. The training company and/or instructor need to ensure that trainees observe the safety precautions specified in this workbook. Festo Didactic hereby disclaims any legal liability for damages or injury to trainees, the training company and/or other parties, which may occur during the use/application of this equipment set other than in a training situation and unless such damages are caused with intention or through gross negligence on the part of Festo Didactic.

Order No.: Status: Authors: Editor: Graphics: Layout:

541091 04/2005 M. Pany, S. Scharf Frank Ebel Doris Schwarzenberger 10/2005

© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2005 Internet: www.festo-didactic.com e-mail: [email protected]

The copying, distribution and utilisation of this document as well as the communication of its contents to others without express authorisation is prohibited. Offenders will be held liable for the payment of damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design registration. Parts of this documentation may be copied by the authorised user exclusively for training purposes.

2

© Festo Didactic GmbH & Co. KG • 541091

Contents

Preface ______________________________________________________________ 5 Introduction__________________________________________________________ 7 Notes on safety and operation ___________________________________________ 9 Technology packages for electropneumatics (TP200) _______________________ 11 Training aims of Advanced Level (TP202) _________________________________ 13 Allocation of training aims and exercises _________________________________ 15 Equipment set – Advanced Level (TP202) _________________________________ 17 Allocation of equipment and exercises ___________________________________ 21 Methodological help for the trainer ______________________________________ 23 Methodological structure of the exercises_________________________________ 25 Designation of equipment _____________________________________________ 26 Contents of the CD-ROM _______________________________________________ 27 Equipment set – Basic Level (TP201) _____________________________________ 29 Training aims – Basic Level (TP201)______________________________________ 30

Part A – Exercises Exercise 1: Realising a diverting device ___________________________________A-3 Exercise 2: Insertion of drinks bottles ___________________________________A-15 Exercise 3: Realising a selection station _________________________________A-23 Exercise 4: Machining of key blanks ____________________________________A-39 Exercise 5: Bending of mounting brackets _______________________________A-49 Exercise 6: Realising a filling system ____________________________________A-57 Exercise 7: Bonding of components _____________________________________A-67 Exercise 8: Selecting modes of operation ________________________________A-75 Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function ______________________A-85 Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function______________________A-95 Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function____________________ A-103 Exercise 12: Eliminating a fault on a machining station ___________________ A-113


3

Contents

Part B – Fundamentals

Part C – Solutions Exercise 1: Realising a diverting device ___________________________________C-3 Exercise 2: Insertion of drinks bottles ___________________________________C-13 Exercise 3: Realising a selection station _________________________________C-21 Exercise 4: Machining of key blanks ____________________________________C-37 Exercise 5: Bending of mounting brackets________________________________C-47 Exercise 6: Realising a filling system ____________________________________C-57 Exercise 7: Bonding of components _____________________________________C-67 Exercise 8: Selecting modes of operation ________________________________C-75 Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function ______________________C-85 Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function______________________C-95 Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function_____________________C-107 Exercise 12: Eliminating a fault on a machining station ____________________C-117

Part D – Appendix Organiser _________________________________________________________ D-2 Assembly technology ________________________________________________ D-3 Plastic tubing_______________________________________________________ D-4 Data sheets Circuit diagrams

4


Preface

Festo Didactic’s Learning System for Automation and Technology is orientated towards different training and vocational requirements and is therefore structured into the following training packages: • Basic packages to provide technology-spanning basic knowledge • Technology packages to address the major subjects of open and closed-loop technology • Function packages to explain the basic functions of automated systems • Application packages to facilitate vocational and further training based on actual industrial applications The technology packages deal with the following technologies: Pneumatics, electropneumatics, programmable logic controllers, automation using a personal computer, hydraulics, electrohydraulics, proportional hydraulics and handling technology.


