Neumatica Ejercicios y Soluciones

Pneumatics Basic Level

Workbook TP 101

CD-ROM included

Festo Didactic 541088 en

541088_cover_workbook_tp101_en.indd 1

08.03.2005 14:25:34

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 needs 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 third parties, which may occur during the use/application of this equipment set other than in a training situation and unless such damages are caused by intention or gross negligence on the part of Festo Didactic.

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

541088 04/2005 W. Haring, M. Metzger, R.-C. Weber Frank Ebel Doris Schwarzenberger 08/2005

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

The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization 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.

2

© Festo Didactic GmbH & Co. KG • 541088

Contents

Preface ______________________________________________________________ 5 Introduction__________________________________________________________ 7 Notes on safety and operation __________________________________________ 9 Technology package for pneumatics (TP100) ______________________________ 11 Training aims of Basic Level (TP101) _____________________________________ 13 Allocation of training aims and exercises _________________________________ 15 Equipment set - Basic Level (TP101) _____________________________________ 17 Allocation of equipment and exercises ___________________________________ 21 Methodical help for the trainer__________________________________________ 23 Methodical structure of the exercise _____________________________________ 25 Designation of equipment _____________________________________________ 26 Contents of the CD-ROM _______________________________________________ 27 Equipment set of Advanced Level (TP102) ________________________________ 29 Training aims of Advanced Level (TP102) _________________________________ 30

Part A – Exercises Exercise 1: Pressing of cheese wheels ____________________________________A-3 Exercise 2: Opening of an animal feed silo _______________________________A-11 Exercise 3: Testing of key blanks _______________________________________A-17 Exercise 4: Sorting of packages ________________________________________A-23 Exercise 5: Stopping crates of drinks ____________________________________A-35 Exercise 6: Opening and closing of a pipe ________________________________A-41 Exercise 7: Shutting off using a quick shut-off function _____________________A-47 Exercise 8: Actuation of a shut-off device ________________________________A-53 Exercise 9: Brushing of cheese wheels __________________________________A-61 Exercise 10: Clamping of a workpiece ___________________________________A-67 Exercise 11: Actuation of a sliding door__________________________________A-75 Exercise 12: Supplying of workpieces ___________________________________A-81 Exercise 13: Crushing of drinks cans ____________________________________A-87 Exercise 14: Packaging of brochures ____________________________________A-93 Exercise 15: Mounting of locking clips___________________________________A-99 Exercise 16: Labelling of paint pots ___________________________________ A-105 Exercise 17: Cleaning of workpieces __________________________________ A-111 Exercise 18: Pressing in of lids _______________________________________ A-117


3

Contents

Part B – Fundamentals

Part C – Solutions Exercise 1: Pressing of cheese wheels ___________________________________C-3 Exercise 2: Opening of an animal feed silo ________________________________C-9 Exercise 3: Testing of key blanks _______________________________________C-13 Exercise 4: Sorting of packages ________________________________________C-17 Exercise 5: Stopping crates of drinks ____________________________________C-25 Exercise 6: Opening and closing of a pipe ________________________________C-29 Exercise 7: Shutting off using a quick shut-off function _____________________C-33 Exercise 8: Actuation of a shut-off device ________________________________C-37 Exercise 9: Brushing of cheese wheels __________________________________C-41 Exercise 10: Clamping of a workpiece ___________________________________C-47 Exercise 11: Actuation of a sliding door__________________________________C-51 Exercise 12: Supplying of workpieces ___________________________________C-55 Exercise 13: Crushing of drinks cans ____________________________________C-59 Exercise 14: Packaging of brochures ____________________________________C-63 Exercise 15: Mounting of locking clips___________________________________C-67 Exercise 16: Labelling of paint pots _____________________________________C-71 Exercise 17: Cleaning of workpieces ____________________________________C-75 Exercise 18: Pressing in of lids _________________________________________C-81

Part D – Appendix Storage unit________________________________________________________ D-2 Assembly technology ________________________________________________ D-3 Plastic tubing_______________________________________________________ D-4 Data sheets

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 basic knowledge in all areas of technology • 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, methodical 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 in both the classroom and 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. The technology package TP100 is comprised exclusively of pneumatic control systems. Basic Level TP101 is suitable for basic training in pneumatic control technology and provides knowledge regarding the physical fundamentals of pneumatics and the function and use of pneumatic equipment. The equipment set enables you to construct simple pneumatic control systems. Advanced Level TP102 focuses on further training in pneumatic control technology. The equipment set enables you to construct complex combinational circuits using logic operations of input and output signals and control systems using sequencer modules. Prerequisite for the assembly of control systems is a fixed workstation using a Festo Didactic profile plate, consisting of 14 parallel T-slots at 50 mm spacing. A mobile, sound attenuated compressor (230 V, maximum 8 bar = 800 kPa) can be used for pressure 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 Basic Level TP101 equipment set is used to construct all of the complete control systems for the 18 exercise definitions. The theoretical fundamentals to help you understand this collection of exercises can be found in the textbook • Pneumatics, Basic Level Also available are data sheets regarding 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 roller lever valves manually during fault finding (use a tool). • Observe general safety regulations (DIN 58126). • Limit switches must be mounted laterally to the trip cam (not from the front). • Do not exceed the permissible working pressure (see data sheets). • Pneumatic circuit design: Connect devices using the silver metallic plastic tubing of 4 mm outer diameter, plugging the tubing 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 prior to dismantling the circuit. • The mounting plates of the devices are equipped with mounting variants A, B or C: Variant A, latching system For lightweight non loadable devices (e.g. directional control valves). Simply clip the devices 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 via the blue knurled nut. Variant C, screw system For heavy loadable devices or equipment rarely removed from the profile plate (e.g. Start-up valve with filter control valve). These devices are mounted by means of socket head screws and T-head bolts. • The data for the individual devices specified in the data sheets in Part D must be observed.


9

Notes on safety and operation

A stop watch is required to evaluate the control systems assembled. This is used to: • Adjust one-way flow control valves such that the cylinder stroke time achieves specified values, • Set time delay valves.

10


Technology package for pneumatics (TP100)

The technology package TP100 consists of numerous training media as well as seminars. The object of this package is exclusively pneumatic control systems. Individual components from the technology package TP100 may also form a component part of other packages.

Important elements of TP100

• Fixed workstation with Festo Didactic profile plate • Compressor (230 V, 0.55 kW, maximum 8 bar = 800 kPa) • Equipment sets of individual components (e.g. cylinders, directional control valves, predetermining counters, stepper modules, logic elements, pneumatic proximity sensors) • Optional training aids (e.g. visual displays, 5/3-way valve, pulling/pushing load) • Practical training models • Complete laboratory setups Training documentation Textbooks

Basic Level TP101 Fundamentals of pneumatic control technology Maintenance of pneumatic devices and systems

Workbooks

Basic Level TP101 Advanced Level TP102

Optional Teachware

Sets of overhead transparencies Magnetic symbols, drawing template ®

Simulation software FluidSIM Pneumatic WBT Fluid Studio Pneumatic Cutaway model set 1 + 2 with storage case


11

Technology package for pneumatics (TP100)

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 systems

P-AL

Pneumatics 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 Basic Level (TP101)

• 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 3/2-way valve. • To be able to identify and draw types of directional control valve actuation. • To be able to explain and design a direct actuation. • To be able to analyse and evaluate circuits. • To familiarise yourself with the design and mode of operation of a double-acting cylinder. • To familiarise yourself with the design and mode of operation of a 5/2-way valve. • To be able to explain and design an indirect actuation. • To familiarise yourself with the mode of operation of a 5/2-way valve with pneumatic actuation. • To be able to differentiate between a signalling element and a control element. • To be able to measure pressure in pneumatic control systems. • To be able to differentiate between and utilise types of flow control according to specifications. • To be able to set cylinder advancing and retracting speeds. • To familiarise yourself with one type of signal storage in pneumatic control systems. • To be able to explain and realise logic AND/OR/NOT operations. • To be able to explain and configure latching circuits.


13

Training aims of Basic Level (TP101)

• To familiarise yourself with one possibility of cylinder end position sensing. • To be able to combine logic operations. • To familiarise yourself with the design and mode of operation of magnetic proximity sensors. • To be able to differentiate between and select and use 5/2-way valves according to specifications. • To be able to further develop existing circuits. • To familiarise yourself with the design and mode of operation of a pressure sequence valve. • To be able to design pressure-dependent control systems. • To familiarise yourself with the design and mode of operation of a pressure regulating valve. • To be able to analyse circuits and optimise these according to specifications. • To familiarise yourself with the design and mode of operation of a time delay valve. • To be able to design circuits with oscillating movements. • To be able to use time delay valves dependent on parameters. • To be able to analyse and design circuits using two cylinders.

14


Allocation of training aims and exercises

Exercise

1

2

3

•

•

•

•

•

•

•

•

•

•

•

•

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

Training aims 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 3/2-way valve. To be able to identify and draw types of directional control valve actuation. To be able to explain and design an example of direct actuation. To be able to analyse and evaluate

•

•

•

circuits. To familiarise yourself with the

•

design and mode of operation of a double-acting cylinder. To familiarise yourself with the

•

•

design and mode of operation of a 5/2-way valve. To be able to explain and design an

•

•

example of indirect actuation. To be able to differentiate between

•

a signalling element and a control element. To be able to measure pressure in pneumatic control systems.

•

To be able to differentiate between

•

•

and utilise types of flow control according to specifications. To be able to set cylinder advancing and retracting speeds.


•

•

15

Allocation of training aims and exercises

Exercise

1

2

3

4

5

6

7

8

9

10

11

12

•

•

•

•

•

•

13

14

15

16

•

•

•

17

18

Training aims To familiarise yourself with one type

•

of signal storage in pneumatic control systems. To be able to explain and realise logic AND/OR/NOT operations. To be able to explain and design latching circuits. To familiarise yourself with one

• •

possibility of cylinder end position sensing. To be able to combine logic operations. To familiarise yourself with the

•

design and mode of operation of magnetic proximity sensors. To be able to differentiate between

•

and select and use 5/2-way valves according to specifications. To be able to further develop

•

existing circuits. To familiarise yourself with the

•

design and mode of operation of a pressure sequence valve. To beable to design pressuredependent control systems. To familiarise yourself with the

•

•

design and mode of operation of a pressure regulating valve. To familiarise yourself with the

•

design and mode of operation of a time delay valve. To be able to design circuits with oscillating movements.

•

To be able to use time delay valves

•

dependent on parameters. To be able to analyse and design circuits using two cylinders.

16

•


Equipment set – Basic Level (TP101)

This equipment set has been compiled for basic training in pneumatic control technology. It contains all the components required to meet the specified training aims and can be expanded in any way with other equipment sets. The profile plate and a compressed air supply are required in addition. Equipment set – Basic Level (TP101 Order No.: 540710)

Description

Order No.

Quantity

3/2-way pneumatic valve, pneumatically actuated, one side

539768

1

3/2-way roller lever valve, normally closed

152866

2

3/2-way valve with pushbutton actuator, normally open

152861

1

3/2-way valve with pushbutton actuator, normally closed

152860

2

3/2-way valve with selector switch, normally closed

152863

1

5/2-way double pilot valve, pneumatically actuated, both sides

539769

3

5/2-way valve, pneumatically actuated, one side

538694

1

5/2-way valve with selector switch

152862

1

Double-acting cylinder

152888

1

Dual-pressure valve (AND)

539770

2

Manifold

152896

1

One-way flow control valve

539773

2

Plastic tubing, 10 m, PUN 4 x 0.75

151496

2

Pressure gauge

152865

2

Pressure regulator valve with gauge

539756

1

Pressure sequence valve

152884

1

Proximity switch, pneumatic, with cylinder attachment

539775

2

Push-in sleeve

153251

10

Push-in T-connector

153128

10

Quick-exhaust valve

539772

1

Shuttle valve (OR)

539771

1

Single-acting cylinder

152887

1

Start-up valve with filter control valve

540691

1

Time-delay valve, normally closed

540694

1


17


Equipment set symbol

Description

Symbol

2

3/2-way valve with pusbutton actuator, normally closed

1

3 2

3/2-way valve with pushbutton actuator, normally open

1

3

4


2

5

3

1

2


1

3

Pressure gauge

2


1

2

Pneumatic proximity switch

1

3 2

3/2-way pneumatic valve, normally closed

3

12 1

5/2-way pneumatic valve

3 4

2

5

1 3

4

2

14

5/2-way pneumatic double pilot valve

14

12 5

18

1 3



Description

Symbol

Shuttle valve

2 1/3

1 Dual pressure valve

2 1/3

1

2

Time delay valve, normally closed

1 Quick exhaust valve

2 1


3

1

1/3 2


2

12

1

3




19


Description

Symbol


1 2

3

Pressure regulating valve with pressure gauge

2

1

3

Manifold

Connection elements

20


Allocation of equipment and exercises

Exercise

1

2

3

1

1

1

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

Equipment Cylinder, single-acting Cylinder, double-acting

1 1

1


1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

1

2

2

2

2

2

2

2

1

2

2

1

1

1

1

2

2

1

1

1

1

Quick exhaust valve

1

Pressure gauge 3/2-way valve, pushbutton actuator, normally closed

2

2

1

1

3/2-way valve, pushbutton actuator, normally open

1 2 1

1

3/2-way valve, selector switch,

2

1 2

1

2

2

1

1

1

1

1

2

1

normally closed 3/2-way roller lever valve, normally closed

1

Pneumatic proximity switch

2


2

2

1

1

2

2

1

3/2-way pneumatic double pilot valve 5/2-way valve, selector switch

1


1

1

1

1

5/2-way pneumatic double pilot valve

1

1

1

Shuttle valve

1

1

Dual pressure valve

1 1

2

1

1

1

1

1 2

1

1

1

2


1

1

1


1

2

1

Time delay valve, normally closed

1

1

1

1

1

Manifold

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1


1

1

1

1

1

1

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 a quick progress with learning. The precise training aims are documented in the table. Actual individual training aims are allocated to each problem. • Time required The time required to work through a problem depends on the trainee’s prior knowledge. Skilled workers in the engineering and electrical field require approximately 2 weeks. Technicians or engineers require approximately 1 week. • Components of the equipment set The collection of exercises and equipment set are harmonised. For all 18 exercises you only require the components of the equipment set of Basic Level TP101. Each Basic Level exercise can be assembled on a profile plate.


23

Methodological help for the trainer

24


Methodological structure of the exercises

All 18 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 assembly • Equipment list


25

Designation of equipment

Components are designated 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 component. Several components within a circuit are numbered consecutively. The designation of pressure ports is P and these are separately consecutively numbered. Cylinder: Valves: Sensors: Signal input: Accessories:

26

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


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 CD-ROM. This version is suitable for the testing of the control systems 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 of the 18 exercises in the technology package.


27

Contents of the CD-ROM

Industrial applications

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

Presentations

Brief presentations are stored in this directory regarding the equipment of 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 technology package. Short sequences are shown of practice-related applications.

28


Equipment set – Advanced Level (TP102)

This Advanced Level equipment set has been compiled for further training in pneumatic control technology. The two equipment sets (TP101 and TP102) comprise the components required for the specified training aims and can be expanded in any way with other equipment sets of the Learning System for Automation and Technology. Equipment set – Advanced Level (TP102 Order No.: 540711)

Description

Order No.

