Elektropneumatika Seminari

541090 EN 04/05
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 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:
541090 04/2005 M. Pany, S. Scharf Frank Ebel Doris Schwarzenberger 09/2005
Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2005 Internet: www.festo-didactic.com e-mail: did@festo.com
The copying, distribution and utilisation of this document as well as the communication of its contents to others without express authorisation is prohibited. Offenders will be held liable for the payment of damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design registration. Parts of this documentation may be copied by the authorised user exclusively for training purposes.
Festo Didactic GmbH & Co. KG 541090
Contents
Preface ______________________________________________________________ 5 Introduction__________________________________________________________ 7 Notes on safety and operation ___________________________________________ 9 Technology package for electropneumatics (TP200) ________________________ 11 Training aims of Basic Level (TP201) _____________________________________ 13 Allocation of training aims and exercises _________________________________ 15 Equipment set Basic Level (TP201) _____________________________________ 17 Allocation of equipment and exercises ___________________________________ 21 Methodological help for the trainer ______________________________________ 23 Methodological structure of the exercises_________________________________ 25 Designation of equipment _____________________________________________ 26 Contents of the CD-ROM _______________________________________________ 27 Equipment set Advanced Level (TP202) _________________________________ 29 Training aims Advanced Level (TP202) __________________________________ 30
Part A Exercises Exercise 1: Realising a sorting device ____________________________________A-3 Exercise 2: Realising a shut-off device___________________________________A-15 Exercise 3: Realising a lid press ________________________________________A-25 Exercise 4: Realising the operation of a hinged lid _________________________A-35 Exercise 5: Realising a diverting device __________________________________A-43 Exercise 6: Actuation of a stacking magazine _____________________________A-53 Exercise 7: Sorting of packages ________________________________________A-65 Exercise 8: Actuation of a sliding platform _______________________________A-73 Exercise 9: Expanding a diverting device _________________________________A-81 Exercise 10: Designing a stamping device________________________________A-91 Exercise 11: Realising a pallet loading station __________________________ A-101 Exercise 12: Eliminating a fault on the pallet loading station_______________ A-107
Contents
Part B Fundamentals
Part C Solutions Exercise 1: Realising of a sorting device __________________________________C-3 Exercise 2: Realising a shut-off device___________________________________C-15 Exercise 3: Realising a lid press ________________________________________C-23 Exercise 4: Realising the operation of a hinged lid _________________________C-33 Exercise 5: Realising a diverting device __________________________________C-41 Exercise 6: Actuation of a stacking magazine _____________________________C-49 Exercise 7: Sorting of packages ________________________________________C-59 Exercise 8: Actuation of a sliding platform _______________________________C-67 Exercise 9: Expanding a diverting device _________________________________C-75 Exercise 10: Designing a stamping device________________________________C-85 Exercise 11: Realising a pallet loading station ____________________________C-95 Exercise 12: Eliminating a fault on the pallet loading station _______________C-101
Part D Appendix Organiser __________________________________________________________ D-2 Assembly technology ________________________________________________ D-3 Plastic tubing_______________________________________________________ D-4 Data sheets
Preface
Festo Didactics Learning System for Automation and Technology is orientated towards different training and vocational requirements and is therefore structured into the following training packages: Basic packages to provide technology-spanning basic knowledge Technology packages to address the major subjects of open and closed-loop technology Function packages to explain the basic functions of automated systems Application packages to facilitate vocational and further training based on actual industrial applications The technology packages deal with the following technologies: Pneumatics, electropneumatics, programmable logic controllers, automation using a personal computer, hydraulics, electrohydraulics, proportional hydraulics and handling technology.
Preface
The modular design of the learning system enables applications beyond the limits of the individual packages. For example, to facilitate PLC actuation of pneumatic, hydraulic and electrical drives. All the training packages are of identical structure: Hardware Teachware Software Seminars The hardware consists of didactically designed industrial components and systems. The didactic, methodological design of the Teachware is harmonised with the training hardware and comprises: Textbooks (with exercises and examples) Workbooks (with practical exercises, additional information, solutions and data sheets) Overhead transparencies and videos (to create an interesting and lively training environment) Tuition and training media are available in several languages and are suitable for use both in the classroom and for self-tuition. Software is available in the form of computer training programs and programming software for programmable logic controllers. A comprehensive range of seminars dealing with the topics of the technology packages completes the range of vocational and further training available.
Introduction
This workbook is a component part of the Learning System for Automation and Technology of Festo Didactic GmbH & Co. KG. This system provides a solid basis for practice-oriented vocational and further training. Technology package TP200 is comprised exclusively of electropneumatic control systems. Basic Level TP201 is suitable for basic training in electropneumatic control technology and provides knowledge regarding the physical fundamentals of electropneumatics and the function and use of electropneumatic equipment. The equipment set enables you to construct simple electropneumatic control systems. Advanced Level TP202 focuses on further training in electropneumatic control technology. The two equipment sets enable you to construct complex combinational circuits with logic operations of input and output signals and program controls. Prerequisite for the assembly of control systems is a fixed workstation using a Festo Didactic profile plate, consisting of 14 parallel T-slots with 50 mm spacing. A shortcircuit protected power supply unit (input: 230 V, 50 Hz, output: 24 V, max. 5 A) is used for DC voltage supply. A mobile, silenced compressor (230 V, maximum 8 bar = 800 kPa) can be used for compressed air supply. Working pressure must not exceed a maximum of p = 6 bar = 600 kPa. Optimum operational reliability is achieved if the control system is operated unlubricated at a working pressure of p = 5 bar = 500 kPa. The equipment set of Basic Level TP201 is used to construct all of the complete control systems of the 12 problem definitions. The theoretical fundamentals to help you understand this collection of exercises can be found in the textbook Electropneumatics Also available are data sheets in respect of the individual devices (cylinders, valves, measuring devices, etc.).
Introduction
Notes on safety and operation
The following advice should be observed in the interest of your own safety: Pressurised air lines that become detached can cause accidents. Switch off supply immediately. Do not switch on compressed air until tubing is securely connected. Caution! Cylinders may advance automatically as soon as the compressed air is switched on. Do not operate an electrical limit switch manually during fault finding (use a tool). Observe general safety regulations. With electrical limit switches you need to distinguish between two designs Actuation from the left Actuation from the right. At high piston speeds, limit switches must be approached only in the designated direction of the trip cam of the cylinder. Limit switches must not be actuated from the front. Do not exceed the permissible working pressure (see data sheets). Only use extra-low voltage 24 V DC. All components are equipped with 4 mm safety sockets, i.e. jack plugs. Only use cables with jack plugs for the electrical connections. Pneumatic circuit assembly: Connect devices using the silver-metallic plastic tubing of 4mm 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 and power supply prior to dismantling the circuit.
Notes on safety and operation
The mounting plates of the devices are equipped with mounting variants A to D: Variant A, latching system For lightweight non loadable devices (e.g. directional control valves). Simply clip the device into the slot in the profile plate. Devices can be released by pressing the blue lever. Variant B, rotary system Medium weight loadable devices (e.g. actuators). These devices are clamped onto the profile plate by means of T-head bolts. Clamping and releasing is effected by means of the blue knurled nut. Variant C, screw system For heavy loadable devices rarely removed from the profile plate (e.g. Start-up valve with filter control valve). These devices are mounted by means of socket head screws and T-head bolts. Variant D, plug-in system Lightweight non loadable devices with locking pins (e.g. indicating devices). These devices are attached by means of plug-in adapters. The data for the individual devices, as specified in the data sheets in Part D, must be observed.