5

Preface

The modular design of the learning system enables applications beyond the limits of the individual packages. For example, to facilitate PLC actuation of pneumatic, hydraulic and electrical drives. All the training packages are of identical structure: • Hardware • Teachware • Software • Seminars The hardware consists of didactically designed industrial components and systems. The didactic, methodological design of the teachware is harmonised with the training hardware and comprises: • Textbooks (with exercises and examples) • Workbooks (with practical exercises, additional information, solutions and data sheets) • Overhead transparencies and videos (to create an interesting and lively training environment) Tuition and training media are available in several languages and are suitable for use both in the classroom and for self-tuition. Software is available in the form of computer training programs and programming software for programmable logic controllers. A comprehensive range of seminars dealing with the topics of the technology packages completes the range of vocational and further training available.

6


Introduction

This workbook is a component part of the Learning System for Automation and Technology of Festo Didactic GmbH & Co. KG. This system provides a solid basis for practice-oriented vocational and further training. Technology package TP200 is comprised exclusively of electropneumatic control systems. Basic Level TP201 is suitable for basic training in electropneumatic control technology and provides knowledge regarding the physical fundamentals of electropneumatics and the function and use of electropneumatic equipment. The equipment set enables you to construct simple electropneumatic control systems. Advanced Level TP202 focuses on further training in electropneumatic control technology. The two equipment sets enable you to construct complex combinational circuits with logic operations of input and output signals and program controls Prerequisite for the assembly of control systems is a fixed workstation using a Festo Didactic profile plate, consisting of 14 parallel T-slots with 50 mm spacing. A shortcircuit protected power supply unit (input: 230 V, 50 Hz, output: 24 V, max. 5 A) is used for DC voltage supply. A mobile, silenced compressor (230 V, maximum 8 bar (800 kPa) can be used for compressed air supply. Working pressure must not exceed a maximum of p = 6 bar (600 kPa). Optimum operational reliability is achieved if the control system is operated unlubricated at a working pressure of p = 5 bar = 500 kPa. The equipment set of Basic Level TP201 is used to construct complete control systems for all of the 12 problem definitions. The theoretical fundamentals to help you understand this collection of exercises can be found in the textbook • Electropneumatics Also available are data sheets in respect of the individual devices (cylinders, valves, measuring devices, etc.).


7

Introduction

8


Notes on safety and operation

The following advice should be observed in the interest of your own safety: • Pressurised air lines that become detached can cause accidents. Switch off supply immediately. • Do not switch on compressed air until tubing is securely connected. • Caution! Cylinders may advance automatically as soon as the compressed air is switched on. • Do not operate an electrical limit switch manually during fault finding (use a tool). • Observe general safety regulations. (DIN 58126 and VDE 100). • With electrical limit switches you need to distinguish between two designs – Actuation from the left – Actuation from the right. • At high piston speeds, limit switches must be approached only in the designated direction of the trip cam of the cylinder. Limit switches must not be actuated from the front. • Do not exceed the permissible working pressure (see data sheets). • Only use extra-low voltage ≤ 24V. • All components are equipped with 4 mm safety sockets, i.e. jack plugs. Only use cables with jack plugs for the electrical connections. • Pneumatic circuit assembly: Connect devices using the silver-metallic plastic tubing of 4 mm outer diameter, the tubing is plugged into the push-in fitting up to the stop; no need for securing! • Releasing of push-in fitting: The tubing can be released by pressing down the releasing ring (disconnection under pressure is not possible!) • Switch off compressed air supply and power supply prior to dismantling the circuit.


9

Notes on safety and operation

• The mounting plates of the devices are equipped with mounting variants A to D: Variant A, latching system For lightweight non-loadable devices (e.g. directional control valves). Simply clip the device into the slot in the profile plate. Devices can be released by pressing the blue lever. Variant B, rotary system Medium weight loadable devices (e.g. actuators). These devices are clamped onto the profile plate by means of T-head bolts. Clamping and releasing is effected by means of the blue knurled nut. Variant C, screw system For heavy loadable devices rarely removed from the profile plate (e.g. On/off valves with filter regulating valve). These components are mounted by means of socket head screws and T-head bolts. Variant D, plug-in system Lightweight non-loadable devices with locking pins (e.g. indicating devices). These devices are attached by means of plug-in adapters. • The data for the individual devices, as specified in the data sheets in Part D, must be observed.