Quantity

3/2-way roller lever valve with idle return, normally closed

152867

1

3/2-way pneumatic valve, pneumatically actuated, one side

539768

4

3/2-way valve with pushbutton actuator, normally closed

152860

2

5/2-way double pilot valve, pneumatically actuated, both sides

539769

2


152888

2


539773

2

Plastic tubing, 10 m, PUN 4 x 0.75

151496

2

3/2-way valve with mushroom-head emergency switch (red),

152864

1

Non-return valve, delockable

540715

2

Back pressure valve

152868

1

Push-in sleeve

153251

10

Stepper module

152886

1

Push-in T-connector

153128

20

Time delay valve, normally open

539759

1

Pneumatic preset counter

152877

1

Shuttle valve (OR)

539771

1

Shuttle valve, 3-off (OR)

152882

1

Dual pressure valve, 3-off (AND)

152883

1

normally open


29

Training aims of Advanced Level (TP102)

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

30

To detect end positions without limit switches To understand and design flip-flop circuits (flip-flop, double pilot valve) To convert a 3/2-way and/or 5/2-way valve To evaluate, use and adjust different sensors To explain the function of a back pressure end stop To describe the function of stepper (modules) To design basic stepper control systems (continuous cycle) To realise a stepper control system using the operating modes AUTOMATIC/MANUAL, START and RESET To realise the OR function of feedback signals To adjust and harmonise delays To be able to interrupt time delays via an OR function To realise a stepper control with idle step (3 steps) To describe and design variable step repetition within a motion sequence using a predetermining counter To develop an input circuit with self-latching loop and the functions AUTOMATIC/MANUAL, START, STOP at CYCLE END and RESET To evaluate and realise the use of sensors for material sensing To actuate a final control element using two stepper modules via a shuttle valve (double stroke of cylinder) To use a proximity sensor in the partial stroke range to realise the reversal of a cylinder To develop an input circuit for a stepper control with protected pilot air and the functions START, EMERGENCY-STOP and RESET To stop a cylinder within the partial stroke range (positioning) by means of pressure applied at both ends (pre-pressurise) To adjust proximity sensors in the end positions and in the partial stroke range The combined use of quick exhaust valve and pressure regulating valve with pressure gauge To design the inversion of a timer signal To realise a control system with command action in combination with a sequence control in stepper design.


Contents

Part A – Exercises

Exercise 1: Pressing of cheese wheels ____________________________________A-3 Exercise 2: Opening of an animal feed silo _______________________________A-11 Exercise 3: Testing of key blanks _______________________________________A-17 Exercise 4: Sorting of packages ________________________________________A-23 Exercise 5: Stopping crates of drinks ____________________________________A-35 Exercise 6: Opening and closing of a pipe _______________________________A-41 Exercise 7: Shutting off using a quick shut-off function _____________________A-47 Exercise 8: Actuation of a shut-off device ________________________________A-53 Exercise 9: Brushing of cheese wheels __________________________________A-61 Exercise 10: Clamping of a workpiece ___________________________________A-67 Exercise 11: Actuation of a sliding door__________________________________A-75 Exercise 12: Feeding of workpieces _____________________________________A-81 Exercise 13: Crushing of drinks cans ____________________________________A-87 Exercise 14: Packaging of brochures ____________________________________A-93 Exercise 15: Fitting of locking clips _____________________________________A-99 Exercise 16: Labelling of paint pots ___________________________________ A-105 Exercise 17: Cleaning of workpieces __________________________________ A-111 Exercise 18: Pressing in of lids _______________________________________ A-117


A-1

Contents

A-2


Exercise 1: Pressing of cheese wheels

Training aims

• 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 3/2-way valve. • To be able to identify and draw types of directional control valve actuation. • To be able to explain and design an example of direct actuation.

Problem definition

During cheese production, pneumatic cylinders are to be used to press cheese wheels into moulds. Design the control system whereby this process can be carried out.

Parameters

• A single-acting cylinder is to be used . • The pneumatic control of the cylinder is to be realised by mean of a manually operated valve.

Project task

1. 2. 3. 4. 5. 6. 7.

Describe the mode of operation of a single-acting cylinder. Describe the mode of operation of a 3/2-way valve. Complete the pneumatic circuit diagram for the pressing device. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Compile an equipment list.


A-3


Positional sketch

Cheese production

1. Cheese wheels are to be manually inserted into the device. 2. Actuation of the pushbutton is to cause the cylinder to advance and press the cover onto the device. 3. The pushbutton is to be pressed until the pressing operation is completed. 4. If the pushbutton is released, the cylinder is to retract again and release the device. 5. The wheel can then be removed.

Note A single-acting cylinder with a strong reset spring must be used for this control system.

Safety advice Please limit the pressure at the service unit to a maximum of 3.5 bar (350 kPa) for this exercise.

A-4



Exercise 1: Pressing of cheese wheels Name:

Date:

Design and mode of operation of a single-acting cylinder

Sheet 1 of 2

– Compare the symbols shown with the schematic representation of the singleacting cylinder. Check whether these match. 1A1

Symbol of a single-acting cylinder

1

2

3

8

7

4

5

6

Schematic representation of a single-acting cylinder

– Assign the designations to the individual components. No.

Description Cylinder barrel End cap Bearing cap Piston rod Piston Reset spring Supply port Exhaust port

Table of component designations


A-5



Date:

Design and mode of operation of a single-acting cylinder

Sheet 2 of 2

The theoretical piston force is calculated according to the following formula: Fth Fth A p

= = = =

A•p Theoretical piston force (N) Effective piston surface (m2) Working pressure (Pa)

The effective piston force is of significance in practice. Frictional resistance is to be taken into account when you calculate this. Friction forces of approx. 10% of the theoretical piston force can be assumed for standard operating conditions (pressure range of 4 to 8 bar (400 to 800 kPa),. The following applies for single-acting cylinders: Feff

=

A • p – (FF + FR) Feff FF FR

= = =

Effective piston force (N) Friction force (approx. 10% of Fth ) (N) Return spring force (N)

– Calculate the effective piston force in the advance stroke for the cylinder when used at an operating pressure of 6 bar (600 kPa)!

Note You will find information regarding the technical data in Chapter D and on the CD-ROM provided. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________

A-6




Date:

Mode of operation of a 3/2-way valve.

Sheet 1 of 1

– Complete the symbol of a 3/2-way valve, manually operated, with spring return, normally closed. 2

1

3

Symbol of a 3/2-way valve

2 3 1

Schematic representation of a 3/2-way valve

– Explain the mode of operation of the 3/2-way valve. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________


A-7



Date:

Completing the pneumatic circuit diagram

Sheet 1 of 1

– Complete the pneumatic circuit diagram for the device and enter the port designations.

Pneumatic circuit diagram

Note The Start-up valve with filter control valve and the manifold are not shown. These components are required for the circuit assembly.

A-8




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-9


A-10


Exercise 2: Opening of an animal feed silo

Training aims

• 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 3/2-way valve. • To be able to identify and draw directional control valves. • To be able to explain and design an example of direct actuation.

Problem definition

The slide of an animal feed silo is to be opened by pressing a pushbutton. The slide is closed again when the pushbutton is released.

Parameters

• A single-acting cylinder is to be used. • The pneumatic control of the cylinder is to be realised by means of a pushbutton actuator.

Project task

1. 2. 3. 4. 5. 6.

Answer the questions regarding the 3/2-way valve. Create the pneumatic circuit diagram for the slide control. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Compile the equipment list


A-11


Positional sketch

Animal feed silo

1. Operation of the pushbutton actuator is to cause the cylinder to retract until the retracted end position is reached. 2. The pushbutton actuator is to be operated for as long as the slide is to remain open. 3. If the pushbutton actuator is released again, the cylinder is to advance thus causing the slide to close the silo opening.

Note A single-acting cylinder with a strong reset spring is to be used for this control system.

Safety advice Please limit the pressure at the service unit to a maximum of 3.5 bar (350 kPa) for this exercise.

A-12



Exercise 2: Opening of an animal feed silo Name:

Date:

Mode of operation of a 3/2-way valve

Sheet 1 of 1

– Complete the symbol of a 3/2-way valve, manually operated, with spring return, normally open. 2

1

3


2 1 3


– Explain the mode of operation of the 3/2-way valve. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________


A-13



Date:


Sheet 1 of 1

– Amend the pneumatic circuit diagram for the device and enter the port designations.

Note Please note that circuits must be shown in their initial position.

1A1

1S1

2

1

3


Note The On-Off valve with filter regulating valve and the manifold are not shown. These components are required for the circuit assembly.

A-14




Date:

Amending the equipment list

Sheet 1 of 1

– Amend the equipment list. Quantity

Description

1

Compressed air supply Tubing material

1


1

3/2-way valve, manually operated, normally closed

Quantity

Description

Equipment list

Amended equipment list


A-15


A-16


Exercise 3: Testing of key blanks

Training aims

• 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 3/2-way valve. • To be able to identify and draw types of directional control valve actuation. • To be able to explain and design an example of direct actuation. • To be able to to analyse and evaluate circuits.

Problem definition

Key blanks are to be tested at a manual workstation. The insertion of the key blanks requires a certain amount of time. It must therefore be possible for the clamping cylinders to be retained in both end positions.

Parameters

• Use one of the circuits from the previous exercises and adapt this for the purpose of this problem.

Project task

1. 2. 3. 4. 5.

Complete the pneumatic circuit diagram for the clamping device Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Amend the equipment list


A-17


Positional sketch

Test station for key blanks

1. Key blanks are to be inserted manually into the test device. 2. Actuation of the selector switch is to cause the cylinder to advance and secure the key blanks. 3. The cylinder is to remain in this position even after the selector switch is released. 4. Resetting of the selector switch is to cause the cylinder to return into the retracted end position and to remain there until the selector switch is actuated again.

Safety note Please limit the pressure at the service unit to a maximum of 3.5 bar (350 kPa) for this exercise.

Additional exercises

A-18

• What errors can occur during the assembly and tubing up of the circuit? • What is the effect of such errors. Describe these.



Exercise 3: Testing of key blanks Name:

Date:


Sheet 1 of 1

– Complete the circuit diagrams below. – Select the optimal circuit and complete this by adding the required type of actuation. Explain the reasons for your choice. a)

b)

Pneumatic circuit diagrams

Note The On/Off valve with the filter regulating valve and the manifold are not shown. These components are required for the circuit assembly.


A-19



Date:


Sheet 1 of 1

– Amend the equipment list. Quantity

Description

1

Cylinder, single-acting

1

3/2-way valve with pushbutton, normally open

1

Manifold

1


1

Compressed air supply

Quantity

Description

Equipment list

Amended equipment list

A-20




Date:

Completing additional exercises

Sheet 1 of 1

– What errors can occur during the assembly and tubing up of the circuit? – What is the effect of such errors? Describe these.

_____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________


A-21


A-22


Exercise 4: Sorting of packages

Training aims

• To familiarise yourself with the design and mode of operation of a double-acting cylinder. • To familiarise yourself with the design and mode of operation of a 5/2-way valve. • To be able to explain and design an example of direct actuation.

Problem definition

Packages are sorted manually from a conveyor into large containers at a sorting station. When the containers are filled, these are transferred and a new container is made available. During this time material flow is to be stopped whilst the conveyor continues to run. The stopping action is realised by means of a mechanical blocking device (slide). This blocking device is to be operated from the sorting position.

Parameters

• A double-acting cylinder is to be used for cost reasons.

Project task

1. 2. 3. 4. 5. 6. 7.

Describe the mode of operation of a double-acting cylinder. Describe the mode of operation of a 5/2-way valve. Draw a pneumatic circuit diagram for the package blocking device. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Compile an equipment list.


A-23


Positional sketch

Package conveyor

1. Actuation of the selector switch is to cause the cylinder to advance and push the slide into the material flow. 2. The cylinder is to remain in this position even after the selector switch is released and the material flow is to remain interrupted. 3. Resetting of the selector switch is to cause the cylinder to return into the retracted end position and release the material flow again. 4. The cylinder is to remain in this position until the selector switch is actuated again.


A-24




• What errors can occur during the assembly and tubing up of the circuit? • What is the effect of such errors? Describe these. • What are your observations with regard to the advance and return movement of the cylinder? Explain these. • Why is a double-acting cylinder more cost effective than a single-acting cylinder? • Determine the requirements placed on the directional control valve. • Give the reasons why a selector switch has been chosen to realise the actuating function.


A-25


A-26



Exercise 4: Sorting of packages Name:

Date:

Design and mode of operation of a double-acting cylinder

Sheet 1 of 4

– Compare the symbol shown with the schematic representation of the doubleacting cylinder. Check whether these match. 1A1

Symbol of a double-acting cylinder


A-27



Date:


Sheet 2 of 4

1

9

2

3

8

4

7

5

6

Schematic representation of a double cylinder

– Assign the designations to the individual components. No.

Designation Cylinder barrel End cap Bearing cap Piston rod Piston Supply port of piston chamber Supply port of piston rod chamber Adjusting screw of end position cushioning


A-28




Date:


Sheet 3 of 4

The piston force generated by a working element is dependent on the air pressure, cylinder diameter and frictional resistance of the sealing elements. The theoretical piston force is calculated according to the following formula: Fth Fth A p

= = = =

A•p Theoretical piston force (N) Effective piston surface (m2) Working pressure (Pa)

The effective piston force is of significance in practice. Frictional resistance is to be taken in account when you calculate this. Under normal operating conditions, friction forces of approx. 10% of the theoretical piston force can be assumed. The following applies for double-acting cylinders: Advance stroke Return stroke

Feff Feff Feff A

= = = = =

A'

= =

p FF D d


= = = =

(A • p) – FF (A' • p) – FF Effective piston force (N) Effective piston surface (m2) D2 • π ) ( 4 Effective annular surface (m2) π (D 2 − d 2 ) 4 Working pressure (Pa) Friction force (approx. 10% of Fth ) (N) Cylinder diameter (m) Piston rod diameter (m)

A-29



Date:


Sheet 4 of 4

– Calculate the effective piston force of the advance stroke and return stroke for the cylinder in question using at a working pressure of 6 bar (600 kPa).

Note You will find information regarding the technical data in Chapter D and on the CD-ROM provided. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________

A-30




Date:

Mode of operation of a 5/2-way valve

Sheet 1 of 1

– Complete the symbol of a 5/2-way valve, manually operated, with spring return.


14

5

4

1

2

3


– Explain the mode of operation of a 5/2-way valve. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________


A-31



Date:

Designing the pneumatic circuit diagram

Sheet 1 of 1

– Complete the circuit diagram below and also enter the required type of actuation. Explain the reasons for your choice.


Note The Start-up valve with filter control valve is not shown. These components are required for the circuit assembly.

A-32




Date:


Sheet 1 of 1


Description

Equipment list


A-33



Date:

Completing aditional exercises

Sheet 1 of 1

– – – –

What errors can occur during the assembly and tubing up of the circuit? What is the effect of such errors? Describe these. Describe the mode of operation of a double-acting cylinder. What are your observations with regard to the advance and return movement of the cylinder? Explain these. – Why is a double-acting cylinder more cost effective than a single-acting cylinder? – Determine the requirements placed on the directional control valve. – Explain your reasons why the selector switch is the form of actuation selected for the directional control valve. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________

A-34


Exercise 5: Stopping crates of drinks

Training aims

• To be able to explain and design an example of indirect actuation. • To familiarise yourself with the mode of operation of a 5/2-way valve with pneumatic actuation. • To be able to differentiate between a signal element and a control element.

Problem definition

Crates of drinks are to be provided with new labels. This process is to be checked via a test set-up. The crates of drinks are supplied on a conveyor and must be individually transported past a labelling device. The crates are to be stopped by means of a mechanical stop (slide). The slide is to operated from the system control console.

Parameters

• Stopping of the material flow is to be effected from a second control console, where compressed air is available and a pneumatic solution is therefore to be used.

Project task

1. Determine the circuit requirements with regard to the actuating components and control element. 2. Complete the pneumatic circuit diagram for the stopping of material flow. 3. Carry out the assembly. 4. Check the assembled circuit. 5. Describe the mode of operation of the circuit. 6. Compile an equipment list


A-35


Positional sketch

Labelling crates of drinks

1. Actuation of a selector switch is to cause the cylinder to advance and push the slide into the material flow; the crates are thus stopped. 2. Resetting of the selector switch is to cause the cylinder to return into the retracted end position and once again release the flow of material. 3. It is to remain in this position until the selector switch is actuated again.



A-36

• What errors can occur during the design and tubing up of the circuit? • What is the effect of such errors? Describe these. • Explain the terms „pilot control“ and „remote control“.



Exercise 5: Stopping crates of drinks Name:

Date:


Sheet 1 of 1

– Complete the circuit diagram below.