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Technology package for electropneumatics (TP200)
The technology package TP200 consists of numerous individual training media as well as seminars. The subject matter of this package is exclusively electropneumatic control systems. Individual components from the technology package TP200 may also form a component part of other packages.
Important elements of TP200
Fixed workstation with Festo Didactic profile plate Compressor (230 V, 0.55 kW, maximum 8 bar = 800 kPa ) Equipment sets or individual components Optional training aids Practical training models Complete laboratory setups
Training documentation Textbooks Basic Level TP201 Fundamentals of pneumatic control technology Maintenance of pneumatic devices and systems Workbooks Basic Lvel TP201 Advanced Level TP202 Sets of overhead transparencies and overhead projector Magnetic symbols, drawing template WBT Fluid Studio Electropneumatics Cutaway model sets 1 + 2 with storage case Simulation software FluidSIM Pneumatic
Optional Teachware
11
Technology package for electropneumatics (TP200)
Seminars P111 P121 IW-PEP Fundamentals of pneumatics and electropneumatics Maintenance of and fault finding on pneumatic and electropneumatic systems Maintenance and servicing in control technology pneumatic and electropneumatic control systems Electropneumatics for vocational training
EP-AL
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.
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Training aims of Basic Level (TP201)
To familiarise yourself with the design and mode of operation of a single-acting cylinder. To familiarise yourself with the design and mode of operation of a double-acting cylinder. To be able to calculate piston forces according to specified values. To familiarise yourself with the design and mode of operation of a 3/2-way solenoid valve. To familiarise yourself with the design and mode of operation of a double solenoid valve. To be able to select solenoid valves according to requirements. To be able to identify and draw the various types of actuation of directional control valves. To be able to convert solenoid valves. To be able to explain and design an example of direct actuation. To be able to explain and design an example of indirect actuation. To familiarise yourself with logic functions and to design these. To familiarise yourself with different types of end position control and to be able to select a suitable type. To be able to calculate electrical characteristic values. To familiarise yourself with latching circuits with different characteristics. To be able to explain and design an electrical latching circuit with dominant switch-off signal. To be able to design a pressure-dependent control system. To familiarise yourself with the design and mode of operation of magnetic proximity sensors. To familiarise yourself with displacement-step diagrams and to be able to design these for specified problem definitions. To be able to realise a sequence control using two cylinders. To be able to identify and eliminate errors in simple electropneumatic control systems.
13
Training aims of Basic Level (TP201)
14
Allocation of training aims and exercises
Exercise Training aims To familiarise yourself with the design and mode of operation of a singleacting cylinder. To familiarise yourself with the design and mode of operation of a doubleacting cylinder. To be able to calculate piston forces according to specified values. To familiarise yourself with the design and mode of operation of a 3/2-way solenoid valve. To familiarise yourself with the design and mode of operation of a double solenoid valve. To be able to select a solenoid valve according to requirements. To be able to identifiy and draw the various types of actuation of directional control valves. To be able to convert solenoid valves. To be able to explain and design an example of direct actuation. To be able to explain and design an example of indirect actuation. To familiarise yourself with different types of end position control and to be able to select a suitable type. To familiarise yourself with logic functions and to be able to design these. To be able to calculate electrical characteristic values
10
11
12
15
Allocation of training aims and exercises
Exercise Training aims To familiarise yourself with latching circuits with different characteristics. To be able to explain and design an electrical latching circuit with dominant switch-off signal. To be able to design a pressuredependent control system. To familiarise yourself with the mode of operation of magnetic proximity sensors. To familiarise yourself with displacement step diagrams and to be able to create these for specified problem definitions. To be able to realise a sequence control using two cylinders. To be able to detect and eliminate errors in simple electropneumatic control systems.
10
11
12
16
Equipment set Basic Level (TP201)
This equipment set has been compiled for basic training in electropneumatic control technology. It contains all the components required to meet the specifed 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 (TP201 Order No.: 540712)
Description 2 x 3/2-way solenoid valve, normally closed 5/2-way double solenoid valve 5/2-way solenoid valve Blanking plug Double-acting cylinder Limit switch, electrical, actuated from the left Limit switch, electrical, actuated from the right Manifold One-way flow control valve Plastic tubing 4 x 0.75, 10 m Pressure sensor Proximity sensor, electronic Proximity sensor, optical Push-in sleeve Push-in T-connector Relay, 3-off Signal input, electrical Single-acting cylinder Start-up valve with filter control valve Order No. 539776 539778 539777 153267 152888 183322 183322 152896 539773 151496 539757 540695 178577 153251 153128 162241 162242 152887 540691 Quantity 1 2 1 10 2 1 1 1 4 2 1 2 1 10 20 2 1 1 1
17
Equipment set symbols
Description Relay, 3-off
Symbol
A1
12 14
22 24
32 34
42 44
A2 A1
11 12 14
21 22 24
31 32 34
41 42 44
A2 A1
11 12 14
21 22 24
31 32 34
41 42 44
A2
Signal input, electrical
11
13 23
21
31
31
41
41
14 13
24 23
32 31
42 41
14 13
24 23
32 31
42 41
14
3/2-way solenoid valve, normally closed
24
32
2
42
1M1
1M1
18
Description 5/2-way solenoid valve
Symbol
4 1M1 5 1M1 1
5/2-way double solenoid valve
4 1M1 5 1M1 1M2 1
2 1M2 3
Proximity sensor, electronic
Pressure sensor
Proximity sensor, optical
Limit switch, electrical
4 1
One-way flow control valve
19
Description Single-acting cylinder
Symbol
Double-acting cylinder
Start-up valve with filter control valve
1 2 3
Manifold
Connection elements
20
Allocation of equipment and exercises
Exercise Equipment Cylinder, single-acting Cylinder, double-acting One-way flow control valve 3/2-way double solenoid valve, normally closed 5/2-way solenoid valve 5/2-way double solenoid valve Pressure sensor Limit switch, electrical Proximity sensor, normally open conact Pushbutton, electrical, normally open contact Pushbutton, electrical, normally closed button Relay Manifold Start-up valve with filter control valve Power supply unit 24 V DC
10
11
12
1 1 1 1 2 1 2
1 1 1 (1) 2 1 2 1 2 1 2 1 2 1 2
1 1 3 1
1 1 3 1
1 1 1 1
1 1 1 1 1 2 2 2 2 2 1 1
1 1 1 1 1 1 1 1 1 1
1 1 1 1
2 1 1 1
2 1 1 1
3 1 1 1
1 1 1 1
3 1 1 1
3 1 1 1
3 1 1 1
3 1 1 1
21
Allocation of equipment and exercises
22
Methodological help for the trainer
Training aims The overall aim of this collection of exercises is the systematic design of circuit diagrams and practical assembly of a control system on a profile plate. This direct interaction of theory and practice ensures quick progress with learning. The detailed training aims are documented in the table. Actual individual training aims are allocated to each problem and major training aims are shown in brackets. Time required The time required to work through a problem depends on the trainees prior knowledge. Skilled workers in the engineering and electrical fields require approximately 2 weeks. Technicians or engineers require approximately 1 week. Components of the equipment set The book of exercises and equipment set are harmonised. For all 18 exercises you only require the components of the equipment set of Basic Level TP201. Each of the Basic Level exercises can be assembled on a profile plate. Representation Abbreviated notation and motion diagrams are used for the representation of motion sequences and switching statuses.