10


Technology package for electropneumatics (TP200)

The technology package TP200 consists of numerous individual training media as well as seminars. The subject matter of this package is exclusively electropneumatic control systems. Individual components from the technology package TP200 may also form a component part of other packages.

Important elements of TP200

• • • • • •

Fixed workstation with Festo Didactic profile plate Compressor (230 V, 0.55 kW, maximum 8 bar (800 kPa) Equipment sets or individual components Optional training aids Practical training models Complete laboratory setups

Training documentation Textbooks

Basic Level TP201 Fundamentals of pneumatic control technology Maintenance of pneumatic devices and systems

Workbooks

Basic Level TP201 Advanced Level TP202

Optional Teachware

Sets of overhead transparencies and overhead projector Magnetic symbols, drawing template WBT Fluid Studio Electropneumatics Cutaway model sets 1 + 2 with storage case ® Simulation software FluidSIM Pneumatic


11

Technology package for electropneumatics (TP200)

Seminars P111

Fundamentals of pneumatics and electropneumatics

P121

Maintenance of and fault finding on pneumatic and electropneumatic systems

IW-PEP

Maintenance and servicing in control technology – pneumatic and electropneumatic control circuits

EP-AL

Electropneumatics for vocational training

Details of venues, dates and prices can be found in the current seminar planner. Information regarding further training media is available in our catalogues and on the Internet. The Learning System for Automation and Technology is continually updated and expanded. The sets of overhead transparencies, films, CD-ROMs and DVDs as well as technical books are available in several languages.

12


Training aims of Advanced Level (TP202)

• • • • • • • • • • • • • • • • • • • • • • • •

To familiarise yourself with the design and function of valve terminals. To be able to use valve terminals in accordance with requirements. To be able to design a displacement-step diagram for a sequence control. To be able to transcribe a function chart to GRAFCET . To be able to solve the problem of signal overlaps in a sequence control according to the group method. To be able to detect signal overlaps in a sequence control. To be able to design a sequence chain using spring-return valves. To be able to design a sequence chain using double solenoid valves. To familiarise yourself with the mode of operation of different proximity sensors. To be able to select proximity sensors in line with parameters. To familiarise yourself with logic operations and to be able to realise these. To familiarise yourself with the design and function of a pneumatic-electrical converter. To familiarise yourself with the options for sensing pressure and time in electropneumatic control systems. To familiarise yourself with the function and possible applications of a time relay with switch-on delay. To familiarise yourself with modes of circuit operation and to be able to design circuits with which single cycle and continuous cycle modes can be realised. To familiarise yourself with the function of an electrical preselect counter and to be able to use this in circuits. To be able to develop and design the EMERGENCY-STOP function for a control system with spring-return valves. To be able to develop and design the EMERGENCY-STOP function for a control system with double solenoid valves. To be able to design a specified motion sequence with EMERGENCY-STOP. To be able to design the EMERGENCY-STOP condition „Cylinder remains in its current position during EMERGENCY-STOP“. To familiarise yourself with the design and mode of operation of a 5/3-way valve. To be able to replace a 5/3-way solenoid valve with 3/2-way solenoid valves. To be able to integrate the mode of operation „resetset“. To be able to identify and eliminate faults in complex electropneumatic control systems.


13

Training aims of Advanced Level (TP202)

14


Allocation of training aims and exercises

Exercise

1

2

To familiarise yourself with the design and function of valve terminals.

•

•

To be able to use valve terminals in accordance with requirements.

•

•

3

4

5

•

•

6

7

8

9

10

11

12

Training aims

To be able to solve the problem of

•

signal overlap in a sequence control according to the group method. To be able to design a displacementstep diagram for a sequence control. To be able to transcribe a function

•

•

chart to GRAFCET. To be able to design a sequence chain with spring-return valves.

•

To be able to detect signal overlaps in a sequence control.

•

To be able to design a sequence chain

•

using double solenoid valves. To familiarise yourself with the mode

•

of operation of different proximity sensors. To be able to select proximity sensors in line with parameters.