4

5

2

1

3




A-37



Date:


Sheet 1 of 1


Description

Equipment list

A-38



Exercise 5: Stopping of crates of drinks Name:

Date:


Sheet 1 of 1

– What errors can occur during the assembly and tubing up of the circuit? – What is the effect of such errors? Describe these. – Explain the terms „pilot control“ and „remote control“. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________


A-39


A-40


Exercise 6: Opening and closing of a pipe

Training aims

• To be able to measure pressure in pneumatic control systems. • To be able to differentiate between and utilise types of flow control in accordance with specifications.

Problem definition

The slide in a pipe is to be opened and closed. Actuation is to be triggered by means of a valve with selector switch. A double-acting cylinder is to be used as the drive.

Parameters

• The slide is to open/close only gradually since the load on the pipe would otherwise be to great (the formation of surges is to be avoided).

Project task

1. 2. 3. 4. 5. 6.

Design the pneumatic circuit diagram. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Compile an equipment list Observe the pressure ratios upstream and downstream of the flow control valve and document these.


A-41


Positional sketch

Waste water treatment

1. If the selector switch is actuated, the cylinder is to advance and open up flow. 2. If the selector switch is reset, the cylinder is to return into the initial position and the slide is to close.



A-42

• • • •

What errors can occur during the assembly and tubing up of the circuit? What is the effect of such errors? Describe these. At what pressure do you notice juddering operation? Describe what causes juddering operation.



Exercise 6: Opening and closing of a pipe Name:

Date:

Function of a one-way flow control valve

Sheet 1 of 1

1

2

Symbol of a one-way flow control valve

1

2

Schematic representation of a one-way flow control valve

– Describe the function of a one-way flow control valve. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________


A-43



Date:


Sheet 1 of 1

– Complete the circuit diagram below. Enter the symbols of the one-way flow control valves. 1A1

1V1

1S1

1

1

2

2

4

5

1V2

2

1

3



A-44




Date:


Sheet 1 of 1

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

Description

Equipment list


A-45



Date:


Sheet 1 of 1

– – – –

What errors can occur during the assembly and tubing up of the circuit? What is the effect of such errors? Describe these. At what pressure do you notice juddering operation? Describe what causes juddering operation.

_____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________

A-46


Exercise 7: Shutting off using a quick shut-off function

Training aims

• To be able to set cylinder advancing and retracting speeds. • To be able to differentiate between and utilise types of flow control in accordance with specifications.

Problem definition

A filling plant fills pots of paint with wall and ceiling paint. The pipes through which the paint flows are to close quickly. The opening of the pipe is to be effected gradually.

Parameters

• A double-acting cylinder is to be used

Project task

1. 2. 3. 4. 5.

Create the pneumatic circuit diagram for the shut-off device. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Compile the equipment list.


A-47


Positional sketch

Filling paint pots

1. Actuation of a selector switch is to cause a shut-off valve to open gradually. 2. Resetting of the selector switch is to cause the shut-off valve to close quickly.



A-48

• What errors can occur during the tubing up? • What is the effect of such tubing errors? Describe these.



Exercise 7: Shutting-off using a quick shut-off function Name:

Date:


Sheet 1 of 1

– Complete the circuit diagram below and add the symbols of the one-way flow control valves. 1A1

1Z2

1V1

1Z1

1S1

1

1

2

2

4

5

1V2

2

1

3




A-49


Exercise 7: Shutting off using a quick shut-off function Name:

Date:


Sheet 1 of 1


Description

Equipment list

A-50




Date:


Sheet 1 of 1

– What errors can occur during tubing? – What are the effects of such tubing errors. Describe these. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________


A-51


A-52


Exercise 8: Actuation of a shut-off device

Training aims

• To familiarise yourself with one type of signal storage in pneumatic control systems. • To be able to set cylinder advancing and retracting speeds.

Problem definition

The slide of a plastic granulate filling system is to close quickly. The opening of the slide is to be effected gradually.

Parameters

• A double-acting cylinder is to be used.

Project task

1. 2. 3. 4. 5. 6. 7.

Describe the mode of operation of a quick exhaust valve. Describe the mode of operation of a 5/2-way double pilot valve. Design the pneumatic circuit diagram for the shut-off device. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Compile the equipment list


A-53


Positional sketch

Granulate filling system

1. Actuation of a pushbutton is to cause a shut-off device (ball valve) to open gradually. 2. Actuation of a second pushbutton is to cause the shut-off device to close quickly.

Safety note Please limit the pressure at the service unit to a maximum of 3.5 bar (350 kPa) for this exercise..


A-54

• What errors can occur during the assembly and tubing up of the circuit? • What is the effect of such errors? Describe these.



Exercise 8: Actuation of a shut-off device Name:

Date:

Function of a quick exhaust valve

Sheet 1 of 1

2 1

1/3

Symbol of a quick exhaust valve

3

2

1

Schematic representation of a quick exhaust valve

– Describe how a quick exhaust valve functions. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________


A-55



Date:

Mode of operation of a 5/2-way double pilot

Sheet 1 of 1

14

5

4

1

2

3

12

Schematic representation of a 5/2-way double pilot valve

– Explain the mode of operation of the 5/2-way double pilot valve. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________

A-56




Date:


Sheet 1 of 1


1

2

2

4

5

2

1

3




A-57



Date:


Sheet 1 of 1


Description

Equipment list

A-58




Date:


Sheet 1 of 1

– What errors can occur during the assembly and tubing up of a circuit? – What is the effect of such errors? Describe these. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________


A-59


A-60


Exercise 9: Brushing of cheese wheels

Training aims

• To be able to explain and configure an indirect actuation. • To be able to explain and realise logic AND/OR/NOT operations. • To be able to explain and configure.

Problem definition

Cheese wheels are to be brushed during production. Loading of the brushing device is to be controlled manually. The cheese wheels are to be supplied via a conveyor. Material flow is to be stopped by means of a slide if the device is filled .

Parameters

• Material flow is to be controlled via two valves and the use of pushbuttons, i.e. one pushbutton actuator to block and one to release material flow. • Since the signal of the pushbutton actuators is only briefly applied, a circuit that stores the signal status needs to be designed.

Project task

1. 2. 3. 4. 5. 6. 7.

Describe the function of a shuttle valve. Describe the construction of a self-latching loop. Complete the pneumatic circuit diagram. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Compile the equipment list


A-61


Positional sketch

Cheese production

1. Actuation of the pushbutton is to cause the cylinder to advance and push the slide into the material flow. 2. The cylinder retains this position even after the pushbutton is released and material flow is to remain interrupted. 3. Actuation of the second pushbutton is to cause the cylinder to return into the retracted end position and release material flow again. 4. It is to remain there until the first pushbutton is actuated again.


A-62

• What errors can occur during tubing up? • What are the effects of such tubing errors? Describe these. • Describe the mode of operation of the self-latching loop on the basis of the circuit.



Exercise 9: Brushing of cheese wheels Name:

Date:

Function of a shuttle valve

Sheet 1 of 1

2 1/3

1

Symbol of a shuttle valve

2

1

1/3

Schematic representation of a shuttle valve

– Describe the function of a shuttle valve. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________


A-63



Date:


Sheet 1 of 1

– Design the required self-latching circuit and complete the circuit diagram below. 1A1

1

1

2

2

4

2

14 5

1S1

1

3

2

1

3


A-64




Date:


Sheet 1 of 1


Description

Equipment list


A-65



Date:


Sheet 1 of 1

– What errors can occur during tubing up? – What are the effects of such tubing errors? Describe these. – Describe the mode of operation of the self-latching loop on the basis of the circuit. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________

A-66


Exercise 10: Clamping of a workpiece

Training aims

• To be able to explain and realise logic AND/OR/NOT operations. • To familiarise yourself with one possibility of cylinder end position sensing.

Problem definition

An automatic rotary indexing machine is used in production for the feeding of workpieces. Workpieces to be processed are to be clamped in the individual workpiece retainers. A clamping device is to be designed and checked by means of a test setup.

Parameters

• The clamping operation must not be started until the cylinder is in the retracted end position. • Actuation of a second pushbutton is to cause the cylinder to return into the retracted end position and release the workpiece. • A pressure gauge is to be installed at each of the working ports between the oneway flow control valve and cylinder to display the pressure.

Project task

1. 2. 3. 4. 5. 6. 7.

Describe the function of a dual pressure valve. Describe the function of a 3/2-way roller lever valve. Complete the pneumatic circuit diagram. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Compile an equipment list.


A-67


Positional sketch

Automatic rotary indexing machine

1. A double-acting cylinder is to advance only if a pushbutton is actuated AND if the cylinder is in the retracted end position at the same time, since it is otherwise not possible to insert a workpiece for processing. 2. The clamping cylinder is to retain the forward end position until the workpiece is processed. The duration of the processing time can vary. 3. Pressing of a second pushbutton is to cause the workpiece to be released.



A-68

• What errors can occur during the assembly and tubing up of the circuit? • What is the effect of such errors? Describe these. • What is the effect of adjusting the 3/2-way roller lever valve?



Exercise 10: Clamping of a workpiece Name:

Date:

Function of a dual pressure valve

Sheet 1 of 1

2 1/3

1

Symbol of a dual pressure valve

2

1

1/3

Schematic representation of a dual pressure valve

– Describe the function of a dual pressure valve. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________


A-69



Date:

Function of a 3/2-way roller lever valve

Sheet 1 of 1

2

1

3

Symbols of a 3/2-way roller lever valve

– Describe the function of a 3/2-way roller lever valve. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________

A-70




Date:


Sheet 1 of 1

– Complete the circuit diagram below. 1A1

1B1

1

1

2

2

4

2

14

12 5

1B1

1

1

3

2

3



A-71



Date:


Sheet 1 of 1

Apart from a 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-72




Date:


Sheet 1 of 1

– What errors can occur during the assembly and tubing up of the circuit diagram? – What is the effect of such errors? Describe these. – What is the effect of adjusting the 3/2-way roller lever valve? _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________


A-73


A-74


Exercise 11: Actuation of a sliding door

Training aims

• To be able to explain and realise logic AND/OR/NOT operations. • To be able to combine logic operations. • To familiarise yourself with the design and mode of operation of magnetic proximity sensors. • To be able to differentiate between and select and utilise 5/2-way valves in accordance with specifications.

Problem definition

A sliding door is to be opened and closed from both sides by means of a pushbutton. Only one pushbutton is to be located on each of the door in order to eliminate incorrect operation in cases of emergency.

Parameters

• Both functions must only be started if the door is in the forward end position. • For reasons of safety, pressure must be limited to 3 bar (300 kPa) (risk of being trapped).

Project task

1. 2. 3. 4. 5.

Design a pneumatic circuit diagram for the control system of the sliding door. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Compile an equipment list


A-75


Positional sketch

Sliding door

1. Provided that the sliding door is in a defined end position, it can be moved into the opposite end position by means of pressing a button. The sliding door can thus be opened or closed. 2. It is not possible to start the opening or closing function for as long as the door is not in an end position.

Safety note Please limit the pressure at the service unit to a maximum of 3 bar (300 kPa) for this exercise.


A-76

• What errors can occur during the assembly and tubing up of the circuit? • What is the effect of such errors? Describe these. • What happens if compressed air supply fails during the advancing and retracting movement? • How can the circuit be re-started; what needs to be done for this?



Exercise 11: Actuation of a sliding door Name:

Date:

Function of a pneumatic proximity sensor

Sheet 1 of 1

2

1

3

Symbol of a pneumatic proximity sensor

2

1

S N

3

N S

Schematic representation of the pneumatic proximity sensor

– Describe the function of the pneumatic proximity sensor. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________


A-77



Date:


Sheet 1 of 1

– Complete the circuit diagram below. 1B1

1A1

1B2

1

1

2

2

4

2

14

12 5

1B1

1

1S1

2

3

1S2

2

1

3

3

1B2

2

1

3

2

1

3


A-78




Date:


Sheet 1 of 1


Description

Equipment list


A-79



Date:


Sheet 1 of 1

– What errors can occur during the assembly or tubing up of the circuit? – What is the effect of such errors? Describe these. – What happens if the compressed air supply fails during the advancing and retracting movement? – How can the circuit be re-started and what needs to be done to this effect? _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________

A-80


Exercise 12: Feeding of workpieces

Training aims

• To familiarise yourself with the logic NOT operation. • To be able to combine logic operations. • To be able to further develop existing circuits.

Problem definition

Workpieces are to be fed from a magazine towards a machining process. The ejecting of a workpieces must be prevented if the removal position is not clear.

Parameters

• The checking function as to whether a workpiece is present in the removal position is to be effected by means of a roller lever valve. • The cylinder is to be throttled during advancing and retracting.

Project task

1. 2. 3. 4. 5.

Complete the pneumatic circuit diagram. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Compile an equipment list.


A-81


Positional sketch

Automatic rotary indexing machine

1. The ejecting function is to be started by means of a pushbutton if the cylinder is in the retracted end position. The ejecting cylinder is to push a workpiece from the magazine only if a sensor in the removal area signals that the removal position is NOT occupied. 2. If the removal position is clear, the cylinder is to move into the forward end position with exhaust air restricted, eject the workpiece and immediately return into the retracted end position.


A-82

• What errors can occur during the assembly and tubing up of the circuit? • What is the effect of such errors? Describe these. • How would you need to change the circuit if the ejecting process were to start only once a workpiece is present in the magazine AND the removal position is clear?



Exercise 12: Feeding of workpieces Name:

Date:


Sheet 1 of 1

– Complete the circuit diagram below. 1A1

1

1

2

2

4

2

14

12 5

1

3

Pneumatic circuit diagram Note Use a 3/2-way valve with pushbutton actuator or selector switch in the circuit instead of a 3/2-way roller lever valve in order to simulate whether the removal position is clear or occupied.


A-83



Date:


Sheet 1 of 1


Description

Equipment list

A-84




Date:

Carying out additional exercises

Sheet 1 of 1

– What errors can occur during the assembly and tubing up of the circuit? – What is the effect of such errors? Describe these. – How would you need to change the circuit, if the ejecting process were to start only once a workpiece is in the magazine AND the removal position is clear ? _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________


A-85


A-86


Exercise 13: Crushing of drinks cans

Training aims

• To familiarise yourself with the design and mode of operation of a pressure sequence valve. • To be able to design pressure-dependent control systems.

Problem definition

In a recycling plant drinks cans are to be crushed into a block for space-saving storage. The pressing operation is to be triggered by means of a pushbutton. The return stroke can be triggered by a pushbutton. The pressing operation is to start only if sufficient pressure is available.

Parameters

• The retracted end position is the initial position of the pressing cylinder. • The pressing operation is to start only if the system pressure is above 6 bar (600 kPa). • The return stroke can be triggered manually since, depending on material load, the pressing cylinder does not reach the forward end position.

Project task

1. 2. 3. 4. 5.

Complete the pneumatic circuit diagram for the crushing of cans. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Compile an equipment list.


A-87


Positional sketch

Tin can press

1. A pressure sequence valve is to switch upon reaching the preset pressure and to release compressed air for the circuit. The circuit must not function below a pressure of 4.5 bar (450 kPa). 2. It should not be possible to commence the pressing operation via a start button unless the pressing cylinder is in the upper end position. The pressing cylinder is to move up to the forward end position or a stop predefined by the material. 3. The return stroke is to be triggered by means of a limit switch or pushbutton.

Note The required protective grid is not shown.


A-88




Exercise 13: Crushing of drinks cans Name:

Date:

Function of a pressure sequence valve

Sheet 1 of 1

2

12

1

3

Symbol of a pressure sequence valve

3 2 1

12

Schematic representation of a pressure sequence valve

– Describe the function of a pressure sequence valve. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________


A-89



Date:


Sheet 1 of 1


1V6

1V5

1A1

1B2

1

1

2

2

4

2

14

12 5

1V3

1

2

3 1V4

1/3

1

1B1 2

1

1V7

1

1S1

1S2

2

1

3 1V2

1V1

1/3

1B2

2

1

3

2

3

2

1

3

2

12

1

3

2

1

3


A-90




Date:


Sheet 1 of 1


Description

Equipment list


A-91



Date:


Sheet 1 of 1

– What errors can occur during the assembly and tubing up of the circuit? – What is the effect of such errors? Describe these. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________

A-92


Exercise 14: Packaging of brochures

Training aims

• To familiarise yourself with the design and mode of operation of a pressure regulating valve. • To be able to design pressure-dependent control circuits.