23
Methodological help for the trainer
24
Methodological structure of the exercises
All 12 exercises in Part A are of identical methodological structure. The exercises are divided into: Title Training aims Problem definition Parameters as well as Project task Positional sketch Worksheets The proposed solutions in Part C are divided into: Circuit diagram Solution description as well as Circuit assembly Equipment list
25
Designation of equipment
The designation of components in the circuit diagrams is effected in accordance with the DIN-ISO 1219-2 standard. All components of a circuit have the same main code number. Letters are assigned depending on components. Several components within a circuit are numbered consecutively. The designation of pressure ports is P and these are separately consecutively numbered. Drives: Valves: Sensors: Signal input: Accessories: Pressure strings: 1A1, 2A1, 2A2, ... 1V1, 1V2, 1V3, 2V1, 2V2, 3V1, ... 1B1, 1B2, ... 1S1, 1S2, ... 0Z1, 0Z2, 1Z1, ... P1, P2, ...
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Contents of the CD-ROM
The CD-ROM supplied provides you with additional media. The contents of Part A Exercises and Part C Solutions are stored in the form of pdf files. The structure of the CD-ROM is as follows: Operating instructions Data sheets Demo Festo catalogue FluidSIM circuit diagrams Industrial applications Presentations Product information Videos
Operating instructions
Operating instructions are available for the various pieces of equipment of the technology package to assist you in the use and commissioning of the equipment.
Data sheets
The data sheets for the equipment of the technology package are available in the form of pdf files.
Demo
A demo version of the software package FluidSIM Pneumatic is stored on the CDROM. This version is suitable for the testing of the control 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 12 exercises in the technology package.
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Contents of the CD-ROM
Industrial applications
Photos and pictures are provided of industrial applications to enable you to illustrate your own problem definitions. These can also be added to project presentations.
Presentations
Brief presentations are stored in this directory regarding the equipment 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 training package. Short sequences are shown of practice-related applications.
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Equipment set Advanced Level (TP202)
This Advanced Level equipment set has been compiled for further training in pneumatic control technology. The two equipment sets (TP201 and TP202) comprise the components required for the specified training aims and can expanded in any way with other equipments sets of the Learning System for Automation and Technology. Equipment set Advanced Level (TP202 Order No.: 540713)
Description Relay, 3 off Signal input, electrical Time relay, 2 off Predetermining counter Proximity sensor, inductive Proximity sensor, capacitive EMERGENCY-STOP button Valve terminal with 4 valve slices (MMJJ) Non-return valve, piloted Order No. 162241 162242 162243 162355 178574 178575 183347 540696 540715 Quantity 2 1 1 1 1 1 1 1 2
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Training aims of Advanced Level (TP202)
To describe the design and use of valve terminals To solve sequence controls with signal overlap solution according to group method To solve sequence controls with signal overlap solution with sequence chain using spring-return valves To solve sequence control with signal overlap solution with sequence chain using double solenoid valves (with control step) To be able to describe and configure modes of operation (single cycle, continuous cycle, , ...) To describe the function and use of a predetermining counter To explain and realise an EMERGENCY-STOP FUNCTION using spring-return valves To realise special EMERGENCY-STOP conditions: Actuators must stop during EMERGENCY-STOP To explain the function and use of a 5/3-way solenoid valve To describe and configure the Reset mode of operation To carry out fault finding in complex electropneumatic circuits
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Contents
Part A Exercises
Exercise 1: Realising a sorting device ____________________________________A-3 Exercise 2: Realising a shut-off device___________________________________A-15 Exercise 3: Realising a lid press ________________________________________A-25 Exercise 4: Realising the operation of a hinged lid _________________________A-35 Exercise 5: Realising a diverting device __________________________________A-43 Exercise 6: Actuation of a stacking magazine _____________________________A-53 Exercise 7: Sorting of packages ________________________________________A-65 Exercise 8: Actuation of a sliding platform _______________________________A-73 Exercise 9: Expanding a diverting device _________________________________A-81 Exercise 10: Designing a stamping device________________________________A-91 Exercise 11: Realising a pallet loading station __________________________ A-101 Exercise 12: Eliminating a fault on the pallet loading station_______________ A-107
A-1
Contents
A-2
Exercise 1: Realising a sorting device
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 solenoid valve. To be able to identify and draw various types of actuation of directional control valves. To be able to explain and design an example of direct actuation. A sorting device is to be used to sort water samples according to the size of the sample bottle. Design a control system whereby this process can be carried out. A single-acting cylinder is to be used. The control of the cylinder is to be effected by means of a pushbutton. In the event of a power failure the cylinder piston rod is to return into the retracted end position. 1. Answer the questions or carry out the exercises regarding the fundamentals of the training contents listed. 2. Draw the pneumatic and electrical circuit diagram. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile an equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.
Problem definition
Parameters
Project task
A-3
Positional sketch
Sorting device
1. Pressing of a pushbutton causes the piston rod of a single-acting cylinder to push the sample bottle off the conveyor. 2. When the pushbutton is released, the piston rod is to return into the retracted end position.
A-4
Exercise 1: Realising the operation of a sorting device Name: Fundamentals: Function of pneumatic working components Date: Sheet 1 of 7
Pneumatic working components can be divided into two groups: Working components using linear movement Working components using rotary movement Describe the function of the working components shown.
Symbol 1 Symbol 2 Symbol 3
Description of function Symbol 1:
Symbol 2:
Symbol 3:
A-5
Exercise 1: Realising the operation of a sorting device Name: Fundamentals: Completing solenoid valve symbols Date: Sheet 2 of 7
Complete the individual symbols with the help of the corresponding component descriptions.
Description Directly actuated 3/2-way solenoid valve, normally open, with manual override, with spring return Pilot actuated 3/2-way solenoid valve, normally closed, with manual override, with spring return Symbol
A-6
Exercise 1: Realising the operation of a sorting device Name: Fundamentals: Normal positions of directional control valves Date: Sheet 3 of 7
An electrically actuated 3/2-way solenoid valve has two switching positions. It can be in the normal position (unactuated) or in the switching position (actuated). In the normal position the valve can be open or closed. Describe the effects on the motion sequence of the following application arising as a result of the different normal positions. The single-acting cylinder shown is controlled by an electrically actuated 3/2-way solenoid valve.
2 1M1 1M1 2
Description: Normal position closed
Description: Normal position open
A-7
Exercise 1: Realising the operation of a sorting device Name: Fundamentals: Direct and indirect actuation Date: Sheet 4 of 7
An electrically actuated solenoid valve can be actuated either directly or indirectly. Describe the difference with the help of the following application: Electrical actuation of a spring-returned 3/2-way solenoid valve using a pushbutton.
Description: Direct actuation Description: Indirect actuation
A-8
Exercise 1: Realising the operation of a sorting device Name: Design and function of an electrical switch Date: Sheet 5 of 7
Switches are basically divided into pushbutton and control switch designs and perform the function of a normally open or normally closed contact or changeover switch. Describe the design and function of the switches shown.
3 4
Description: Design/Function
1 2
4 1
A-9
Exercise 1: Realising the operation of a sorting device Name: Fundamentals: Mode of operation of different valve types Date: Sheet 6 of 7
Electrically actuated directional control valves are switches with the help of solenoids. Basically, these can be divided into two groups: Spring-return solenoid valves Double solenoid valves Describe the differences between the two groups with regard to function and behaviour in the event of power failure.