•

To familiarise yourself with logic

•

operations and to be able to realise these. To familiarise yourself with the

•

options for sensing pressure and time in electro-pneumatic control systems. To familiarise yourself with the design

•

and function of a pneumatic-electrical converter. To familiarise yourself with the

•

function and possible applications of a time relay with switch-on delay.


15

Allocation of training aims and exercises

Exercise

1

2

3

4

5

6

7

8

9

10

11

12

Training aim To familiarise yourself with modes of

•

•

circuit operation and to be able to design circuits with which single cycle and continuous cycle modes can be realised. To familiarise yourself with the

•

function of an electrical preselect counter and to be able to use this in circuits. To be able to develop and design the

•

EMERGENCY-STOP function for a control system with spring-return valves. To be able to develop the

•

EMERGENCY-STOP function for a control system using double solenoid valves. To be able to develop and design a

•

specified motion sequence with EMERGENCY-STOP. To be able to design the EMERGENCY-

•

STOP condition „Cylinder remains in its current position“ during EMERGENCY-STOP. To familiarise yourself with the design

•

and mode of operation of a 5/3-way solenoid valve. To be able to replace a 5/3-way

•

solenoid valve with 3/2 way solenoid valves. To be able to integrate the mode of operation „reset“. To be able to identify and eliminate

•

•

faults in complex electropneumatic control systems.

16


Equipment set – Advanced Level (TP202)

The equipment set for the advanced level has been compiled for further training in electro-pneumatic control technology. The two equipment sets (TP201 and TP202) contain all the components required to meet the specified training aims and can be expanded as desired with other equipment sets of the Learning System for Automation and Technology. Equipment set – Advanced Level (TP202 Order No.: 540713)

Description

Order No.

Quantity

EMERGENCY-STOP button

183347

1

Non-return valve, piloted

540715

2

Preselect counter, electrical

162355

1

Proximity sensor, capacitive

178575

1

Proximity sensor, inductive

178574

1

Relays, 3-off

162241

2

Signal input plate, electrical

162242

1

Time relay, 2-off

162243

1

Valve terminal with 4 valve slices (MMJJ)

540696

1


17


Equipment set symbols

Description

Symbol

Relay, 3-off

A1

A2 A1

A2 A1

A2 Signal input plate, electrical

18

12 14

22 24

32 34

42 44

11

21

31

41

12 14

22 24

32 34

42 44

11

21

31

41

12 14

22 24

32 34

42 44

11

21

31

41

13

23

31

41

14

24

32

42

13

23

31

41

14

24

32

42

13

23

31

41

14

24

32

42



Description

Symbol

Time relay, 2-off

A1

17

27

35

45

18

28

36

46

17

27

35

45

18

28

36

46

with switch-on delay

A2

A1 with switch-off delay

A2


1

A1

A2

4 2

R1

R2

Proximity sensor, inductive


EMERGENCY-STOP button

13

21

14

22

Non-return valve, piloted

2

1 21


19


20


Allocation of equipment and exercises

Equipment set TP202 Exercise

1

2

3

4

5

6

7

8

9

10

11

12

1

1

1

6

6

6

3

1

Equipment Proximity sensor, inductive

1


1

EMERGENCY-STOP button Relay

2

6

6

6

6

6

4

5

6

Pushbutton, electrical, normally open

2

1

1

1

1

1

1

2

1

Pushbutton, electrical, normally

1

closed Non-return valve, piloted

2

Valve terminal with 4 valve slices (MMJJ)