Problem definition

10 brochures at a time are to be manually wrapped in plastic film. In order for the film to be neatly bonded, the brochures will need to be clamped. To be able to securely clamp the brochures a minimum pressure of 6 bar (600 kPa) must be available. However at the clamping cylinder a maximum pressure of 8 bar (800 kPa) is to be applied. The advance and return stroke are to be triggered by means of a pushbutton. The end positions of the clamping cylinder are to be sensed via pneumatic proximity sensors.

Parameters

• The process can only be started if the clamping cylinder is in the retracted end position. • It must only be possible to start the circuit if the operating pressure is above 6 bar (600 kPa. • The return stroke is to be triggered intentionally since the duration of the packaging process varies.

Project task

1. 2. 3. 4. 5.

Complete the pneumatic circuit diagram for the packaging unit. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Compile an equipment list.


A-93


Positional sketch

Brochure production

1. A pressure sequence valve is to switch when the preset pressure is reached and release the compressed air into the circuit. 2. The clamping operation is to start when the clamping cylinder is in the retracted end position and a pushbutton is pressed. The cylinder is to advance and remain in this position. 3. The process is to be completed via a second pushbutton and the cylinder to return into the retracted end position. Additional exercises

A-94

• What errors can occur during the assembly and tubing up of the circuit? • What is the effect of such errors? Describe these. • What is the function of the one-way flow control valve which is connected in parallel to the pressure regulating valve?



Exercise 14: Packaging of brochures Name:

Date:

Function of a pressure regulating valve

Sheet 1 of 1

2

1

3

Symbol of a pressure regulating valve

p1

p2

Schematic representation of a pressure regulating valve

– Describe the function of a pressure regulating valve. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________


A-95



Date:


Sheet 1 of 1


1A1

1

2 1 2

2

1

1V4

4

3

2

14

12 5

1

1V2

1V1

3

2

12

1

3

2

1

3


A-96




Date:


Sheet 1 of 1


Description

Equipment list


A-97



Date:


Sheet 1 of 1

– What errors can occur during the assembly and tubing up of the circuit? – What is the effect of such errors? Describe these. – What is the function of the one-way flow control valve, which is connected in parallel to the pressure regulating valve? _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________

A-98


Exercise 15: Mounting of locking clips

Training aims

• To be able to design pressure-dependent control systems. • To be able to analyse circuits and optimise these in accordance with specifications.

Problem definition

Locking clips are to be fitted onto connector housings by means of an automatic assembly system. Previously, pressure was set at the assembly system via a pressure regulating valve, which repeatedly led to malfunctioning of the assembly process. The assembly process is to be tested using a test setup. Each assembly function is to be triggered manually. The circuit is to be changed such that it only operates if the pressure does not exceed a certain level.

Parameters

• The pressure at the working port of the assembly cylinder must be a minimum of 3.5 bar (350 kPa), in order for the locking clips to be securely fitted. • It must not be possible to start the process if the pressure is greater than 3.8 bar (380 kPa). • The return stroke of the assembly cylinder is to start automatically once the forward end position is reached.

Project task

1. 2. 3. 4. 5.

Complete the pneumatic circuit diagram for the automatic assembly system. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit . Compile the equipment list.


A-99


Positional sketch

Automatic assembly system of connector housings

1. The process is to be started via a pushbutton, when the assembly cylinder is in the retracted end position. 2. The cylinder is to move into the forward end position using minimal force. 3. There it is to actuate a limit switch. 4. Then it is to return into the retracted end position.

A-100



Exercise 15: Fitting of locking clips Name:

Date:

Complete the pneumatic circuit diagram

Sheet 1 of 1


1V7

1V6

1A1

1B2

1

1

2

2

4

1V8

2

14

12 5

1

3



A-101



Date:

Analysing the pneumatic circuit diagram

Sheet 1 of 2

– Analyse the circuit diagram below. 1B1

1A1

1V7

1

2

1V6 1V5

1 2

2

1

1V4

4

3

2

14 1V3

2

5

1

1S1

2

1

3

1/3

1 1B1

12

1S2

2

1

3

1

3

1V2

1V1

2

3

2

12

1

3

2

1

3


A-102




Date:

Analysing the pneumatic circuit diagram

Sheet 2 of 2

– Check whether the circuit of sheet 1 is also suitable for this problem definition? – Where does the difference between these two circuits lie? _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________


A-103



Date:


Sheet 1 of 1


Description

Equipment list

A-104


Exercise 16: Labelling of paint pots

Training aims

• To be able to design pressure-dependent control systems. • To familiarise yourself with the design and mode of operation of a time delay valve.

Problem definition

Pots of paint are to be labelled in a bonding fixture. The bonding process is to be triggered via a pushbutton on the device. A press-on time of 10 s is required in order for the adhesive to take effect. The system is ready to start if the piston of the press-on cylinder is in the retracted end position.

Parameters

• The working pressure must be adjustable since the labels are to be bonded onto the paint pots using minimal pressure. • The cylinder is to retract as quickly as possible. • The working pressure must be adjustable between 3 and 7 bar (300 and 700 kPa). • The pressure is to be readable from a pressure gauge in front of the cylinder.

Project task

1. 2. 3. 4. 5.

Complete the pneumatic circuit diagram Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Compile the equipment list


A-105


Positional sketch

Labelling device

1. The process is to be started using a pushbutton if the cylinder is in the retracted end position. 2. The cylinder is to move into the forward end position using minimal force and to remain in this position for a variable time period. 3. It is then to return into the retracted end position. 4. The pressure during advancing is to be displayed on a pressure gauge. Additional exercises

A-106




Exercise 16: Labelling of paint pots Name:

Date:

Function of a time delay valve

Sheet 1 of 1

2 12

1

3

Symbol of a time delay valve

12

3

2

1

Schematic representation of a time delay valve

– Describe the function of a time delay valve. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________


A-107



Date:


Sheet 1 of 1


1A1

1B2

2 1

1/3 2

1 4

2

14

12 5

2

1

3

1/3

1

2 1B1 2

1S1

1B2

2 1

1

3

1

3

2

3 1

3


A-108




Date:


Sheet 1 of 1


Description

Equipment list


A-109


A-110


Exercise 17: Cleaning of workpieces

Training aims

• To be able to design circuits with oscillating movements. • To be able to use time delay valves dependent on parameters.

Problem definition

A wire-mesh container with workpieces is to be moved in a cleaning bath. The process is to be started via a pushbutton. The number of movements in the cleaning bath is to be adjustable via a time delay valve.

Parameters

• A roller lever valve is to be used to detect the retracted end position. • 6 movements are to be carried out in the cleaning bath.

Project task

1. 2. 3. 4. 5. 6.

Convert a 5/2-way double pilot valve into a 3/2-way double pilot valve. Complete the pneumatic circuit diagram for the automatic washing plant. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Compile an equipment list.


A-111


Positional sketch

Automatic washing plant

1. The process is to be started via a pushbutton if the lifting cylinder is in the retracted end position. 2. The lifting device cylinder is to advance up to the forward end position and then move up to the mid position and move back again to the forward end position. This movement is to continue until the time delay valve interrupts the process. 3. The cylinder is then return into the retracted end position. Additional exercises

A-112

• Which components do you need to install in the circuit to ensure that the wiremesh container does not drop into the cleaning bath if the compressed air supply is switched off? • What is the effect of the one-way flow control valve on the operating behaviour of the cylinder?



Exercise 17: Cleaning of workpieces Name:

Date:

Converting a 5/2-way double pilot valve

Sheet 1 of 1

4

2

14

12 5

1 3

Symbol of a 5/2-way double pilot valve

– What functions can be realised as a result of the conversion of a 3/2-way valve? _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________


A-113



Date:


Sheet 1 of 1

– Complete the circuit diagram below. 1A1 1B3 1B2

1V4 4

1B1

2

14

12 5

1V3

2

1B3

2

1

3

1/3

1 1B1

1

1B2

2

1

3

2

1

3

3

1V2 2 10

12 1

1V1

2

3 1S1

2

1

1

3

3


A-114




Date:


Sheet 1 of 1


Description

Equipment list


A-115


Aufgabe 17: Cleaning of workpieces Name:

Date:


Sheet 1 of 1

– Which component needs to be installed in the circuit to ensure that the wiremesh container does not drop into the cleaning bath if the compressed air supply is switched off? – What is the effect of the one-way flow control valves on the operating behaviour of the cylinder? _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________

A-116


Exercise 18: Pressing in of lids

Training aims

• To be able to analyse and design circuits using two cylinders.

Problem definition

Lids are to be pressed into a fixture in a machining station. First, the lids are placed onto the fixture. They are then to be pressed into the fixture by means of a press-in cylinder. Clamping of the lids is to be effected via a pushbutton. Once clamped, the pressing process is to start. When the press-in cylinder reaches the forward end position, both cylinders are to retract again.

Note Any protective devices required are not taken into consideration.

Parameters

• A single-acting cylinder is to be used for the clamping of workpieces. • A roller lever valve is to be used to detect whether the clamping cylinder has reached is forward end position. • A double-acting cylinder is to be used as a press-in cylinder. • The feed speed of the clamping and press-in cylinders is to be adjustbable.

Project task

1. 2. 3. 4. 5.

Analyse the pneumatic circuit diagram for the press-in device. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Compile an equipment list.


A-117


Positional sketch

Press-in device

1. Plastic lids are to be placed into a fixture. 2. The pressing in process is to be started via a pushbutton. 3. A limit switch is to be used to detect whether the clamping cylinder has reached its position. 4. The pressing-in cylinder is to advance only once the clamping cylinder has reached its forward end position. 5. Both cylinders are to retract when the plastic lid is pressed in.


A-118

• What errors can occur during the assembly and tubing up of the circuit? • What is the effect of such errors? Describe these. • What happens if the proximity sensor 1B2 on the cylinder is moved?



Exercise 18: Pressing-in of lids Name:

Date:


Sheet 1 of 1


1A1

1V3

2B1

1B2

2V2

2

2 2V1

2

12

10 1

2B2

1

1 1V2

2A1

3

4

2

14

12 5

1

3



A-119



Date:


Sheet 1 of 1


Description

Equipment list

A-120




Date:


Sheet 1 of 1

– What errors can occur during the assembly and tubing up of the circuit? – What is the effect of such errors? Describe these. – What happens if the pneumatic proximity switch 1B2 is moved? _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________


A-121


A-122


Part B – Fundamentals

The theoretical fundamentals for the Pneumatics training package are summarised in the textbook: Pneumatics, Basic Level This standard textbook deals with the fundamentals of pneumatic control technology as well as the function and use of pneumatic components. Numerous illustrations facilitate and ensure comprehension and pneumatic circuits are explained with the help of examples. Model solutions and detailed explanations consolidate the knowledge acquired regarding circuit design and functions. P. Croser, F. Ebel, 2002 edition, 274 pages, bound Order No.: 093131


B-1

B-2


Contents

Part C – Solution

Exercise 1: Pressing of cheese wheels ____________________________________C-3 Exercise 2: Opening of an animal feed silo ________________________________C-9 Exercise 3: Testing of key blanks _______________________________________C-13 Exercise 4: Sorting of packages ________________________________________C-17 Exercise 5: Stopping of crates of drinks _________________________________C-25 Exercise 6: Opening and closing of a pipe ________________________________C-29 Exercise 7: Shutting off using a quick shut-off function _____________________C-33 Exercise 8: Actuation of a shut-off device ________________________________C-37 Exercise 9: Brushing of cheese wheels __________________________________C-41 Exercise 10: Clamping of a workpiece ___________________________________C-47 Exercise 11: Actuation of a sliding door__________________________________C-51 Exercise 12: Feeding of workpieces _____________________________________C-55 Exercise 13: Crushing of drinks cans ____________________________________C-59 Exercise 14: Packaging of brochures ____________________________________C-63 Exercise 15: Fitting of locking clips _____________________________________C-67 Exercise 16: Labelling of paint pots _____________________________________C-71 Exercise 17: Cleaning of workpieces ____________________________________C-75 Exercise 18: Pressing in of lids _________________________________________C-81


C-1

Contents

C-2


Exercise 1: Pressing of cheese wheels Solutions


Date:


Sheet 1 of 1

1A1

1S1

2

1

3 0Z2

0Z1

1 2

3



C-3



Date:

Process description

Sheet 1 of 1

Initial position In the normal position, the direction of flow in the valve is closed. The piston rod of cylinder 1A1 is retracted. Steps 1-2 If the pushbutton of the 3/2-way valve 1S1 is pressed, compressed air flows into the piston chamber and the cylinder 1A1 advances. Steps 2-3 If the pushbutton is released, the valve exhausts and the cylinder returns into its initial position as a result of the reset spring action.

Safety note Please limit the pressure at the service unit to a maximum of 3.5 bar (350 kPa) for this experiment.

C-4




Date:


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

1


1

3/2-way valve with pushbutton, normally closed

1

Manifold

1


1


Equipment list


C-5



Date:


Sheet 1 of 3

Assembly error • Cylinder is not sufficiently secured. Component moves along the slot.

Tubing errors • Tubing is not properly clipped in. Tubing ends can whip to and fro at more than 100 km/h. Risk of injury. • Tubing is not properly pushed in. Compressed air escapes.

Mode of operation of a single-acting cylinder. Compressed air flows into the cylinder piston chamber (pressurised at one end), where pressure builds up and generates a force across the piston surface. If this force increases beyond the static friction, the piston moves forward. Only if the piston has advanced fully, can pressure build up to the full operating pressure. If this pressure drops, a built-in reset spring presses the piston back into the initial position. The spring force is not sufficiently great to enable it to move heavy loads on the piston rod. Single-acting cylinders therefore only perform work in one direction.

Calculation of piston force The following applies for single-acting cylinders: Feff

=

A • p – (FR + FF)

Feff

=

0.9 • A • p – FF

Feff

=

0.9 • (π • 0.012) • 600.000 – 13.5

Feff

=

169.66 – 13.5 = 156.15 N

Data in data sheet: 150 N

C-6




Date:


Sheet 2 of 3

Component parts of a single-acting cylinders 1

2

3

8

7

4

5

6

Schematic representation of a single-acting cylinder

– Allocated designations to the individual components. No.

Designation

1

End cap

2

Supply port

3

Cylinder barrel

4

Exhaust port

5

Piston rod

6

Bearing cap

7

Reset spring

8

Piston



C-7



Date:


Sheet 3 of 3

Mode of operation of a 3/2-way valve. The 3/2-way valve has 3 working ports and 2 switching positions. It is shown in the normal position. In this example, the valve is shown in the normally closed position, which means that compressed air cannot flow through the valve. If the pushbutton is actuated, the valve opens the air flow and piston of a connected cylinder advances.

Monitoring advancing and retracting movement The single-acting cylinder advances quickly and retracts slowly. Reason Compressed air can quickly increase the working pressure against the reset spring and push out the piston. The reset spring first has to work against the air cushion in the piston chamber.

C-8


Exercise 2: Opening of an animal feed silo Solutions


Date:


Sheet 1 of 1

1A1

1S1

2

1

3 0Z2

0Z1

1 2

3



C-9



Date:

Process description

Sheet 1 of 1

Initial position The 3/2-way valve is open in the direction of flow and the piston chamber is pressurised. The piston rod of the cylinder is extended. Steps 1-2 If pushbutton 1S1 is pressed, the piston exhausts via the 3/2-way valve and the cylinder retracts. Steps 2-3 If the pushbutton is released again, the spring pushes the 3/2-way valve into the normal position, the piston is pressurised and the cylinder advances again.