Valve type Spring-return valve Mode of operation
Double solenoid valve
A-10
Exercise 1: Realising the operation of a sorting device Name: Fundamentals: Port designations of valves Date: Sheet 7 of 7
In order to prevent incorrect tubing up of directional control valves, the valve ports (working and pilot lines) are identified in accordance with ISO 5599, both on the valve itself and in the circuit diagram. Describe the meaning and function of the designations below.
Designation Meaning, function
12
10
A-11
Exercise 1: Realising the operation of a sorting device Name: Completing the pneumatic and electrical circuit diagram Date: Sheet 1 of 1
Complete the pneumatic and electrical circuit diagram for the sorting device.
Pneumatic circuit diagram

+24 V 1
0V
Electrical circuit diagram
A-12
Exercise 1: Realising the operation of a sorting device Name: Compiling the equipment list 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
Equipment list
A-13
A-14
Exercise 2: Realising a shut-off device
Training aims
To familiarise yourself with the design and mode of operation of a double-acting cylinder. To be able to explain and design an example of direct actuation. In a water treatment system numerous pipes need to be opened or and closed by means of shut-off devices. A test setup is to be used to find a possible means of actuating the shut-off valve. A double-acting cylinder is to be used. The cylinder control is to be effected by means of a pushbutton. In the event of power failure the cylinder piston rod is to return into the retracted end position. 1. Answer the questions or carry out the exercises regarding the fundamentals of the training contents listed. 2. Design the pneumatic and electrical circuit diagrams. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile an equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.
Problem definition
Parameters
Project task
A-15
Positional sketch
Shut-off device
1. Pressing of a pushbutton is to cause the valve to open the slide 2. Releasing of the pushbutton is to cause the slide to close.
A-16
Exercise 2: Realising a shut-off device Name: Fundamentals: Comparison of directly actuated and pilot actuated valves Date: Sheet 1 of 5
Differentiation is made between directly actuated and pilot actuated solenoid valves with regard to the type of actuation of the valve piston. Compare these two valve types and describe the respective advantages and disadvantages.
Directly actuated valve Pilot actuated valve
A-17
Exercise 2: Realising a shut-off device Name: Port designations of valves Date: Sheet 2 of 5
In order to prevent incorrect tubing up of directional control valves, valve ports (working and pilot lines) are identified in accordance with ISO 5599-3, both on the valve itself and in the circuit diagram. Describe the meaning and function of the designations below.
Designation 4 Meaning, function
14
82/84
A-18
Exercise 2: Realising a shut-off device Name: Fundamentals: Mode of operation of a solenoid valve Date: Sheet 3 of 5
A valve symbol provides information regarding the function of the valve, i.e. the number of ports, switching positions and type of actuation, but not about the constructional design. Describe the mode of operation of the directional control valve shown.
4 1M1 5 1 3 2
Description: Mode of operation of a directional control valve
A-19
Exercise 2: Realising a shut-off device Name: Fundamentals: IP classification Date: Sheet 4 of 5
Depending on the installation and ambient conditions, electrical equipment is protected by means of a housing or cover. The required protection class against dust, humidity and foreign objects is to be identified. The classification IP 65 is shown on a valve Describe the meaning of this classification.
Description of IP 65 classification
A-20
Exercise 2: Realising a shut-off device Name: Fundamentals: Symbols of pneumatic cylinders Date: Sheet 5 of 5
Piston rod cylinders with linear action can be divided into two groups: Single-acting cylinders Double-acting cylinders Describe the meaning of the cylinder symbol shown.
Symbol 1 Symbol 2
Description of symbolic representation
A-21
Exercise 2: Realising a shut-off device Name: Completing the pneumatic and electrical circuit diagrams Date: Sheet 1 of 1
Complete the pneumatic and electrical circuit diagrams for the sorting device.

+24 V 1
0V
A-22
Exercise 2: Realising a shut-off device Name: Compiling the equipment list Date: Sheet 1 of 1
Equipment list
A-23
A-24
Exercise 3: Realising a lid press
Training aims
To familiarise yourself with the design and mode of operation of a double-acting cylinder. To be able to explain and design an example of indirect actuation. In a filling plant, wall or ceiling paints are filled into plastic pots. Once filled, slip-lids are to be pressed onto the plastic pots. A double-acting cylinder is to be used. The cylinder control is to be effected indirectly and by means of a pushbutton. In the event of power failure the cylinder piston rod is to return into the retracted end position. 1. Answer the questions or carry out the exercises regarding the fundamentals of the training contents listed. 2. Design the pneumatic and electrical circuit diagrams. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile an equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.
Problem definition
Parameters
Project task
A-25
Positional sketch
Filling of pots of paint
1. Pressing of a pushbutton is to cause the pressing ram to advance and the slip-lid to be pressed on. 2. Once the pushbutton is released, the pressing ram is to be returned into the initial position.
A-26
Exercise 3: Realising of a lid press Name: Fundamentals: Mode of operation of relays Date: Sheet 1 of 4
A relay is a remotely controlled electromagnetically actuated switch with several contacts. The main components are: Coil with core Winding of coil Contact set Return spring Armature Terminal lugs
The following illustration shows a sectional representation of a relay. Allocate the component designations.
2 3
1 4 5
A1 A2
4 2
A-27
Exercise 3: Realising a lid press Name: Fundamentals: Design and mode of operation of relays Date: Sheet 2 of 4
Describe the mode of operation of a relay.

Description of mode of operation of a relay
A-28
One or several contacts can be switched by a relay coil. Relays with normally closed, normally open or changeover contact(s) are used depending on the function required. Additional designs of electromagnetically actuated switches are for instance a remanence relay, the time relay with switch-on delay, the time relay with switch-off delay and the contactor. Describe the design and contact alignment of the relays shown.
Description of design/contact alignment Symbol
A1
13
23
31
41
A2
A1
14
12 14
24
22 24
32
32 34 42 44
42
A2
11
21
31
41
A-29
List the possible applications of relays in electrical or electropneumatic control systems.

Description: Possible applications
A-30
Exercise 3: Realising a lid press Name: Completing the pneumatic and electrical circuit diagrams Date: Sheet 1 of 2
Design the pneumatic and electrical circuit diagrams for the lid press.
A-31
+24 V
0V
11 21 31 41
12 14 22 24 32 34 42 44
A-32
Exercise 3: Realising a lid press Name: Compiling the equipment list Date: Sheet 1 of 1
Equipment list
A-33
A-34
Exercise 4: Realising the operation of a hinged lid
Training aims
To be able to design an example of indirect actuation To familiarise yourself with logic operations To be able to select solenoid valve according to requirements Plastic granulate is to be filled from a storage silo. The silo is to be opened or closed using a hinged lid. The process is to be effected from two points. A single-acting cylinder is to be used. The cylinder control is to be indirect and via hand levers. In the event of power failure, the cylinder piston rod is to advance into the forward end position. 1. Answer the questions or carry out the exercises regarding the fundamentals of the training contents listed. 2. Design the pneumatic and electrical circuit diagrams. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile an equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.
Problem definition
Parameters
Project task
A-35
Positional sketch
Filling of plastic granulate
1. Pressing of either one of the pushbuttons is to cause the hinged lid to open and to empty the bulk material from the container. 2. Once the pusbutton is released, the hinged lid closes.