1

1

1

1

1

1

1


1

1

1

1

1

1

Time relay, 2-off

1

Equipment set TP201 Exercise

1

2

3

4

5

6

7

8

9

10

11

12

Cylinder, double-acting

1

2

2

2

2

2

1

1

2

2

1

2

One-way flow control valve

2

4

4

4

4

4

2

2

4

4

2

4

1

1 2

2

2

2

Equipment

Pressure sensor Limit switch, electrical

2

2

2

2

2

Proximity sensor, electronic

2

2

2

2

2

Proximity sensor, optical

1

2

2

2 2

2

1

Pushbutton, electrical, normally closed contact

2

Relay

3

4

2

3

4

5

3

3

Manifold

1

1

1

1

1

1

1

1

1

1

1

1

On/off valve with filter regulating valve

1

1

1

1

1

1

1

1

1

1

1

1

Power supply unit 24V DC

1

1

1

1

1

1

1

1

1

1

1

1


21

Allocation of equipment and exercises

22


Methodological help for the trainer

• Training aims The overall aim of this collection of exercises is the systematic design of circuit diagrams and practical assembly of a control system on a profile plate. This direct interaction of theory and practice ensures quick progress with learning. The detailed training aims are documented in the table. Actual individual training aims are allocated to each problem and major training aims are shown in brackets. • Time required The time required to work through a problem depends on the trainee’s prior knowledge. Skilled workers in the engineering and electrical fields require approximately 2 weeks. Technicians or engineers require approximately 1 week. • Components of the equipment set The book of exercises and equipment set are harmonised. You will require the components of the equipment set for Basic Level TP 201 and Advanced Level TP202. Each of the Advanced Level exercises can be assembled on a profile plate. For exercise 11 you will require an additional electrical input or will need to assemble the circuit in a different form. • Representation Abbreviated notation and motion diagrams are used for the represention of motion sequences and switching statuses.


23

Methodological help for the trainer

24


Methodological structure of the exercises

All 12 exercises in Part A are of identical methodological structure. The exercises are divided into: • Title • Training aims • Problem definition • Parameters as well as • Project task • Positional sketch • Worksheets The proposed solutions in Part C are divided into: • Circuit diagram • Solution description as well as • Circuit design • Equipment list


25

Designation of equipment

The designation of components in a circuit is effected in accordance with the DIN-ISO 1219-2 standard. All components of a circuit have the same main code number. Letters are assigned depending on components. Several components within a circuit are numbered consecutively. The designation of multiple pressure ports is P and these are consecutively numbered separately. Drives: Valves: Sensors: Signal input: Accessories: Pressure ports:

26

1A1, 2A1, 2A2, ... 1V1, 1V2, 1V3, 2V1, 2V2, 3V1, ... 1B1, 1B2, ... 1S1, 1S2, ... 0Z1, 0Z2, 1Z1, ... P1, P2, ...


Contents of the CD-ROM

The CD-ROM supplied provides you with additional media. The contents of Part A – Exercises, and Part C – Solutions, are stored in the form of pdf files. The structure of the CD-ROM is as follows: • Operating instructions • Data sheets • Demo • Festo catalogue • FluidSIM® circuit diagrams • Industrial applications • Presentations • Product information • Videos

Operating instructions

Operating instructions are available for the various pieces of equipment of the technology package to assist you in the use and commissioning of the equipment.

Data sheets

The data sheets for the equipment of the technology package are available in the form of pdf files.

Demo

A demo version of the software package FluidSIM® Pneumatic is stored on the CDROM. This version is suitable for the testing of the control system developed.

Festo catalogue

Pages from the Festo AG & Co. KG catalogue are provided for selected pieces of equipment. The representation and description of equipment in this form is intended to illustrate how such equipment is represented in an industrial catalogue. You will also find additional information here regarding the equipment.

FluidSIM® circuit diagrams

FluidSIM® circuit diagrams are stored in this directory for all 12 exercises in the technology package. For the introduction to logic programming, all FluidSIM® circuit diagrams are also stored in a variant with logic control in addition to the circuit diagrams with relay control.


27

Contents of the CD-ROM

Industrial applications

Photos and pictures are provided of industrial applications to enable you to illustrate your own problem definitions. These can also be added to project presentations.

Presentations

Brief presentations are stored in this directory regarding the equipment for this technology package. These presentations can for instance be used to create project presentations.

Product information

This directory provides you with the product information and data sheets of Festo AG & Co. KG regarding the equipment of the technology package and is intended to explain what information and data are provided for an industrial component.

Videos

A number of videos of industrial applications complete the media for the training package. Short sequences are shown of practice-related applications.

28


Equipment set – Basic Level (TP201)

This equipment set has been compiled for basic training in electropneumatic control technology. It comprises all the components required for the training aims specified and can be expanded in any way with other equipment sets. In addition you will also need a profile plate, electrical power supply unit and compressed air supply to assemble a fully functional control system. Equipment set – Basic: Level (TP201 Order No.: 540712)

Description

Order No.