C-10




Date:


Sheet 1 of 1


Description

1


1


1

Manifold

1


1


Equipment list


C-11



Date:


Sheet 1 of 1

Mode of operation of a 3/2-way valve. The 3/2-way valve has 3 working ports and 2 switching positions. It is shown in the normal position. In this example, the valve is in the normally open position, which means that compressed air can flow to the piston through the valve. If the pushbutton is pressed, the valve blocks the air flow and the piston of a connected cylinder can exhaust via the valve.

C-12


Exercise 3: Testing of key blanks Solutions


Date:


Sheet 1 of 1

1A1

1S1

2

1

3 0Z2

0Z1

1 2

3


Solution

Correct solution = a). Reason No load on the reset spring of the cylinder in the normal position, which prevents wear.


C-13



Date:

Process description

Sheet 1 of 1

Initial position The direction of flow is closed in the valve. The cylinder piston rod is retracted. Steps 1-2 If the selector switch 1S1 is actuated, compressed air flows into the piston chamber and the cylinder advances. Steps 2-3 If the selector switch is reset, the valve exhausts and the cylinder returns into the initial position as a result of the effect of the reset spring.


C-14




Date:


Sheet 1 of 1

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

Description

1


1


1

Manifold

1


1


Equipment list


C-15



Date:


Sheet 1 of 1

Assembly errors • Cylinder is not sufficiently secured. Device moves along the slot.

Tubing errors • Tubing is not properly clipped in. Tubing ends can whip to and fro at more than 100 km/h. Risk of injury. • Tubing is not properly clipped in. Compressed air escapes.

C-16


Exercise 4: Sorting of packages Solutions


Date:


Sheet 1 of 1

1A1

1S1

4

5

2

1

3 0Z2

0Z1

1 2

3


Solution

Actuator = Selector switch Reason A pushbutton cannot be held whilst the containers are being exchanged.


C-17



Date:

Process description

Sheet 1 of 1

Initial position The righthand supply port of the cylinder is pressurised and the lefthand port exhausted. The piston is retained in the retracted end position. Steps 1-2 If the selector switch is actuated the valve switches and the lefthand port of the cylinder is pressurised and the righthand port exhausted. The cylinder moves into the forward end position. The cylinder remains in this position even if the selector switch is not held. Steps 2-3 If the selector switch is reset the cylinder returns into the initial position.


C-18




Date:


Sheet 1 of 1


Description

1

Cylinder, double-acting

1


1

Manifold

1


1


Equipment list


C-19



Date:


Sheet 1 of 4

Assembly error • Cylinder is not sufficiently secured. Device moves along the slot.

Tubing errors • Tubing is not properly clipped in. Tubing ends can whip to and fro at more than 100 km/h. Risk of injury. • Tubing is not properly clipped in. Compressed air escapes. • Connections 2 and 4 at the 5/2-way valve mixed up Cylinder advances in initial the position.

Mode of operation of a double-acting cylinder. Compressed air flow through port 2 into the cylinder piston chamber on the primary side, where pressure builds up and generates a force via the piston surface. If this force increase beyond the static friction, then the piston advances and the air in the piston chamber on the secondary side escapes via port 2. Only once the piston is completely advanced is it possible for pressure to build up to full operating pressure. If reversed, the air flow into port 2 of the secondary side and builds up pressure there until the piston moves back. The air on the primary side escapes through port 1. More air is consumed compared to a single-acting cylinder. Since the cylinder surfaces are of different sizes, the magnitude of the acting forces therefore varies with identical pressure.

C-20




Date:


Sheet 2 of 4

Calculation of piston force The following applies for double-acting cylinders: Forward stroke = (A • p) – FR Feff Feff

=

0.9 • A • p

Feff

=

0.9 • (π • 0.012) • 600.000

Feff

=

169.66 N

Data in data sheet: 189 N Return stroke Feff = (A' • p) – FR Feff

=

0.9 • [(π • 0012) – (π • 0.0042)] • 600.000

Feff

=

142.5 N

Monitoring of advance and return movement The double-acting cylinder advances and returns quickly. Reason During the advance and return motion, the compressed air can quickly build up the working pressure against the air cushion and extend and return the piston.


C-21



Date:


Sheet 3 of 4

1

9

2

3

8

4

7

5

6

Schematic representation of a double-acting cylinder

– Allocate designations to the individual components. No.

Designation

1

Supply port of piston chamber

2

Piston

3

Cylinder barrel

4

Supply port of piston rod chamber

5

Piston rod

6

Bearing cap

7, 8

Adjusting screws of end position cushioning

9

End cap


C-22




Date:


Sheet 4 of 4

Requirements for the directional control valve Compressed air must be available in both switching positions since the doubleacting cylinder cannot retract without compressed air. The 5/2-way valve have five working ports and two switching positions. It is mainly used as a control element for the actuation of cylinders.

Why is a double-acting cylinder more cost effective? The reset spring is omitted.

Actuating function of a selector switch Explain why a switch is selected for the actuating function on the directional control valve! This has to be a switch, since a pushbutton cannot be kept actuated whilst the containers are being exchanged.


C-23


C-24


Exercise 5: Stopping crates of drinks Solutions

Exercise 5: Stopping of crates of drinks Name:

Date:


Sheet 1 of 1

1A1

1V1

4

2

14 1S1

5

2

1

1

3 0Z2

3

0Z1

1 2

3



C-25



Date:

Process description

Sheet 1 of 1

Initial position Both the signalling element and control element are in the position created by the reset spring. Steps 1-2 If the selector switch of the 3/2-way valve 1S1 is actuated, this switches through and the pneumatic control port 14 of the 5/2-way valve 1V1 is pressurised, thereby switching the 5/2-way valve. The lefthand port (piston side) of the double-acting cylinder is pressurised, the righthand port (piston rod side) is exhausted and the cylinder advances. Steps 2-3 If the selector switch is reset, the compressed air in the 3/2-way valve is blocked, the 5/2-way valve loses pressure at the control port 14 and switches. This causes the piston side of the cylinder to exhaust and the piston rod side to be pressurised. The cylinder moves into the retracted end position.

C-26




Date:


Sheet 1 of 1


Description

1


1

5/2-way valve, pneumatic, with reset spring

1

3/2-way valve, selector switch, normally closed

1

Manifold

1


1


Equipment list


C-27



Date:


Sheet 1 of 1

Assembly error Cylinder is not correctly attached. The cylinder moves along the slot.

Tubing errors and effect • The 5/2-way valve is without air The cylinder does not advance • On 3/2-way valve, connections 1 and 2 mixed up Circuit not functioning, merely blowing air. • At 5/2-way valve, connections 2 and 14 mixed up. circuit not functioning, merely blowing air. • At 5/2-way valve, connections 4 and 14 mixed up. Piston oscillating

Pilot control Large volumetric flow rates are to be controlled via pilot control using a low signal flow. A small pilot valve switches the pilot air flow, which in turn acts on the main valve for high volumetric flow rates.

Remote control The directional control valve for the control of a cylinder is to be installed close to the cylinder so that the piston can advance rapidly whilst conserving air. Since no work is carried out in the lines and these are only used to transmit signals, they should be as short as possible. Since larger systems by definition involve greater distances between the point of actuation and the cylinder, the directional control valve is remotely controlled with pneumatic actuation at one end.

C-28


Exercise 6: Opening and closing of a pipe Solutions


Date:


Sheet 1 of 1

1A1

1Z2

1V1

1Z1

1S1

1

1

2

2

4

5

1V2

2

1

3


Supply air flow control • The compressed air flow to the cylinder is restricted. • The exhaust air flows unrestricted from the cylinder via the non-return valve flow. • In the case of load fluctuations on the piston rod (e.g.traversing of a limit switch), this results in irregularities in the feed speed. Exhaust air flow control • The compressed air flows to the cylinder unrestricted via the non-return valve. • The exhaust air flows from the cylinder restricted. • The piston is clamped between two air cushions. • Improved feed/return stroke performance


C-29

Exercise 6: Öffnen und Schließen einer Rohrleitung Solutions


Date:

Process description

Sheet 1 of 1

Initial position In the initial position the piston assumes the retracted end position. The piston chamber is exhausted via the 5/2-way valve using selector switch 1S1. Steps 1-2 Switching of the 5/2-way valve causes the cylinder piston chamber to be pressurised via the one-way flow control valve. The double-acting cylinder moves into the forward end position. The required advancing time is set via the one-way for flow control valve. Use a stop watch to do so. The required setting can be fixed via the lock nut. Steps 2-3 When the selector switch is reset the cylinder piston chamber is pressurised via the one-way flow control valve and the 5/2-way valve. The cylinder moves into the retracted end position.

Pressure behaviour The pressure gauge upstream of the one-way flow control valve indicates the operating pressure while the cylinder advances and remains in the forward end position. Whereas the pressure gauge downstream of the one-way flow control valve indicates a rising pressure during advancing. Pressure continues to rise even after the advancing movement until the operating pressure is obtained.

C-30




Date:


Sheet 1 of 1


Description

1


2


2

Pressure gauge

1


1

Manifold

1


1


Equipment list


C-31



Date:


Sheet 1 of 1


Tubing errors • Tubing is not properly clipped in. Tubing ends can whip to and fro at more than 100 km/h hin-. Risk of injury. • Tubing is not properly clipped in. Compressed air escapes. • Connections at one-way flow control valve mixed up Inverted effect.

Describe what causes juddering operation. Juddering operation is often also referred to as stick-slip operation and sometimes occurs during very slowly advancing or retracting pistons. The reasons for this is that the build-up of pressure acts against the static or sliding friction. Pressure builds up at the stationary piston and acts against the static friction. If the pressure force is greater than the coefficient of friction or static friction, the piston extends whereby the lesser sliding friction acts. However, this causes the air to expand again and the pressure to drop since it cannot be built up again quickly enough. The piston remains stationary and the process is repeated, i.e. the piston judders.

Describe the function of a one-way flow control valve. The one-way flow control valve is a combination of two components. With a one-way flow control valve, air is only restricted in one direction. The nonreturn valve closes air flow in one direction and air is only able to flow via the set cross section. In the opposite direction, air is able to flow freely via the open nonreturn valve. These valves are used to regulate the speed of pneumatic cylinders and, if possible, should be mounted directly on the cylinder.

C-32


Exercise 7: Shutting off using a quick shut-off function Solutions

Exercise 7: Shutting off using a quick-shut-off function Name:

Date:


Sheet 1 of 1

1A1

1Z2

1V1

1Z1

1S1

1

1

2

2

4

5

1V2

2

1

3



C-33



Date:

Process description

Sheet 1 of 1

Initial position In the initial position, the piston assumes the retracted end position. The piston chamber is exhausted via the 5/2-way valve 1S1. Steps 1-2 Switching of the 5/2-way valve causes the cylinder piston chamber to be pressurised via the one-way flow control valve. The cylinder advances into the forward end position. Steps 2-3 Resetting of the selector switch causes the cylinder piston chamber to be pressurised via the one-way flow control valve and the 5/2-way valve. The cylinder moves into the retracted end position. The required retracting time is set via the one-way flow control valve. Use a stop watch to do so. The required setting can be fixed using the lock nut.

Note Supply and exhaust air flow control is used to operate this circuit.

C-34



Exercise 7: Shutting-off using a quick shut-off function Name:

Date:


Sheet 1 of 1


Description

1


2


2

Pressure gauge

1


1

Manifold

1


1


Equipment list


C-35



Date:


Sheet 1 of 1


Tubing errors • Tubing not properly clipped in. Tubing ends can whip to and fro at more than 100 km/h. Risk of injury. • Tubing not properly clipped in. Compressed air escapes. • Connections at one-way flow control valve mixed up Inverted effect

C-36


Exercise 8: Actuating a shut-off device Solutions

Exercise 8: Actuating a shut-off device Name:

Date:


Sheet 1 of 1

1A1

1Z1 1V3 1V2

1

1

2

1V1

4

2 12

5

1

3

1S2

2

1

1/3

2

14

1S1

2

3

2

1

3



C-37


Exercise 8: Actuating a shut-off device Name:

Date:

Process description

Sheet 1 of 1

Initial position In the initial position the piston assumes the retracted end position. The piston chamber is exhausted via the 5/2-way double-pilot valve and the piston rod chamber is pressurised. Steps 1-2 Actuation of the 3/2-way valve 1S1 causes the 5/2-way double pilot valve to reverse, the cylinder piston chamber is pressurised via the one-way flow control valve. The double-acting cylinder advances into the forward end position. The piston rod chamber is exhausted via the quick exhaust valve. Steps 2-3 Actuation of the 3/2-way valve 1S2 causes the 5/2-way double pilot valve to be reversed. The piston rod chamber of the cylinder is pressurised via the quick exhaust valve. The cylinder piston chamber is exhausted via the one-way flow control valve and the 5/2-way double pilot valve. The cylinder moves into the retracted end position. Retracting time The required retracting time is set via the one-way flow control valve. Use a stop watch to do so. The required flow control setting can be fixed using the lock nut.

C-38




Date:


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

1


1


1

Quick exhaust valve

1

Pressure gauge

1

5/2-way double pilot valve

2


1

Manifold

1


1


Equipment list


C-39


Exercise 8: Actuating of a shut-off device Name:

Date:


Sheet 1 of 1


Tubing errors • Tubing not properly clipped in. Tubing ends can whip to an fro at more than 100 km/h. Risk of injury. • Tubing not properly clipped in. Compressed air escapes. • Connections at one-way flow control valve mixed up Inverted effect. • Connections at quick exhaust valve mixed up Compressed air exhaustes.

Describe the mode of operation of a quick exhaust valve. Quick exhaust valves are used to increase the piston speed of cylinders. Lengthy retraction times, particularly in the case of single-acting cylinders, are thereby reduced. The piston rod is able to retract at almost full speed since the exhaust air flow resistance during the retracting movement is reduced via the quick exhaust valve. The valve has a blockable pressure port 1, a blockable exhaust port 3 and an output 2.

Describe the mode of operation of a 5/2-way double pilot valve. The 5/2-way double pilot valve has 5 working ports and 2 switching positions. The valve has a storing characteristic in that a brief signal (pulse) is sufficient for reversing. A pneumatic signal at control port 12 effects flow from port 1 to port 2. A pneumatic signal at control port 14 effects flow from port 1 to port 4. If signals are applied at both control ports, then the first incoming signal is dominant.

C-40


Exercise 9: Brushing of cheese wheels Solutions


Date:


Sheet 1 of 2

1A1

1V4

1V3

1

1

2

2

4

1V5

2

14 5 1V2

1

2

0Z2

12 1

1S2

1 1S1

3

2

1 1V1

3

3

2 1/3

2

1

3 0Z1

1 2

3



C-41



Date:


Sheet 2 of 2

1A1

1V4

1V3

1

1

2

2

4

1V5

2

14 5 1V2

1

3

2

12 1

1S2

1 1V1 1 1S1

3

2

3

2 1/3

2

1

3

Pneumatic circuit diagram, simplified representation without Start-up valve with filter control valve and manifold

C-42




Date:

Process description

Sheet 1 of 1

Self-latching loop The 1S1, 1S2, 1V1 and 1V2 valve group is a self-latching loop. Actuation of the pushbutton 1S1 triggers a constant signal at the output of valve 1V2. The self-latching loop is interrupted if the normally open 3/2-way valve 1S2 is actuated. A signal is no longer applied at the output of valve 1V2. If both pushbuttons 1S1 and 1S2 are actuated simultaneously, a signal is similarly not applied at the output. This circuit is known as an RS-flip-flop.

Initial position Pressure is available. The piston chamber of the double-acting cylinder is exhausted, the piston rod chamber is pressurised and the cylinder is in the retracted end position. Steps 1-2 If the pushbutton of valve 1S1 is actuated, the cylinder 1A1 advances. The cylinder remains in the forward end position as a result of the self-latching loop. Steps 2-3 Once the pushbutton of the normally open valve 1S2 is actuated the cylinder retracts again. The self-latching loop is switched off. The 5/2-way valve switches to normal position and the piston rod chamber is pressurised. The cylinder moves into the retracted end position.