A-36
Exercise 4: Realising the operation of a hinged lid Name: Fundamentals: Converting solenoid valves Date: Sheet 1 of 3
In industrial practice, there are numerous different requirements with regard to a valve. If a valve with all the required features is not available, it is often possible to use a valve with a different number of ports. The table below lists a selection of directional control valves frequently in use in industrial applications. Describe the valve types shown. Identify all solenoid valves that can be replaced by a 5/2-way solenoid valve of the type shown.. If measures are required to convert the valve, describe these. Note By conversion measures we understand the simplest of conversions such as the sealing of working ports 2 or 4 using a blanking plug.
4 14 1M1 5 1 3 2
Symbol
Description of valve type
Replacement possible
Description of necessary conversions
2 12 1M1
2 12 1M1
1 2
10 1M1
1 4
3 2
14 1M1
A-37
Exercise 4: Realising the operation of a hinged lid Name: Fundamentals: Selecting solenoid valves Date: Sheet 2 of 3
Valves are selected according to the following criteria: Exercise definition, Required behaviour in the event of power failure, Minimum possible overall costs The following valves are available for selection for the actuation of a single-acting cylinder: A pilot actuated, spring return 3/2way solenoid valve with manual override, A pilot actuated, spring-return 5/2-way solenoid valve with manual override Select a valve and explain the reasons for your decision. Note Apart from the cost of the valve, the above overall costs also include the cost of installation, maintenance and storage for replacement parts.
Valve type Reason
A-38
Exercise 4: Realising the operation of a hinged lid Name: Fundamentals: Logic operations: The OR function Date: Sheet 3 of 3
Triggering the advancing of a cylinder piston rod is to be possible using two pushbuttons S1 and S2. If at least one of the two pushbuttons is actuated, the valve coil 1M1 is energised, the solenoid valve 1V1 switches into the actuated position and the piston rod advances. If both pushbuttons are released, the valve switches into the initial position and the piston rod retracts. Create the appropriate function table and the logic symbol. Note 0 means: Pushbutton not actuated, i.e. piston rod does not advance 1 means: Pushbutton actuated, i.e. piston rod advances
S1 S2 1M1 1V1
Function table
Logic symbol
A-39
Exercise 4: Realising the operation of a hinged lid Name: Completing the pneumatic and electrical circuit diagrams Date: Sheet 1 of 2
Design the pneumatic and electrical circuit diagrams for the operation of the hinged lid.
A-40
+24 V
12 K1
14 11
A1 K1 A2 0V
11 21 31 41
1M1
12 14 22 24 32 34 42 44
A-41
Exercise 4: Realising the operation of a hinged lid Name: Compiling the equipment list Date: Sheet 1 of 1
Equipment list
A-42
Exercise 5: Realising a diverting device
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 double solenoid valve. Packages are to be pushed from one conveyor to another via a diverting device. A double-acting cylinder is to be used. The cylinder control is to be effected indirectly and via a pushbutton. In the event of power failure the cylinder piston rod is to remain in the current position. 1. Answer the questions and carry out the exercises regarding the training contents listed. 2. Design the pneumatic and electrical circuit diagrams. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile an equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.
Problem definition Parameters
Project task
A-43
Positional sketch
Diverting device
1. Pressing of a pushbutton is to cause the frame of the diverting device to be advanced. The package is transferred and transported away. 2. Pressing of another pushbutton causes the frame to be moved into the initial position.
A-44
Exercise 5: Realising a diverting device Name: Fundamentals: Use of solenoid valves Date: Sheet 1 of 4
Two factors are to be considered regarding the question as to which valve type is to be used for a particular application: Duration, i.e. time frame, Quantity or frequency of required switching operations. In order to utilise a directional control valve as efficiently as possible, you will need to decide in each case whether the use of a double solenoid valve or a spring-return directional control valve is more cost effective for the required application. Decide whether a double solenoid or a spring-return solenoid valve seems more cost effective for the applications listed and explain the reasons for your choice. Application 1 The clamping cylinder of a milling device is to firmly hold in position a workpiece for the duration of a milling operation (duration of approx. 10 min, 60 clamping operations per day).
Valve type Reason
Application 2 The ejecting cylinder of a sorting device is to push defective workpieces from a conveyor (duration of approx.1s, 600 ejecting operations per day).
Valve type Reason
A-45
Exercise 5: Realising a diverting device Name: Fundamentals: Mode of operation of a solenoid valve Date: Sheet 2 of 4
Describe the mode of operation of the directional control valve shown.
4 1M1 5 1
2 1M2 3
Description of mode of operation of a directional control valve
A-46
Exercise 5: Realising a diverting device Name: Fundamentals: Calculating the current consumption of a valve coil Date: Sheet 3 of 4
A spring-return solenoid valve is to be switched via pushbutton S1. Calculate the current consumption of the valve coil 1M1 at a voltage supply of 24 V DC and a coil resistance of 48 (Ohm).
+24 V 1
13 S1 14
1M1
0V
Current consumption in 1M1 Power rating of 1M1
A-47
Exercise 5: Realising a diverting device Name: Fundamentals: Calculate the current consumption of a valve coil Date: Sheet 4 of 4
Would the current consumption in 1M1 be the same, higher or lower if the above valve coil is connected to a 24V AC voltage? Explain the reasons for your answer.
Identical Higher Lower Reason
A-48
Exercise 5: Realising a diverting device Name: Completing the pneumatic and electrical circuit diagram Date: Sheet 1 of 2
Design the pneumatic and electrical circuit diagrams for the diverting device.
A-49
Exercise 5: Realising a diverting device Name: Completing the pneumatic and electrical circuit diagrams Date: Sheet 2 of 2
+24 V
0V
11 21 31 41
12 14 22 24 32 34 42 44
11 21 31 41
12 14 22 24 32 34 42 44
A-50
Exercise 5: Realising a diverting device Name: Compiling the equipment list Date: Sheet 1 of 1
Equipment list
A-51
A-52
Exercise 6: Actuation of a stacking magazine
Training aims
To be able to use a double-acting cylinder. To familiarise yourself with the design and mode of operation of a double solenoid valve. To familiarise yourself with the option of sensing the end positions of cylinders. Wooden boards are to be pushed from a stacking magazine into an assembly device. The forward end position of the cylinder is to be sensed. 1. Answer the questions or carry out the exercises regarding the fundamentals of the training contents listed. 2. Design the pneumatic and electrical circuit diagrams. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile an equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.
Problem definition Parameters Project task
A-53
Positional sketch
Stacking magazine
1. Pressing of a pushbutton causes a wooden board to be pushed out of the stacking magazine. 2. Once the forward end position is reached, the slide is moved into the initial position.
A-54
Exercise 6: Actuation of a stacking magazine Name: Fundamentals: Components of an electropneumatic system Date: Sheet 1 of 6
The components of an electropneumatic system are represented in a pneumatic circuit diagram and/or in an electrical circuit diagram. Determine where the components below are to be represented.
Component Pneumatic circuit diagram Electrical circuit diagram
Manually operated pushbutton Cylinder Valves Valve coils Relay Electromechanical limit switch Electronic proximity sensor Indicating devices
A-55
The function of sensors in electropneumatic control systems is to acquire information and to transmit this for signal processing. What function(s) can an electromechanical limit switch fulfill in an electropneumatic control system?
Description: Function(s) of electromechanical limit switches
A-56
Exercise 6: Actuation of a stacking magazine Name: Fundamentals: Representation of limit switches Date: Sheet 3 of 6
Limit switches can be actuated in different ways, via the function of a normally closed or normally open contact or changeover switch and, in the normal position of the system, can be either actuated or unactuated. Describe the appropriate design or function of the symbols shown.