Quantity

2 x 3/2-way way solenoid valve, normally open

539776

1

5/2-way double solenoid valve

539778

2

5/2-way solenoid valve

539777

1

Blanking plug

153267

10

One-way flow control valve

539773

4

Pressure sensor

539757

1

On/off valve with filter regulating valve

540691

1

Limit switch, electrical, actuation from the left

183322

1

Limit switch, electrical, actuation from the right

183322

1

Plastic tubing 4 x 0.75, 10 m

151496

2

Proximity sensor, electronic

540695

2

Proximity sensor, optical

178577

1

Relay, 3-off

162241

2

Signal input plate, electrical

162242

1

Push-in sleeve

153251

10

Push-in T-connector

153128

20

Manifold

152896

1

Cylinder, double-acting

152888

2

Cylinder, single-acting

152887

1


29

Training aims of Basic Level (TP201)

• To familiarise yourself with the design and mode of operation of a single-acting cylinder. • To familiarise yourself with the design and mode of operation of a double-acting cylinder. • To be able to calculate piston forces according to specified values. • To familiarise yourself with the design and mode of operation of a 3/2-way solenoid valve. • To familiarise yourself with the design and mode of operation of a double solenoid valve. • To be able to select solenoid valves according to requirements. • To be able to identify and draw the various types of actuation of directional control valves. • To be able to convert solenoid valves. • To be able to explain and design an example of direct actuation. • To be able to explain and design an example of indirect actuation. • To familiarise yourself with logic functions and to design these. • To familiarise yourself with different types of end position control and to be able to select a suitable type. • To be able to calculate electrical characteristic values. • To familiarise yourself with latching circuits with different characteristics. • To be able to explain and design an electrical latching circuit with dominant switch-off signal. • To be able to design a pressure-dependent control system. • To familiarise yourself with the design and mode of operation of magnetic proximity sensors. • To familiarise yourself with displacement-step diagrams and to be able to design these for specified problem definitions. • To be able to realise a sequence control using two cylinders. • To be able to identify and eliminate errors in simple electropneuamtic control systems.

30


Contents

Part A – Exercises

Exercise 1: Realising a diverting device ___________________________________A-3 Exercise 2: Insertion of drinks bottles ___________________________________A-15 Exercise 3: Realising a selection station _________________________________A-23 Exercise 4: Machining of key blanks ____________________________________A-39 Exercise 5: Bending of mounting brackets _______________________________A-49 Exercise 6: Realising a filling system ____________________________________A-57 Exercise 7: Bonding of components _____________________________________A-67 Exercise 8: Selecting modes of operation ________________________________A-75 Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function ______________________A-85 Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP FUNCTION ____________________A-95 Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function____________________ A-103 Exercise 12: Eliminating a fault on a machining station ___________________ A-113


A-1

Contents

A-2


Exercise 1: Realising a diverting device

Training aims

• To familiarise yourself with the design and function of valve terminals. • To be able to use valve terminals in accordance with requirements.

Problem definition

Drinks bottles are to be diverted from one conveyor to another using a diverting device. By pressing a pushbutton the frame of the diverting device is to advance. A bottle is transferred and conveyed in the opposite direction. By pressing another pushbutton, the frame is to return into the initial position.

Parameters

• A double-acting cylinder is to be used. • Cylinder control is to be realised indirectly and via a pushbutton. • In the event of a power failure the cylinder piston rod is to remain in the assumed position.

Project task

1. Answer the questions or carry out the exercises regarding the fundamentals of the training contents listed. 2. Draw the pneumatic and electrical circuit diagrams. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile an equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.


A-3


Positional sketch

Diverting device for drinks bottles

1. Cylinder 1A1 is in the retracted end position. 2. The 5/2-way double solenoid valve 1V1 is to switch by pressing pushbutton S1 and the cylinder to move into the forward end position. 3. The 5/2-way double solenoid valve is to reverse by pressing pushbutton S2 and the cylinder to move into the retracted end position.