C-43



Date:


Sheet 1 of 1


Description

1


2


1

5/2-way valve, pneumatic, with spring return

1


1


1

3/2-way valve, pneumatic, normally closed

1

Shuttle valve (OR)

1

Manifold

1


1

Compessed air supply

Equipment list

C-44




Date:


Sheet 1 of 1


Tubing errors • Tubing not properly clipped in. Tubing ends can whip to and from at more than 100 km/h. Risk of injury. • Tubing not properly clipped in. Compressed air excapes. • Connections at double-acting cylinder mixed up. Direction of movement of cylinder reversed.

Describe the mode of operation of the self-latching loop. Actuation of the pushbutton at valve 1S1 causes the ball in the shuttle valve (OR) 1V1 to release compressed air flow. Since the valve 1S2 is switched through in the normal condition, the compressed air is able to actuate the 3/2-way valve 1V2. This causes the 5/2-way valve 1V3 to reverse and the cylinder piston to advance. The condition simultaneously becomes true via the return line to the shuttle valve (OR) 1V1. The pressure in the lines remains stored and maintains the valve 1V2 actuated. If the pushbutton at valve 1S2 is actuated, the pressure in the lines is exhausted, the valve 1V2 is de-energised, as well as the 5/2-way valve. The cylinder piston retracts again.

Describe the mode of operation of a shuttle valve. The shuttle valve is used for the logic OR function. Pneumatic signals at input 1, input 1(3) or at both inputs trigger a signal at output 2. There is no output signal if there is no input signal. Output signals • If signals are applied at both inputs, the signal with the higher pressure reaches the output.


C-45


C-46


Exercise 10: Clamping of a workpiece Solutions


Date:


Sheet 1 of 1

1A1

1B1

1Z1

1Z2

1V3

1V2

1

1

2

2

4

2

14 1V1 1

1S1

1

12 5

2

3

1

3

1/3

1B1

2

1V4

1

1S2

2

3

2

1

3



C-47



Date:

Process description

Sheet 1 of 1

Initial position Pressure is available. The piston chamber of the double-acting cylinder is exhausted and the piston rod chamber is pressurised. The 3/2-way roller lever valve 1B1 is actuated. The cylinder is in the retracted end position. Steps 1-2 If the pushbutton of the 3/2-way valve 1S1 is actuated, compressed air is applied at both inputs of the dual pressure valve 1V1 and compressed air is now available at the output of the dual pressure valve. The 5/2-way double pilot valve 1V2 is reversed via the signal applied at the control port 14.This causes the cylinder to reverse and the piston to advance. The 3/2-way roller lever valve switches to normal position and the output signal at the dual pressure valve is switched off. The cylinder remains in the forward end position due to the self-latching circuit. Steps 2-3 Actuation of the pushbutton on the 3/2-way valve 1S2 causes the 5/2-way double pilot valve 1V2 to reverse again (signal at pilot port 12).The piston rod chamber of the cylinder is pressurised and the cylinder moves into the retracted end position. The 3/2-way roller lever valve 1B1 is actuated again.

C-48




Date:


Sheet 1 of 1


Description

1


2


2

Pressure gauge

1

5/2-way valve, pneumatic

1

Dual pressure valve (AND)

1


2


1

Manifold

1


1


Equipment list


C-49



Date:


Sheet 1 of 1


Tubing errors • Tubing not properly clipped in. Tubing ends can whip to and fro at more than 100 km/h. Risk of injury. • Tubing not properly clipped in. Compressed air escapes. • Connections at double-acting cylinder mixed up Direction of movement of cylinder reversed.

Describe the mode of operation of a 3/2-way roller lever valve. The 3/2-way roller lever valve has 3 control ports and 2 switching positions. The roller lever valve is for instance actuated by the switching cams of a cylinder. A reduced actuating force is obtained as a result of the pilot control.

What is the effect of adjusting the 3/2-way roller lever valve? Depending on the position of the roller lever valve the circuit no longer functions since the AND condition is no longer fulfilled.

Describe the mode of operation of a dual pressure valve. The dual pressure valve is used for the logic AND operation. Pneumatic signals at inputs 1 and 1(3) cause a signal at output 2. There is no output signal if there are no input signals or only one input signal. Output signals • With time-related differences in input signals, the last incoming signal reaches the output. • With pressure-related differences in input signals, the signal with lower pressure reaches the output.

C-50


Exercise 11: Actuation of a sliding door Solutions


Date:


Sheet 1 of 1

1B1

1V5

1V4

1A1

1B2

1

1

2

2

4

2

14

12 5

1V2

1

1V3 1/3

1

1S1

3

1/3

1S2

2

1

1/3

2

1

2

2

1 1V1

1B1

3

2

1

1V6

3

1B2

2

1

3

2

1

3



C-51



Date:

Process description

Sheet 1 of 1

Initial position The cylinder is in the retracted end position. The pneumatic proximity sensor 1B1 is attenuated. A pneumatic signal is applied at one input of dual pressure valve 1V2. Steps 1-2 The shuttle valve 1V1 supplies an output signal if one of the two pushbuttons is actuated. A signal is now applied at pilot port 14 of the 5/2-way double pilot valve and the valve switches. The cylinder advances. When the cylinder reaches the forward end position, the pneumatic proximity sensor 1B2 is attenuated. Steps 2-3 The shuttle valve 1V1 supplies an output signal if one of the two pushbuttons is actuated. A signal is now applied at pilot port 12 of the 5/2-way double pilot valve. The valve switches and the cylinder advances. The pneumatic proximity sensors 1B1 is attenuated when the cylinder reaches the retracted end position.

C-52




Date:


Sheet 1 of 1


Description

1


2


1

5/2-way double pilot valve, pneumatic

2

Proximity sensor, pneumatic

2


2


1

Shuttle valve (OR)

1

Manifold

1


1


Equipment list


C-53



Date:


Sheet 1 of 1


Tubing errors • Tubing is not properly clipped in. Tubing ends can whip to and fro at more than 100 km/h. Risk of injury. • Tubing is not properly clipped in. Compressed air escapes. • Connections at double-acting cylinder mixed up Circuit malfunctions. • Connections at 5/2-way valve mixed up Circuit malfunctions.

Function of the pneumatic proximity sensor The proximity sensor consists of a 3/2-way stem actuated valve, normally open, and a rocker with 2 permanent magnets. The stem of the valve is actuated via the rocker by means of a compression spring. The magnetic field of the magnet on the cylinder piston causes the rocker to tilt. The valve is no longer actuated and a pneumatic signal is applied at the output of the valve.

What happens if the compressed air supply fails during the advance or return movement? The door stops its actual position.

How can the circuit be re-started and what needs to be done for this? The door needs to be pushed into one of the end positions for a re-start since the start conditions (door in one of the two end positions) is otherwise not fulfilled.

C-54


Exercise 12: Feeding of workpieces Solutions


Date:


Sheet 1 of 1

1B1

1V4

1V3

1A1

1B2

1

1

2

2

4

2

14

12 5

1V2

1

1/3 1V1

2 1/3

1

1B1

2

1

3

2

1

1S1

1V5

3

1

1S2

2

3

1B2

2

1

3

2

1

3



C-55


Exercise 12: Supplying of workpieces Name:

Date:

Process description

Sheet 1 of 1

Initial position Compressed air is available. The cylinder is in the retracted end position. The pneumatic proximity sensor 1B1 is attenuated and switched in free-flow direction. The piston rod chamber is pressurised. Steps 1-2 The 3/2-way valve 1S2 is not actuated unless the withdrawal area is free. The dual pressure valve 1V1 does not supply an output signal, the 5/2-way double pilot valve cannot be reversed. The 3/2-way valve 1S2 is actuated if the withdrawal area is free. The dual pressure valve 1V1 supplies an output signal. If the pushbutton of the 3/2-way valve 1S1 is actuated, the dual pressure valve 1V2 supplies an output signal and a signal is applied at pilot port 14 of the 5/2-way double pilot valve. The 5/2-way double pilot valve reverses and the cylinder advances. Steps 2-3 The pneumatic proximity sensor 1B2 is attenuated and switches in the free-flow direction. A signal is applied at pilot port 12 of the 5/2-way double pilot valve. The 5/2-way double pilot valve 1V3 reverses and the cylinder moves into the retracted end position. The pneumatic limit switch 1B1 is attenuated and switches in the freeflow direction. Steps 3-1 Same as step 1

C-56




Date:


Sheet 1 of 1


Description

1


2


1


2


1


1


2


1

Manifold

1


1


Equipment list


C-57



Date:


Sheet 1 of 1


Tubing errors • Tubing is not properly clipped in. Tubing ends can whip to and fro at more than 100 km/h. Risk of injury. • Tubing is not properly clipped in. Compressed air escapes. • Connections at the double-acting cylinder mixed up Circuit malfunctions. • Connections at the 5/2-wau double pilot valve mixed up Circuit malfunctions. • Connections at the one-way flow control valve mixed up No exhaust air- but instead throttled supply air.

How would you need to modify the circuit if the ejecting function is to start only if a part is present in the magazine and the withdrawal position is free? An additional sensor needs to be linked with the workpiece sensing. This requires the appropriate sensor (roller lever valve) and a shuttle valve (AND). Instead of the 3/2-way valve 1S2, the AND operation of the sensors is inserted.

C-58


Exercise 13: Crushing of drinks cans Solutions


Date:


Sheet 1 of 1

1B1

1V6

1A1

1B2

1

2 1V5

2

4

2

14

12 5

1V3

1

1

2

3 1V4

1/3

1

1B1

1V7

1

1

1S1

2

1S2

2

1

3 1V2

1V1

1/3

1B2

2

1

3

2

3

2

1

3

2

12

1

3

2

1

3



C-59



Date:

Process description

Sheet 1 of 1

Initial position The double-acting cylinder is in the retracted end position. The pneumatic proximity sensor 1B1 is actuated and switched to free-flow direction. Compressed air is available. The required pressure is preset at the pressure regulating valve of the service unit. The required pressure is set at the pressure sequence valve. Steps 1-2 The pushbutton of valve 1S1 is actuated whereby the condition at the dual pressure valve (AND) 1V3 becomes true. The 5/2-way double pilot valve 1V5 is switched into the operating position and the double-acting cylinder advances. Steps 2-3 The pneumatic proximity sensor 1B2 is actuated and switches into the operating position. The 5/2-way double pilot valve 1V5 is reversed via the shuttle valve (OR) 1V4. Alternatively, this process can be initiated via the pushbutton of valve 1S2. The 5/2way double pilot valve is reversed via the shuttle valve (OR) 1V4. The double-acting cylinder moves into the initial position and the process is completed when the pneumatic proximity sensor 1B1 is actuated.

C-60




Date:


Sheet 1 of 1


Description

1


2


1


2


2


1


1

Shuttle valve (OR)

1


1

Pressure regulating valve

1

Manifold

1


1


Equipment list

Note The equipment set only contains 1 pressure regulating valve. Use the pressure regulating valve, built into the Start-up valve with filter control valve, as valve 1V1 in the circuit assembly.


C-61



Date:


Sheet 1 of 1


Tubing errors • Tubing is not properly clipped in. Tubing ends can whip to and fro at more than 100 km/h. Risk of injury. • Tubing is not properly clipped in. Compressed air escapes. • Connections at double-acting cylinder mixed up Circuit malfunctions. • Connections at 5/2-way valve mixed up Circuit malfunctions. • Pressure at the pressure regulating valve is lower than that at the pressure sequence valve Circuit malfunctions.

Describe the function of a pressure sequence valve. The actuated 3/2-way valve switches if pressure at pilot port exceeds a specific, adjustable value; compressed air is available at working port 2. The 3/2-way valve reverses if the pressure at the control port falls below the set value.

C-62


Exercise 14: Packaging of brochures Solutions


Date:


Sheet 1 of 1

1B1

1A1

1V7

1

2

1V6 1V5

1 2

2

1

1V4

4

3

2

14 1V3

2

5

1

1S1

2

1

3

1/3

1 1B1

12

1S2

2

1

3

1

3

1V2

1V1

2

3

2

12

1

3

2

1

3



C-63



Date:

Process description

Sheet 1 of 1

Initial position The double-acting cylinder is in the retracted end position. The pneumatic limit switch 1B1 is attenuated and switched in free-flow direction. Compressed air is available. The desired pressure is preset at the pressure regulating valve of the service unit, the pressure sequence valve and at the pressure regulating valve in the cylinder supply air. Steps 1-2 Pushbutton valve 1S1 is actuated and switches in the free-flow direction. The pneumatic proximity sensor 1B1 is switched to operating position and consequently the condition at the dual pressure valve (AND) 1V3 becomes true and the 5/2-way double pilot valve 1V4 is switched to operating position. The double-acting cylinder advances pressure regulated. Steps 2-3 Pushbutton 1S2 is actuated and switches in free-flow direction. This causes the 5/2-way double pilot valve to reverse. The double-acting cylinder returns to the initial position. The process is completed if the pneumatic proximity sensor 1B1 is attenuated.

Note The one-way flow control valve 1V7 is used to by-pass the pressure regulating valve. The throttle is fully closed. The compressed air is able escape via the non-return valve when the cylinder retracts.

C-64




Date:


Sheet 1 of 1

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

Description

1


2


1

5/2-way double-pilot valve, pneumatic

1


2


1


1


1


1

Manifold

1


1


Equipment list


C-65



Date:


Sheet 1 of 1


Tubing errors • Tubing is not properly clipped in. Tubing ends can whip to and fro at more than 100 km/h. Risk of injury. • Tubing is not properly clipped in. Compressed air escapes. • Connections at double-acting cylinder mixed up Circuit malfunctions. • Connections at 5/2-way valve mixed up Circuit malfunctions. • Pressure at the pressure regulating valve is lower than that at the pressure sequence valve Circuit malfunctions.

Describe the function of a pressure regulating valve. Input pressure (primary pressure) at the pressure regulating valve must always be higher than output pressure (secondary pressure). Pressure regulation as such is effected via a diaphragm. Output pressure acts on the one side of the diaphragm and the force of a spring on the other. The spring force is adjustable via an adjusting screw. If pressure increases on the secondary side, e.g. with a load change on the cylinder, the diaphragm is pressed against the spring and the outlet cross-sectional area is reduced or closed. The valve seat of the diaphragm opens and compressed air is able to escape via the relief ports in the housing. If pressure drops on the secondary side, the spring force opens the valve. Regulating the air pressure to the preset operating pressure therefore means a constant opening and closing of the valve seat, triggered by the air volume flowing through. The operating pressure is indicated on the pressure gauge.

C-66


Exercise 15: Fitting of locking clips Solutions


Date:


Sheet 1 of 1

1B1

1V7

1V6

1A1

1B2

1

1

2

2

4

2

14 1V5

12 5

2

1V4

2

3

2

10

1/3

1

1

1/3

1 1V3

1V8

1

1V2

3

2

12

1

3

1V1

1B1

1

1S1

2

3

2

2

1

3

1

1B2 3

2

1

3



C-67



Date:

Process description

Sheet 1 of 1

Initial position The double-acting cylinder is in the retracted end position. The pneumatic proximity sensor 1B1 is attenuated. Compressed air is available. The required pressure is set at the pressure regulating valve and pressure sequence valve. Steps 1-2 Pushbutton 1S1 is actuated and the pneumatic proximity sensor 1B1 is attenuated, consequently the condition at the first dual pressure valve (AND) 1V3 becomes true. When the pressure sequence valve has switched with sufficient pressure, the 3/2-way valve is switched into the operating position. The condition at the second two-way valve (AND) 1V5 consequently becomes true and the 5/2-way double pilot valve switches reverses into the operating position. The double-acting cylinder advances. Steps 2-3 The pneumatic proximity sensor 1B2 is attenuated and switches into the operating position. The 5/2-way double pilot valve is reversed. The double-acting cylinder returns into the initial position. The process is completed if the pneumatic proximity sensor 1B1 is attenuated.

C-68




Date:


Sheet 1 of 1


Description

1


2


1


2


1

3/2-way valve, pneumatic, normally open

1


2


1


1


1

Manifold

1


1


Equipment list


C-69



Date:


Sheet 1 of 1


Tubing errors • Tubing is not properly clipped in. Tubing ends can whip to and fro at more than 100 km/h. Risk of injury. • Tubing is not properly clipped in. Compressed air escapes. • Connections at double-acting cylinder mixed up Circuit malfunctions. • Connections at 5/2-way valve mixed up Circuit malfunctions. • Pressure at pressure regulating valve is lower than at the pressure sequence valve Circuit malfunctions.