Description: Design/function Symbol
2 1 4 1
A-57
Exercise 6: Actuation of a stacking magazine Name: Fundamentals: Creating a logic element table Date: Sheet 4 of 6
One possibility of recording the allocated contacts of a relay is by means of listing these in a logic element table. Create the logic element tables for relays K6 and K9.
+24 V 12 K5 11 12 K1 11 14 10 14 12 K6 11 11 14 12 K2 11 12 14 12 K7 11 13 14 12 K4 11 14 14 12 K8 11 15 14 12 K3 11 16 14 12 K9 11 17 14 32 K6 31 18 34 32 K7 31 19 34 ...
22 K9
24 21 A1
22 K6
24 21 A1
22 K7
24 21 A1
22 K8
24 21 A1
32 K9
34 31
32 K8
34 31
K6 A2 ... 0V
K7 A2
K8 A2
K9 A2
1M1
2M1
Logic element table K6
Description: Logic element table
K9
A-58
Another method of recording the allocated contact sets of a relay can be seen in the electrical circuit diagram below.
+24 V 1 21 NA EMERGENCY 22 STOP 2 3 4 5 6 7 8 9 10 12 K11 11 12 14 12 K6 11 12 K1 11 14 11 11 13 14 12 14 12 K7 11 14 12 K4 11 16 14 12 K8 11 17 14 12 K3 11 18 14 12 K9 11 19 14 22 K1 21 20 24 12 K10 11 21 14 32 K6 31 22 34 32 K7 31 23 34 32 K8 31 24 34 11 14 25 22 K11 21 26 34 22 K3 31 21 24 27 32 K11 31 34
1B1
1B2
2B1
2B2 S1 Start
13 14
12 K5
32 K9
24
22 K10
24 21
22 K6
24 21 A1
22 K7
24 21 A1
22 K8
24 21 A1
22 K9
24 21 A1
42 K7
44 41
42 K8
44 41
42 K9
44 41
32 K10
34 31
A1 K11 A2 0V
11 21 31 41
A1 K1 A2 K2
A1 K3 A2
A1 K4 A2
A1 K5 A2
A1 K6 A2
A1 K7 A2
1M1
2M1
2M2
1M2
K8 A2 A2
K9 A2
K10 A2 1A1+ 2A1+ 2A11A1-
12 14 .11 22 24 .25 32 34 .27 42 44
11 21 31 41
12 14 .12 22 24 .20 32 34 42 44
11 21 31 41
12 14 .14 22 24 32 34 42 44
11 21 31 41
12 14 .18 22 24 .27 32 34 42 44
11 21 31 41
12 14 .16 11 22 24 32 34 42 44 21 31 41
12 14 .12 22 24 32 34 42 44
11 21 31 41
12 14 .13 22 24 .14 32 34 .22 42 44
11 21 31 41
12 14 .15 22 24 .16 32 34 .23 42 44 .22
11 21 31 41
12 14 .17 22 24 .18 32 34 .24 42 44 .23
11 21 31 41
12 14 .19 22 24 .20 32 34 .26 42 44 .24
11 21 31 41
12 14 .21 22 24 .12 32 34 .26 42 44
A-59
Complete the information regarding the relays shown by: Indicating the current path in which the respective contact is used and specifying the function fulfilled by the contact set (normally open or normally closed contact).
Relay Current path Function: Normally open contact Function: Normally closed contact
Relay K9
Relay K10
A-60
Exercise 6: Actuation of a stacking magazine Name: Completing the pneumatic and electrical circuit diagrams Date: Sheet 1 of 2
Design the pneumatic and electrical circuit diagrams for the stacking magazine.
1A1
1V2
1V3
2 1V1 4 2
A-61
+24 V
12 K1
14 11
12 K2
14 11
A1 K1 A2 0V
11 21 31 41
A1 K2 A2
12 14 22 24 32 34 42 44
11 21 31 41
12 14 22 24 32 34 42 44
A-62
Exercise 6: Actuation of a stacking magazine Name: Compiling the equipment list Date: Sheet 1 of 1
Equipment list
A-63
A-64
Exercise 7: Sorting of packages
Training aims
To be able to calculate piston forces according to specific values To be able to calculate electrical characteristic values To be able to explain and design an example of indirect actuation To familiarise yourself with logic functions and to be able to design these
Problem definition
Packages are to be transported on a conveyor past workstations. The packages can be diverted by means of deflectors. A double-acting cylinder is to be used. The cylinder control is to be effected indirectly via pushbuttons and electromechanical limit switches. Triggering of the advancing movement is to be possible only if the piston rod is in the retracted end position. 1. Answer the questions or carry out the exercises regarding the fundamentals of the training contents listed. 2. Design the pneumatic and electrical circuit diagrams. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile an equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.
Parameters
Project task
A-65
Positional sketch
Conveyor belt for packages
1. The piston rod of a cylinder is to advance automatically as soon as pushbutton S1 is actuated. 2. If the pushbutton is no longer actuated, the piston rod is to assume the retracted end position.
A-66
Exercise 7: Sorting of packages Name: Fundamentals: Calculation of piston force Date: Sheet 1 of 3
The piston of a double-acting cylinder has a diameter of 16 mm and the piston rod a diameter of 8 mm. The frictional losses within the cylinder are 10 %. 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 ) ( 4 Effective annular surface (m2) (D 2 d 2 ) 4 Working pressure (Pa) Friction force (approx. 10% of Fth ) (N) Cylinder diameter (m) Piston rod diameter (m)
Calculate the effective piston force in the advance and return stroke at an operating pressure of 6 bar (600 kPa).
To be calculated Advance stroke Solution approach
Return stroke
A-67
Exercise 7: Sorting of packages Name: Fundamentals: Calculation of electrical characteristic values Date: Sheet 2 of 3
A relay in an electropneumatic circuit is designated as follows: 580 , 1 W. Calculate the permissible operating voltage which ensures that no overload occurs on the relay.
To be calculated Max. Operating voltage Solution approach
A-68
Exercise 7: Sorting of packages Name: Fundamentals: Date: Sheet 3 of 3
Triggering of the advancing movement of the piston rod of a cylinder is to be achieved by means of two pushbuttons S1 and S2. The valve coil 1M1 is energised if both pushbuttons are actuated simultaneously and the solenoid valve 1V1 switches into the actuated position causing the piston rod to advance. If at least one of the two pushbuttons is released, the valve switches into the initial position and the piston rod retracts. Create an appropriate function table and the logic symbol. Note 0 means: Pushbutton not actuated, i.e. piston rod not advancing 1 means: Pushbutton actuated, i.e. piston rod advances
S1 S2 1M1 1V1
Function table
Logic symbol
A-69
Exercise 7: Sorting of packages Name: Completing the pneumatic and electrical circuit diagrams Date: Sheet 1 vof 2
Configure the pneumatic circuit diagram and design the electrical circuit diagram for the feeding device.