A-4



Exercise 1: Realising a diverting device Name:

Date:

Fundamentals: Installation costs

Sheet 1 of 5

The configuration, tubing and wiring of the components of an electropneumatic control system should be selected such as to keep the sum total of equipment, installation and maintenance costs as low as possible. The following choices are available as regards wiring: • Conventional wiring technology, e.g. terminal strips • Advanced installation concepts, e.g. wiring using multi-pin connectors

The following choices are available in respect of configuration, i.e. number of drives and tubing requirements: • Individual mounting of solenoid operated directional control valves • Block mounting (manifold or valve terminal)


A-5



Date:


Sheet 2 of 5

– Compare the above listed concepts using the example of this control system in terms of reducing the tubing costs.

Note Use the individual valves from TP201 or the MPA valve terminal from TP202 and the respective technical descriptions.

Components

Individual mounting

Block mounting of

Saving when using

of directional control valves

directional control valves

block mounting

Tubing Number of compressed air distribution units Amount of tubing for supply to compressed air distribution unit Amount of tubing for compressed air supply to control chains Amount of tubing between directional control valves and cylinders Silencers Number of silencers for control chains

A-6




Date:


Sheet 3 of 5

– Which concept enables you to achieve a reduction in tubing costs? Explain the reason for your choice.


Reason


Individual mounting

Block mounting of

of directional control valves

directional control valves

A-7



Date:


Sheet 4 of 5

– Compare the above listed concepts using the example of this control system with regard to reducing wiring costs

Note Use the individual valves of TP201 or the MPA valve terminal from TP202 and the respective technical descriptions.

Wiring table Components

Cables

Number of

Number of

terminals/components

terminals/components Multi-pin wiring concept

Conventional wiring technology Control cabinet Terminal strip 1 in control cabinet

1

1

Earthing cable Supply voltage (24 V) PLC outputs (actuation of solenoid coils) PLC inputs (evaluation of proximity sensors)

Terminal strip 1 in control cabinet, overall Cable from control cabinet to terminal box

Cable between terminal strips 1 and 2

Cable from terminal strip 2

Proximity sensors (3 wires per

(in terminal box)

proximity sensor) Solenoids (2 wires per solenoid)

Terminal strip 2, overall Cable to directional control valves and sensors

A-8

Connection of solenoid coils Connection of sensors




Date:

Fundamentals: Reducing the wiring costs

Sheet 5 of 5

– Which concept enables you to achieve a reduction in wiring costs? Explain the reason for your choice.


Reason


Conventional wiring

Multi-pin wiring

technology

concept

A-9



Date:

Completing the pneumatic and electrical circuit diagrams

Sheet 1 of 3

– Complete the pneumatic circuit diagram for the diverting device.

4

5

2

1

3

Pneumatic circuit diagram with individual valve

A-10




Date:


Sheet 2 of 3

– Complete the pneumatic circuit diagram for the diverting device.

0V1 4

-VM

S

14

3/5 82/84 12/14 1

2

14

-M1

3/5 82/84 12/14 1

4

-VM

-M1

3/5 82/84 12/14 1

2

4

1V1 J

14

1M1

3/5 82/84 12/14 1

2

4

-VJ

1M2

12

14

-M1

3/5 82/84 12/14 1

2

-M2

12

3/5 82/84 12/14 1

1

Pneumatic circuit diagram with valve terminal (circuit diagram in DIN A3 format in Part D)


A-11



Date:


Sheet 3 of 3

– Complete the electrical circuit diagram for the diverting device. +24 V

1

0V

2

3

A1

A1

A2

A2

11

12 14

11

12 14

21

22 24

21

22 24

31

32 34

31

32 34

41

42 44

41

42 44

4

Electrical circuit diagram

A-12




Date:

Compiling the equipment list

Sheet 1 of 1

Apart from the circuit diagram, comprehensive project documentation also requires an equipment list. – Compile the equipment list by entering the required equipment in the table below. Quantity

Description

Equipment list


A-13


A-14


Festo ElectroPneumatics Workbook Advanced Level TP202 44 2005

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