Check whether the circuit from sheet 1 „Analysing the pneumatic circuit diagram“ can also be operated using this configuration. Answer: Yes. However there is a risk of the pressure being incorrectly set at the pressure regulating valve in the cylinder supply air and of the clip being damaged.

Where does the different lie between the circuit on sheet 1 „Analysing the pneumatic circuit diagram“? There is an economical advantage: The circuit can be operated without the second limit switch and without a dual pressure valve.

C-70


Exercise 16: Labelling of paint pots Solutions


Date:


Sheet 1 of 1

1B1

1A1

1B2

1Z1

1V6

2

1

1/3 1V5

2

1 1V4

4

2

14 1V2

12 5

2

1

3

1V3

2

1/3

1

1V1

1

2 1B1

1S1

2

1B2

2 1

1

3

1

3

3 2

3 1

3



C-71



Date:

Process description

Sheet 1 of 1

Initial position The double-acting cylinder is in the retracted end position. The pneumatic proximity sensor 1B1 is attenuated. Compressed air is available. The desired pressure is set at the pressure regulating valve. Steps 1-2 Pushbutton 1S1 is actuated and the pneumatic proximity sensor 1B1 is attenuated; consequently the condition at the first dual pressure valve (AND) 1V2 becomes true and the 5/2-way double pilot valve 1V4 switches into the operating position. The double-acting cylinder advances using minimal pressure. Steps 2-3 The pneumatic proximity sensor 1B2 is attenuated and switches into the operating position. This causes compressed air to be supplied to the time delay valve 1V3 and to switch after a preset time interval. The 5/2-way pilot valve is switched back and the double-acting cylinder returns to the initial position using minimal pressure. The piston chamber is exhausted via the quick exhaust valve. The process is completed if the pneumatic proximity sensor 1B1 is attenuated.

C-72




Date:


Sheet 1 of 1


Description

1


1


1

Quick exhaust valve

1


2


1


1

Time delay valve

1


1


1

Pressure gauge

1

Manifold

1


1


Equipment list


C-73



Date:


Sheet 1 of 1


Tubing errors • Tubing is not properly clipped in. Tubing ends can whip to an fro at more than 100 km/h. Risk of injury. • Tubing is not properly clipped in. Compressed air escapes. • Connections at double-acting cylinder mixed up Circuit malfunctions. • Connections at 5/2-way valve mixed up Circuit malfunctions. • Ports at time delay valve mixed up Time not adjustable, cylinder does not return.

Describe the mode of operation of a time delay valve. The functions of three components are combined in a time delay valve. a) 3/2-way valve with spring return b) One-way flow control valve c) Air reservoir If pressure is applied at the input, compressed air flows to the 3/2-way valve and into the air reservoir via the one-way flow control valve. There, a pressure gradually builds up which acts against the spring force of the reset spring at the 3/2-way valve. The 3/2-way valve switches if pressure exceeds the spring force. If pressure is no longer applied at the input, the air reservoir is able to exhaust via the non-return valve.

C-74


Exercise 17: Cleaning of workpieces Solutions


Date:


Sheet 1 of 1

1A1 1B3 1B2

1B1

1

1V6

2 1V5

1

2 1V4 4

2

14

12 5

1V3

1B3

2

1

1B2

2

1

3

1V2

3

3 1S1

2

1

1

1

3

12 1

2

2

2

10 1V1

3

1/3

1 1B1

1

2

3

3



C-75



Date:

Process description

Sheet 1 of 2

Initial position The cylinder assumes the retracted end position in the initial position and actuates the 3/2-way roller lever valve 1B1. The control element 1V4 (5/2-way double pilot valve) assumes the righthand switching position. The signal latch 1V2 (3/2-way double pilot valve) is also in the righthand switching position. The desired pressure is set at the pressure regulating valve. Steps 1-2 Actuation of START button 1S1 causes the signal latch 1V2 to switch. Compressed air is applied at the input of the time delay valve 1V1. The 5/2-way double pilot valve 1V4 is reversed via the actuated 3/2-way roller lever valve 1B1 and the shuttle valve (OR) 1V3; the cylinder advances. Overtravelling of the middle pneumatic proximity sensor 1B3 has no effect since the same pilot input of the control element is actuated. Steps 2-3 The pneumatic proximity sensor 1B2 is actuated in the forward end position. The control element (5/2-way double solenoid valve) reverses. The cylinder partially retracts and actuates the middle pneumatic proximity sensor 1B3. Steps 3-4 Actuation of the middle pneumatic proximity sensor causes the cylinder to reverse again. The switching function takes only a few milliseconds so that the switching cam does not overtravel the pneumatic proximity sensor 1B3. Steps 4-5 See steps 2-3.

C-76




Date:

Process description

Sheet 2 of 2

Oscillating movement The cylinder oscillates between the pneumatic proximity sensors 1B3 and 1B2 until the time set on the time delay valve has expired. Steps n-2 to n Once the time delay valve switches through, the signal latch 1V2 (3/2-way double pilot valve) is reversed. The pneumatic proximity sensor 1B3 and the 3/2-way roller lever valve 1B1 are no longer supplied with compressed air. The cylinder moves into the initial position (retracted end position). The process is completed when the 3/2way roller lever valve 1B1 is actuated.


C-77



Date:


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

1


2


1


1


2


1


1


1

Time delay valve

1

Shuttle valve (OR)

1

Manifold

1


1


Equipment list

Note A 5/2-way double piloted valve, pneumatic, is to be converted into a 3/2-way double pilot valve, pneumatic.

C-78




Date:


Sheet 1 of 1


Tubing errors • Tubing is not properly clipped in. Tubing ends can whip to and fro at more than 100 km/h. Risk of injury. • Tubing is not properly clipped in. Compressed air escapes. • Connections at double-acting cylinder mixed up Cylinder in wrong end position. • Connections at 5/2-way double pilot valve mixed up Circuit malfunctions. • Connections at time delay valve mixed up Time not adjustable, process is not completed.

Convert a 5/2-way double pilot valve into a 3/2-way double pilot valve. What do you need to do? Output 4 is to be sealed with a plug.


C-79


C-80


Exercise 18: Pressing in of lids Solutions

Exercise 18: Pressing in of lids Name:

Date:


Sheet 1 of 1

1A1

1V3

2B1

1B2

2V2

2

2 2V1

2

12

10 1

1V1

2

14

3

12 5

1

3

1/3

2B1

2

1

4

2

1

1S1

2B2

1

1 1V2

2A1

3

1

1B2

2

3

2B2

2

1

3

2

1

3



C-81



Date:

Process description

Sheet 1 of 1

Initial position Pressure is available. Both cylinders assume the retracted end position in the initial position. The piston of the double-acting cylinder attenuates the pneumatic proximity sensor (2B1); this switches in free-flow direction. The control elements 1V2 and 2V1 (5/2-way double pilot valve and 3/2-way double pilot valve) assume the righthand switching position. Steps 1-2 Actuation of pushbutton 1S1 causes the condition at the dual pressure valve (AND) 1V1 to become true. The 3/2-way double pilot valve 1V2 reverses. The single-acting cylinder advances with supply air restricted. Steps 2-3 Roller lever valve 1B2 is actuated when the single-acting cylinder reaches is forward end position and switches the 5/2-way double pilot valve 2V1. The double-acting cylinder advances into the forward end position, where it attenuates the pneumatic proximity sensor 2B2. This switches to free-flow direction. Steps 3-4 The 5/2-way double pilot valve 2V1 and 3/2-way double pilot valve 1V2 reverse. Both cylinders retract. The process is completed when the piston of the doubleacting cylinder attenuates the pneumatic proximity sensor (2B1) and this switches in free-flow direction.

Note The single-acting cylinder 1A1 retracts slightly sooner than the double-acting cylinder 2A1. This is due to the control signal overlap at the pilot ports 14 and 12 of the 5/2-way double solenoid valve 2V1. Only once the single-acting cylinder 1A1 has moved from the forward end position and the 3/2-way roller lever valve 1B2 is no longer actuated, can the 5/2-way double pilot valve 2V1 reverse.

C-82




Date:


Sheet 1 of 1


Description

1


1


2


1


1


2


1


1


1


1

Manifold

1


1


Equipment list

Note A 5/2-way double pilot valve is to be converted into a 3/2-way double pilot valve, pneumatic.


C-83



Date:


Sheet 1 of 1


Tubing errors • Tubing is not properly clipped in. Tubing ends can whip to and fro at more than 100 km/h. Risk of injury. • Tubing is not properly clipped in. Compressed air escapes. • Connections at double-acting cylinder mixed up Cylinder in wrong end position. • Connections at 5/2-way valve mixed up Circuit malfunctions. • Connections at one-way flow control valve mixed up Cylinders not advancing with supply air restricted.

What happens if the pneumatic proximity sensor 1B2 at the cylinder is moved? The pneumatic proximity sensor 1B2 is not attenuated and the 5/2-way double pilot valve and, consequently, the 3/2-way double pilot valve are no longer reset. The cylinder no longer moves into the retracted end position; the proximity sensor 1B1 is therefore not attenuated and the circuit cannot longer be re-started.

C-84


Part D – Appendix

Organiser __________________________________________________________ D-2 Assembly technology ________________________________________________ D-3 Plastic tubing_______________________________________________________ D-4 Data sheets

3/2-way valve with pushbutton actuator, normally closed________________ 152860 3/2-way valve with pushbutton actuator, normally open_________________ 152861 5/2-way valve with selector switch __________________________________ 152862 3/2-way valve with selector switch, normally closed ____________________ 152863 Pressure gauge __________________________________________________ 152865 3/2-way roller lever valve, normally closed ____________________________ 152866 Pressure sequence valve __________________________________________ 152884 Single-acting cylinder _____________________________________________ 152887 Double-acting cylinder ____________________________________________ 152888 Manifold________________________________________________________ 152896 5/2-way valve, pneumatically actuated, one side_______________________ 538694 Pressure regulator valve with gauge _________________________________ 539756 3/2-way pneumatic valve, pneumatically actuated, one side _____________ 539768 5/2-way double pilot valve, pneumatically actuated, both sides___________ 539769 Dual pressure valve (AND) _________________________________________ 539770 Shuttle valve (OR) ________________________________________________ 539771 Quick exhaust valve ______________________________________________ 539772 One-way flow control valve_________________________________________ 539773 Proximity switch, pneumatic, with cylinder attachment __________________ 539775 Start-up valve with filter control valve ________________________________ 540691 Time delay valve, normally closed ___________________________________ 540694


D-1

Organiser

Equipment set in the organiser

All components of the equipment set for the technology package TP101 are stored in an organiser in the Systainer. The organiser also serves as a drawer insert for use in conjunction with our range of laboratory furniture.

D-2


Assembly technology

The components of the equipment set are intended for assembly on the Festo Didactic profile plate, which consists of 14 parallel T-slots in gaps of 50 mm. Three variants are available for the assembly of equipment on the profile plate: Variant A A latching system, without auxiliary means, clamping mechanism using a lever and spring, Adjustable in the direction of the slot, for lightweight non loadable components . Variant B A rotary system, without auxiliary means, knurled nut with locking disk and T-head bolts, vertical and horizontal alignment, for medium weight loadable components. Variant C A screw system, with auxiliary means, socket head screw with T-head bolt, vertical and horizontal alignment, for heavy loadable components and equipment which is rarely released from the profile plate. The proven ER units on plug-in board can be attached to the profile plate with adapters. In the case of variant A, a slide is engaged in the T-slot of the profile plate. The slide is pre-tensioned by means of a spring and, by pressing the blue lever, is pulled back whereby the component can be removed from or attached to the profile plate. Components are aligned along the slot and can be moved in the direction of the slot. With variant B, components are attached to the profile plate by means of a T-head bolt and blue knurled nut. A locking disc serves to fix the device in position, which can be secured in any 90° direction. Devices can thus be mounted on the profile plated either lengthwise or diagonally to the slot. Once the desired locking disc position is set, the device is mounted on the profile plate. Turning of the knurled nut in a clockwise direction causes the T-head bolt to be turned in the slot by 90° owing to thread friction. The component is pressed against the profile plate by further turning the knurled nut.


D-3

Variant C is used for heavy or similar devices, screwed on to the profile plate only once or very seldom. Components are attached by means of socket head screws with internal hex and T-head bolts. The time-tested ER units on a plug-in board with locating pins in a 50 mm grid can be mounted on the profile plate with adapters. A black plastic adapter is required for each locating pin. The adapters are plugged into the T-slot, positioned at intervals of 50 mm and secured by means of a 90° turn. The locating pins of the ER unit are plugged into the adapter holes.

Plastic tubing

The polyurethane tubing is particularly flexible and kink resistant. Technical data Pneumatics Colour

silver metallic

Outer diameterr

4 mm

Inner diameter

2.6 mm

Minimum bending radius within temperature range of -35 to +60°C

17 mm

Maximum operating pressure within temperature range of -35 to +30°C

10 bar (1000 kPa)

within temperature range of +30 to +40°C within temperature range of +40 to +60°C

9 bar (900 kPa) 7 bar (700 kPa)

Subject to change

D-4


152860 3/2-way valve with pushbutton actuator, normally closed

2

1

3

Design

The 3/2-way valve with pushbutton actuator, normally closed is assembled in a polymer housing. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative "A").

Function

The valve is actuated by pressing the pushbutton. Releasing of the pushbutton returns the valve to the normal position via a return spring.

Technical data

Pneumatic Medium

Compressed air, filtered (lubricated or unlubricated) (or vacuum; port 1)

Design

Poppet valve, directly actuated on one side, with return spring

Actuation

Pushbutton

Pressure range

-95 – 800 kPa (-0.95 – 8 bar)

Standard nominal flow rate 1...2

60 l/min

Actuating force at 600 kPa (6 bar)

6N

Connection

QSM-4 fittings for plastic tubing PUN 4 x 0.75

© Festo Didactic GmbH & Co. KG, 07/2005

Subject to change

1/1


152861 3/2-way valve with push button, normally open

2

1

3

Design

The 3/2-way valve with plug-in connections is assembled in a plastic housing. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative "A").

Function

The valve is actuated by pressing the push button. Releasing the push button returns the valve to the normal position via a return spring.

Technical data

Pneumatic Medium

Compressed air, filtered (lubricated or unlubricated) (or vacuum; port 1)

Design


Actuation

Push button

Pressure range

-90 – 800 kPa (-0.9 – 8 bar)


60 l/min


6N

Connection



Subject to change

1/1

© Festo Didactic GmbH & Co. KG, 2005

152862 5/2-way valve with selector switch

2

1

3

Design

The two 3/2-way valves with plug-in connections are assembled in a plastic housing. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative "A").

Function

This valve combination operates in the same way as the 5/2-Way valve. It is actuated by turning the selector switch. The switching status is maintained after the selector switch has been released. If the selector switch is reversed, the valve resumes its normal position via the return spring.

Technical data

Pneumatic Medium

Compressed air, filtered (lubricated or unlubricated)

Design


Actuation

Selector switch

Pressure range

-90 – 800 kPa (-0.9 – 8 bar)


60 l/min


6N

Connection



Subject to change

1/1


152863 3/2-way valve with selector switch, normally closed

2

1

3

Design

The 3/2-way valve with plug-in connections is assembled in a polymer housing. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative „A“).

Function

The valve is actuated by turning the selector switch. The switching status is maintained after the selector switch has been released. Rotating the selector switch to its basic setting, returns the valve to the initial position via a return spring.

Technical data

Pneumatic Medium


Design


Actuation

Selector switch

Pressure range

-90 – 800 kPa (-0.9 – 8 bar)


60 l/min


6N

Connection



Subject to change

1/1


152865 Pressure gauge

Design

The pressure gauge is screwed to the function plate which is fitted with two directly linked push-in fittings. The unit is mounted on the profile plate via a quick release detent system with the blue lever, (mounting alternative “A”).