1A1 1B1 1B2
1V2
1V3
2 1V1 1M1 5 1 3 4 2
1M2
A-70
Exercise 7: Sorting of packages Name: Completing the pneumatic and electrical circuit diagram Date: Sheet 2 of 2
+24 V
A1 K1 A2 0V
11 21 31 41
A1 K2 A2 K3 1M1 1M2
12 14 22 24 32 34 42 44
11 21 31 41
12 14 22 24 32 34 42 44
11 21 31 41
12 14 22 24 32 34 42 44
A-71
Exercise 7: Sorting of packages Name: Compiling the equipment list Date: Sheet 1 of 1
Equipment list
A-72
Exercise 8: Actuation of a sliding platform
Training aims
To familiarise yourself with logic functions and to be able to design these To be able to explain and design electrical latching circuits with dominant switchoff signal Wooden boards are to be manually placed onto a sliding platform. The boards are to be pushed under a belt sanding machine by means of a pneumatic drive. A double-acting cylinder is to be used. The cylinder control is to be effected indirectly. 1. Answer the questions or carry out the exercises regarding the fundamentals of the training contents listed. 2. Design the pneumatic and electrical circuit diagrams. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile the equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.
Problem definition
Parameters
Project task
A-73
Positional sketch
Sliding platform
1. The piston rod of a cylinder is to advance if pushbutton S1 is actuated. 2. Actuation of pushbutton S2 is to cause the piston rod to retract.
A-74
Exercise 8: Actuation of a sliding platform Name: Fundamentals: Signal storage Date: Sheet 1 of 3
The actuation of the pushbutton must be stored if the piston rod of a cylinder is to also advance if the pushbutton is only briefly actuated. This signal storage can be effected either in the power section or in the signal control section of a circuit. Describe how signal storage is devised in the power section or in the signal control section respectively.
Place of signal storage Signal storage in the power section Description: Signal storage
Signal storage in the signal control section
A-75
Exercise 8: Actuation of a sliding platform Name: Fundamentals: Analysing circuits Date: Sheet 2 of 3
Describe the behaviour of the circuit specified (pilot actuated, spring-return 5/2-way solenoid valve with manual override, double-acting cylinder) in the event of Power failure Pressure failure.
Power failure
Pressure failure
A-76
Exercise 8: Actuation of a sliding platform Name: Fundamentals: Logic functions Date: Sheet 3 of 3
The lamp P1 is to be illuminated whenever pushbutton S1 is not actuated. Draw up the appropriate function table and the logic symbol(s). 0 means: Pushbutton S1 not actuated, i.e. lamp P1 off 1 means: Pushbutton S1 actuated, i.e. P1 illuminated
S1 P1
Function table
Logic symbol
A-77
Exercise 8: Actuation of a sliding platform Name: Completing the pneumatic and electrical circuit diagrams Date: Sheet 1 of 2
Design the pneumatic and electrical circuit diagrams for the sliding platform.
A-78
+24 V
A1 K1 A2
0V
11 21 31 41
1M1
12 14 22 24 32 34 42 44
A-79
Exercise 8: Actuation of a diverting device Name: Compiling the equipment list Date: Sheet 1 of 1
Equipment list
A-80
Exercise 9: Expanding a diverting device
Training aims
To familiarise yourself with different types of end position control and to be able to select a suitable type. To familiarise yourself with latching circuits of different characteristics. Packages are to be transferred from one conveyor belt to another via a diverting device using reciprocating strokes. Once switched on, the device is to run continuously and only be switched off via a stop signal. The latching circuit used is to exhibit a dominant Off behaviour. 1. Answer the questions or carry out the exercises regarding the fundamentals of the training contents listed. 2. Design the pneumatic and electrical circuit diagram. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile the equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.
Problem definition
Parameters Project task
A-81
Positional sketch
Diverting device for packages
1. Actuation of the pushbutton is to cause a reciprocating movement of the cylinder piston rod to drive the diverting device via a latching drive. 2. The packages are to be deflected and transported in the opposite direction. 3. Pressing of a second pushbutton is to switch off the drive.
A-82
Exercise 9: Expanding a diverting device Name: Fundamentals: Latching circuits Date: Sheet 1 of 4
A latching relay circuit is required in order to store a signal in the signal control section. The relay K1 is energised by actuating pushbutton S1. Complete the electrical circuit diagram below so that the relay latches after the pushbutton S1 is released.
+24 V 1
13 S1 14
A1 K1 A2
0V
11 21 31 41
12 14 22 24 32 34 42 44
A-83
An additional normally closed contact is required in order to cancel a set selflatching loop. Differentiation is made between two groups depending on the configuration of this normally closed contact: Dominant setting self-latching loop Dominant resetting self-latching loop Complete the electrical circuit diagram below so that the self-latching loop is reliably cancelled via the actuation of a pushbutton S2.
+24 V 1
13 S1 14
A1 K1 A2 0V
11 21 31 41
12 14 22 24 32 34 42 44
A-84
The various circuits for signal storage exhibit different behaviour: with simultaneously applicable set and reset conditions in the event of power failure or cable fracture Complete the table and enter the behaviour of the respective valve. Valve position unchanged/valve is actuated/valve switches to normal position
Signal storage via double solenoid valve Signal storage via electrical latching circuit combined with spring-return valve Dominant setting Dominant resetting
Set and reset signal shared Power failure
A-85
Exercise 9: Expanding a diverting device Name: Fundamentals: Limit switches and proximity sensors Date: Sheet 4 of 4
The function of limit switches and proximity sensors is to acquire information and to transmit this for signal processing. These include: Mechanical position switches (limit switches), magnetic proximity sensors (reed switches), optical proximity sensors, capacitive proximity sensors, inductive proximity sensors Allocate the designations to the corresponding symbols in the table.
Designation Symbol
BN BK BU BN BK BU BN BK BU
4 1
BN BK BU
A-86
Exercise 9: Expanding a diverting device Name: Completing the pneumatic and electrical circuit diagrams Date: Sheet 1 of 2
Design the pneumatic and electrical circuit diagram for the diverting device.
1A1
1V2
1V3
2 1V1 1M1 5 1 3 4 2
1M2
A-87
Exercise 9: Expanding a diverting device Name: Completing the pneumatic and electrical circuit diagrams Date: Sheet 1 of 2
+24 V
13 S1 14
12 K1
14 11
31 S2 32
A1 K1 A2 0V
11 21 31 41
1M1
1M2
12 14 22 24 32 34 42 44
A-88
Exercise 9: Expanding a diverting device Name: Compiling the equipment list Date: Sheet 1 of 1
Equipment list
A-89
A-90
Exercise 10: Designing a stamping device
Training aims
To be able to design a pressure-dependent reversal control. To familiarise yourself with the design and mode of operation of magnetic proximity sensors. Small mounting blocks are to be stamped during the production of door frames. These blocks are to be stamped by means of a stamping device. The stamping pressure is to be 5.5 bar (550 kPa). 1. Answer the questions or carry out the exercises regarding the fundamentals of the training contents listed. 2. Design the pneumatic and electrical circuit diagrams. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile an equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.
Problem definition
A-91
Positional sketch
Stamping device
1. The pressing of a pushbutton is to cause the stamping device to advance and the workpiece to be stamped. 2. The stamping tool is to return into the initial position once the stamping pressure is obtained.
A-92
Exercise 10: Designing a stamping device Name: Fundamentals: Magnetic proximity sensor Date: Sheet 1 of 5
In contrast with limit switches proximity sensors are switched contactlessly and without an external mechanical actuating force. Describe the design and function of a magnetic proximity sensor (reed switch).
Description: Design and function Symbol Schematic representation
BN BK BU
A-93
Exercise 10: Designing a stamping device Name: Fundamentals: Magnetic proximity sensors Date: Sheet 2 of 5
As regards polarity there are two different designs of electronic proximity sensors, i.e. PNP or NPN. Describe the differences between these two types.