Function

The pressure gauge indicates the pressure in a pneumatic control system.

Note

During continuous operation the pressure gauge must only be loaded to 75 % of maximum scale reading, and in the case of an alternating load, 66 % of maximum scale reading.

Technical data

Pneumatic Medium


Design

Bourdon tube pressure gauge

Indicating range

0 – 1000 kPa (0 – 10 bar)

Connection

QSM-M5-4 fitting for plastic tubing PUN 4 x 0.75

Quality grade

1.6


Subject to change

1/1

© Festo Didactic GmbH & Co., 07/2005

152866 3/2-way roller lever valve, normally closed

2

1

3

Design

The 3/2-way roller lever valve with push-in elbow fittings is screwed onto a polymer base The unit is mounted on the profile plate via a rotary detent system with blue triple grip nut (mounting alternative "B").

Function

The valve is actuated by pressing the roller lever e.g. by means of cylinder trip cam. The valve is returned to the normal position via return spring after release of the roller lever.

Modification

This valve can be changed from “normally closed” (RS valve type) to “normally open” (ROS valve type). Normally closed (RS valve type) Actuator attachment at the left (number 1 on the actuator attachment above number 1 on housing)

1

2

Technical data

Normally open (ROS valve type) Actuator attachment at the right (number 2 on the actuator attachment above number 2 on housing)

Pneumatic Medium


Design


Pressure range

280 – 800 kPa (2.8 – 8 bar)


120 l/min


1.8 N

Connection

QSML-1/8-4 fittings for plastic tubing PUN 4 x 0.75


Subject to change

1/1


152884 Pressure sequence valve

2

12

1

3

Design

The pressure sequence valve is screwed on to a function plates, which includes the required push-in fittings. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative "A").

Function

The pressure sequence valve (sequence valve) is reversed once the pilot pressure has been reached at port 12, and switched to the initial position via return spring after the signal has been removed. The pressure of the control signal is infinitely adjustable by means of a pressure adjustment screw.

Technical data

Pneumatic Medium


Design

Poppet valve with return spring

Operating pressure range

180 – 800 kPa (1.8 – 8 bar)

Pilot pressure range

100 – 800 kPa (1 – 8 bar)


100 l/min

Connection

QSM-M5-4-I fittings for plastic tubing PUN 4 x 0.75


Subject to change

1/1


152887 Single-acting cylinder

Design

The single-acting cylinder with trip cam and push-in fitting is mounted on a plastic retainer. The unit is mounted on the profile plate via quick release detent system with two blue trip grip nuts (mounting alternative "B").

Function

The piston rod of the single-acting cylinder moves into the forward end position through the supply of compressed air. When the compressed air is switched off, the piston is returned to the retracted end position via a return spring. The magnetic field of a permanent magnet, which is attached to the cylinder piston, actuates the proximity switches.

Technical data

Pneumatic Medium


Design

Piston cylinder

Operating pressure max.

1000 kPa (10 bar)

Piston diameter

20 mm

Max. stroke length

50 mm

Thrust at 600 kPa (6 bar)

139 N

Spring return force min.

13.6 N

Connection

QS-G1/8-4 fittings for plastic tubing PUN 4 x 0.75


Subject to change

1/1


152888 Double-acting cylinder

Design

The double-acting cylinder with trip cam and push-in fittings is mounted on a plastic retainer. The unit is mounted on the profile plate via a quick release detent system with two triple grip nuts (mounting alternative "B").

Function

The piston rod of the double-acting cylinder is reversed by means of alternating supply of compressed air. End position cushioning at both ends prevents a sudden impact of the piston on the cylinder housing. The end position cushioning can be adjusted by means of two regulating screws. The magnetic field of a permanent magnet attached to the cylinder piston actuates the proximity switches.

Technical data

Pneumatic Medium


Design

Piston cylinder


1000 kPa (10 bar)

Piston diameter

20 mm

Max. stroke length

100 mm

Thrust at 600 kPa (6 bar)

189 N

Return force at 600 kPa (6 bar)

158 N

Connection

QS-G1/8-4 fittings for plastic tubing PUN 4 x 0.75


Subject to change

1/1


152896 Manifold

Design

The manifold with eight self-sealing push-in fittings is screwed on to a universal plate. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative "A").

Function

The manifold with a common P-supply enables a control system to be supplied with compressed air eight individual connections.

Technical data

Pneumatic Connection


1 QS-1/8-6 for plastic tubing PUN 6 x 1 8 QSK-1/8-4 for plastic tubing PUN 4 x 0.75

Subject to change

1/1


538694 5/2-way valve, pneumatically actuated, one side

4

2

5

1 3

14

Symbol used in circuit diagrams

4

2

5

1 3

14

The internal structure of this valve allows flowing of compressed air in both directions.

Design

The 5/2-way single pilot valve with push-in fittings is screwed onto the function plate, which is equipped with P-connection and silencers. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative "A").

Function

The single pilot valve is actuated by applying pressure at port 14 (Z). When the signal is removed the valve is returned to the normal position via return spring.

Technical data

Pneumatic Medium

Compressed air, filtered (lubricated or unlubricated) or vacuum

Design

Spool valve, directly actuated on one side, with return spring

Control pressure range

300 to 1000 kPa (3 to 10 bar)


-90 to 1000 kPa (-0.9 to 10 bar)


500 l/min

Response time at 600 kPa (6 bar)

On:

8 ms

OFF: 18 ms Connection


QS-1/8-4-I, QSM-M5-4-I fittings for plastic tubing PUN 4 x 0.75

Subject to change

1/1


539756 Pressure regulator valve with gauge

2

1

3

Design

The pressure regulator with pressure gauge and push-in elbow fittings is screwed on to a function plate. The unit is slotted into the profile plate via a quick release detent system with blue levers (mounting alternative “A).

Function

The pressure regulator adjusts the supply of compressed air to the operating pressure and compensates any pressure fluctuations. The direction of flow is indicated by arrows on the housing. The pressure gauge indicates the pressure set.

Note

The pressure regulator is fitted with an adjusting knob, which can be turned to set the required pressure. By sliding the adjusting knob towards the housing, the setting can be locked.

Technical Data

Pneumatic Medium


Design

Diaphragm control valve

Standard nominal flow rate*

300 l/min

Upstream pressure max.

100 to 1000 kPa (1 to 10 bar)


50 to 700 kPa (0.5 to 7 bar)

Connection

QSL-1/8-4 for plastic tubing PUN 4 x 0.75

* Upstream pressure 1000 kPa (10 bar), Operating pressure 600 kPa (6 bar), Differential pressure 100 kPa (1 bar)


Subject to change

1/1


539768 3/2-way pneumatic valve, pneumatically actuated, one side

2 12 1 or

3 2

10 1

3

Symbol used in circuit diagrams.

4

2

5

1 3

14

The internal structure of this valve

Design

The 5/2-way pneumatic valve with push-in connectors and a single blanking plug is screwed on to an assembly base, which is equipped with P-connection and silencers. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative „A“).

Function

The pneumatic valve switches at port 14 (Z) (10 (Z)) via a pneumatic signal and is returned to the initial position via a spring when the signal has been removed.

Note

The valve ports are identified by numbers: 1 = Supply port 2, 4 = Working or outlet ports 3, 5 = Exhausts (via silencers in function plate) 14, 10 = Pilot port By blocking a working line (2 or 4), the 5/2-way valve can be converted into a 3/2-way valve: Blanking plug in outlet 4 = normally open Blanking plug in outlet 2 = normally closed


Subject to change

1/2

539768 3/2-way pneumatic valve, pneumatically actuated, one side

Technical Data

Pneumatic Medium

Compressed air, filtered

Design

Spool valve, indirectly actuated on one side, with return spring

Pressure range

200 to 1000 kPa (2 to 10 bar)


-90 to 1000 kPa (-0.9 to 10 bar)

Standard nominal

500 l/min

flow rate 1…2, 1...4

2/2

Switching time at 600 kPa (6 bar)

On: 8 ms Off: 18 ms

Connection


Subject to change


539769 5/2-way double pilot valve, pneumatically actuated, both sides

4

2

14

12 5

1 3

Symbol used in circuit diagrams 4

2

14

12 5

1 3

The internal structure of this valve allows flowing of compressed air in both dir

Design

The 5/2-way double pilot valve with push-in fittings is screwed onto the function plate, which is equipped with P-connection and silencers. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative "A").

Function

The double pilot valve is actuated by applying pneumatic signals alternately to ports 14 and 12. It remains in its last switched position until a counter signal is received.

Technical Data

Pneumatic Medium

Compressed air, filtered (lubricated or unlubricated) or vacuum

Design

Spool valve, directly actuated on both sides

Control pressure range

200 to 1000 kPa (2 to 10 bar)


-90 to 1000 kPa (-0.9 to 10 bar)

Standard nominal

500 l/min

flow rate 1...2, 1...4 Response time at 600 kPa (6 bar)

6 ms

Connection



Subject to change

1/1


539770 Dual-pressure valve (AND)

2 1

1/3

Design

The dual-pressure valve with push-in elbow fittings is mounted on a function plate. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative "A").

Function

The dual-pressure valve is switched through (AND function) when signals are applied to both inputs 1 and 1/3. If different pressures are applied to the two inputs, then the lower pressure reaches the output 2.

Technical Data

Pneumatic Medium


Design

AND-Gate (Dual-pressure valve)

Pressure range

100 to 1000 kPa (1 to 10 bar)

Standard nominal flow rate 1, 1/3...2

550 l/min

Connection

QSL-1/8-4 fittings for plastic tubing PUN 4 x 0.75


Subject to change

1/1


539771 Shuttle valve (OR)

2 1

1/3

Design

The shuttle valve with push-in elbow fittings is mounted on a function plate. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative "A").

Function

The shuttle valve is switched through to output 2 by applying a signal either to input 1 or 1/3 (OR-Function). If both inputs are pressurised simultaneously, then the higher pressure reaches the output.

Technical Data

Pneumatic Medium


Design

OR-Gate (Shuttle valve)

Pressure range

100 to 1000 kPa (1 to 10 bar)

Standard nominal flow rate 1, 1/3...2

500 l/min

Connection

QSL-1/8-4 fittings for plastic tubing PUN 4 x 0.75


Subject to change

1/1


539772 Quick exhaust valve

2 1

1/3

Design

The quick exhaust valve with built-in silencer and push-in elbow fitting is screwed on to the function plate, which includes a straight push-in fitting. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative "A").

Function

The compressed air flow via port 1 to port 2. If pressure drops at port 1, then the compressed air from port 2 escapes to atmosphere via the built-in silencer.

Technical Data

Pneumatic Medium


Design

Poppet valve

Pressure range

50 to 1000 kPa (0.5 to 10 bar)

Standard nominal flow rate 1...2 2...3

300 l/min 550 l/min

Connection

QSL-1/8-4, QSM-M5-4-I fittings for plastic tubing PUN 4 x 0.75


Subject to change

1/1


539773 One-way flow control valve

1

2

Design

The adjustable one-way flow control valve is screwed into the function plate, incorporating a straight push-in fitting. The unit is slotted into the profile plate via a quick release detent system with a blue lever (mounting alternative “A”).

Function

The one-way flow control valve consists of a combination of a flow control valve and a non-return valve. The non-return valve blocks the flow of air in one direction, whereby the air flows via the flow control valve. The throttle cross section is adjustable by means of a knurled screw. The setting can be fixed by means of a knurled nut. Two arrows indicate the direction of flow control on the housing. In the opposite direction, the air flow is unrestricted via the non-return valve.

Technical Data

Pneumatic Medium

Compressed air, filtered, (lubricated or unlubricated)

Design


Pressure range

20 to 1000 kPa (0.2 to 10 bar)

Standard nominal flow rate

in throttled direction:

0 – 110 l/min

free flow direction:

110 l/min (Throttle open) 65 l/min (Throttle closed)

Connection


QSM-M5-4 for plastic tubing PUN 4 x 0.75

Subject to change

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539775 Proximity switch, pneumatic, with cylinder attachment

2

1

3

Design

The pneumatic proximity sensor switch comes equipped with push-in fittings and a mounting kit for attachment to cylinders.

Function

A permanent magnet attached to the cylinder piston actuates a pneumatic 3/2-way valve when overtravelled, thus triggering a control signal.

Note

The pneumatic proximity switch complete with mounting kit, is attached direct to the cylinder barrel by clipping on the plastic fixture. The switch can be attached to a linear drive without this mounting kit. A reproducible switching accuracy of ±0.1 mm can be achieved, if the signal generator is approached from the connection side.


Subject to change

1/2

539775 Proximity switch, pneumatic, with cylinder attachment

Technical Data

Pneumatic Medium

Design

Compressed air, filtered (unlubricated) 40 µm, free of contamination Pneumatic signal generator for contactless position indication by means of magnetic field

Display

Visual position indication

Temperature range

-15 – +60 °C to DIN 40040

Mounting position

any

Pressure range

200 to 800 kPa (2 to 8 bar)

Standard nominal flow rate

60 l/min

Reproducibility of switching value*

±0,1 mm

response time

On: 22 ms Off: 52 ms

Connection

QS-4 fittings for plastic tubing PUN 4 x 0.75

* Applies only to drives with protection against torsion

2/2

Subject to change


540691 Start-up valve with filter control valve

1 2

3 1 2

3

Design

The filter regulator with pressure gauge, on/off valve, push-in fitting and quick coupling plug is mounted on a swivelling retainer. The filter bowl is fitted with a metal bowl guard. The unit is mounted on the profile plate by means of cheese head screws and T-head nuts (mounting alternative “C”). Attached is a quick coupling socket with threaded bush and connector nut for plastic tubing PUN 6 x 1.

Function

The filter with water separator cleans the compressed air of dirt, pipe scale, rust and condensate. The pressure regulator adjusts the compressed air supplied to the set operating pressure and compensates for pressure fluctuations. An arrow on the housing indicates the direction of flow. The filter bowl is fitted with a filter drain screw. The pressure gauge shows the preset pressure. The on/off valve exhausts the entire control. The 3/2-way valve is actuated via the blue sliding sleeve.


Subject to change

1/2

540691 Start-up valve with filter control valve

Note

Technical Data

When constructing a circuit, please ensure that the filter regulator is installed in the vertical position. The pressure regulator is fitted with an adjusting knob, which can be turned to set the required pressure. By sliding the adjusting knob towards the housing, the setting can be locked.

Pneumatic Medium

Compressed air

Design

Sintered filter with water separator, diaphragm control valve

Assembly position

Vertical ±5°

Standard nominal flow rate *

110 l/min

Upstream pressure

100 to 1000 kPa (1 to 10 bar)

Operating pressure

50 to 700 kPa (0.5 to 7 bar)

Connection

Coupling plug for coupling socket G1/8 QS push-in fitting for plastic tubing PUN 6 x 1

* Upstream pressure: 1000 kPa (10 bar), Operating pressure: 600 kPa (6 bar), Differential pressure: 100 kPa (1 bar).

2/2

Subject to change


540694 Time delay valve, normally closed

2

1

3

Design

The time delay valve is mounted on a function plate which has been equipped with the required push-in fittings. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative "A").

Function

The time delay valve is actuated by a pneumatic signal at port 12 after a preset time delay has elapsed. It is returned to the normal position via return spring when the signal is removed. The time delay is infinitely adjustable by means of a regulating screw.

Note

The valve ports are identified by numerals: 1 = Air supply port 2 = Working port 3 = Exhaust port


Subject to change

1/2

540694 Time delay valve, normally closed

Technical Data

2/2

Pneumatic Medium


Design

Poppet valve with return spring

Pressure range

200 to 600 kPa (2 to 6 bar)

switch-on pressure

>160 kPa (1.6 bar)


50 l/min

Delay time

0.2 to 3 s (adjustable)

Setting accuracy

±0.3 ms

Time delay to reset

>200 ms

Connection

QSM-M5-4-I fittings for plastic tubing PUN 4 x 0.75

Subject to change


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