PNP NPN
A-94
Exercise 10: Designing a stamping device Name: Fundamentals: Pressure switches Date: Sheet 3 of 5
Pressure sensitive sensors, so-called PE converters, are used to monitor the pressure in a system. Describe the mode of operation of PE converter.
Description of mode of operation
A-95
Exercise 10: Designing a stamping device Name: Fundamentals: Pressure sensors Date: Sheet 4 of 5
Pressure sensors can be divided into two groups whereby differentiation is made between: Pressure sensors with mechanical contact (mechanical principle of action) Pressure sensors with electronic switching (electronic principle of action) Describe the purpose and function of the pressure sensor shown below.
Description: Purpose and function Symbol Schematic representation
A-96
Exercise 10: Designing a stamping device Name: Fundamentals: Choice of proximity sensors Date: Sheet 5 of 5
The end positions of a drive cylinder are to be sensed by means of proximity sensors. The following requirements apply regarding the proximity sensors: The end positions of the piston rod are to be sensed contactlessly The proximity sensors are to be insensitive to dust The piston rod and trip cam of the cylinder are made of metal Choose which proximity sensors meet the specified requirements and explain your reasons for this.
Proximity sensor Reason
A-97
Exercise 10: Designing a stamping device Name: Completing the pneumatic and electrical circuit diagrams Date: Sheet 1 of 2
Design the pneumatic and electrical circuit diagrams for the stamping device.
1A1
1V2
1V3
2 1V1 1M1 5 1 3 4 2
1M2
A-98
+24 V
1B1
1B2
1B3 p
A1 K1 A2 0V
11 21 31 41
A1 K2 A2 K3
A1 1M1 A2 1M2
12 14 22 24 32 34 42 44
11 21 31 41
12 14 22 24 32 34 42 44
11 21 31 41
12 14 22 24 32 34 42 44
A-99
Exercise 10: Designing a stamping device Name: Compiling the equipment list Date: Sheet 1 of 1
Equipment list
A-100
Exercise 11: Realising a pallet loading station
Training aims
To familiarise yourself with displacement-step diagrams and to be able to design these for specified problem definitions. To be able to realise a sequence control using two cylinders. Stacks of roof tiles are to be strapped with a band and then transported to a pallet loading station, where they are to be transferred onto Euro pallets. Adjust the one-way flow control valve so that both cylinders retract at identical speed. 1. 2. 3. 4. 5. 6. 7. Design the displacement-step diagram. Draw up the corresponding function diagram and function chart. Design the pneumatic and electrical circuit diagrams. Simulate the electropneumatic circuit diagram and check its correct functioning. Compile an equipment list. Carry out the pneumatic and electrical circuit assembly. Check the circuit operation.
Problem definition
Parameters
Project task
A-101
Positional sketch
Pallet loading station
1. Cylinder 1A1 is to advance when pushbutton S1 is pressed, whereby a single package arrives at the loading point and sensor 1B2 is actuated. 2. Cylinder 2A1 advances, actuates sensor 2B2, and pushes the package onto the pallet. 3. If 2B2 is actuated and S1 is unactuated, cylinder 1A1 retracts. 1B2 is therefore no longer actuated and cylinder 2A1 retracts. Consequently, the overall sequence is: 1A1+ 2A1+ 1A1 2A1
A-102
Exercise 11: Realising a pallet loading station Name: Fundamentals: Designing the displacement-step diagram Date: Sheet 1 of 3
If pushbutton S1 is actuated, cylinder 1A1 advances whereby the package reaches its loading point and sensor 1B2 is actuated. Cylinder 2A1 advances, actuates sensor 2B2 and pushes the package onto the pallet. If 2B2 is actuated and S1 unactuated, cylinder 1A1 retracts. 1B2 is no longer actuated and cylinder 2A1 retracts. Consequently the overall sequence is: 1A1+ 2A1+ 1A1 2A1 Design the displacement-step diagram for the problem definition described.
1 1
4=1
1A1
0
2A1
0
Displacement-step diagram
A-103
Exercise 11: Realising a pallet loading station Name: Completing the pneumatic and electrical circuit diagrams Date: Sheet 1 of 2
Design the pneumatic and electrical circuit diagrams for the pallet loading station.
1A1 2A1
1V2
1V3
2V2
2 1V1 4 2
2 2V1
1 2
A-104
+24 V
1B2 BN BK BU
2B2 BN BK BU
A1 A2 0V
11 21 31 41
A1 A2
A1 1M1 A2 1M2 2M1
12 14 22 24 32 34 42 44
11 21 31 41
12 14 22 24 32 34 42 44
11 21 31 41
12 14 22 24 32 34 42 44
A-105
Exercise 11: Realising a pallet loading station Name: Compiling the equipment list Date: Sheet 1 of 1
Equipment list
A-106
Exercise 12: Eliminating a fault on the pallet loading station
Training aims
To be able to identify and eliminate faults in simple electropneumatic control systems. The pallet loading station stops during continuous operation. A fault has occurred and must be eliminated. Thereafter the pallet loading station is to be re-started. Only one fault has occurred. 1. Describe the behaviour of the control system. Compare this with the correct control system behaviour. Use the displacement-step diagram to assist you. 2. Localise potential causes of the fault with the help of the pneumatic and electrical circuit diagrams. 3. Find the fault in the control system and eliminate it. 4. Re-start the control system.
Problem definition
A-107
Positional sketch
Pallet loading station
1. Cylinder 1A1 is to advance if pushbutton S1 is pressed. This causes a single package to reach its loading point thereby actuating sensor 1B2. 2. Cylinder 2A1 advances, actuates sensor 2B2 and pushes the package onto the pallet. 3. If 2B2 is actuated and S1 unactuated, cylinder 1A1 retracts, 1B2 is no longer actuated and cylinder 2A1 retracts. Consequently the overall sequence is: 1A1+ 2A1+ 1A1 2A1
A-108
Exercise 12: Eliminating a fault on the pallet loading station Name: Fault finding in simple electropneumatic circuits Date: Sheet 1 of 4
The following fault occurs in the circuit shown below: The piston rod of cylinder 1A1 and the piston rod of cylinder 2A1 advance and remain in the forward end position. Describe what the potential causes of the fault could be.
1A1 1B2 2A1 2B2
1V2
1V3
2V2
2 1V1 1M1 5 1 3 4 2
2 2V1 1M2 2M1
1 2
A-109
Exercise 12: Eliminating a fault on the pallet loading station Name: Fault finding in simple electropneumatic circuits
+24 V 1 3 5
Date: Sheet 2 of 4
6 7 8
1B2
BN BK BU
2B2
BN BK BU S1
13 14
12 K3
14 11
12 K2
14 11
12 K1
14 11
A1 K1 A2 0V
11 21 31 41
A1 K2 A2 K3
A1 1M1 A2 1M2 2M1
12 14 .8 22 24 32 34 42 44
11 21 31 41
12 14 .7 22 24 32 34 42 44
11 21 31 41
12 14 .6 22 24 32 34 42 44
List of potential causes of faults
A-110
A cable break occurs at the areas marked in the circuit shown below. Describe what the effects of a cable break at these respective points are on the functioning of the circuit.
+24 V 1 2 3 4 5 6 7 8
1B2
BN BK BU
2B2 BN BK BU S1
13 14
12 K3
14 11
12 K2
14 11
12 K1
14 11
A1 K1 A2 0V
11 21 31 41
A1 K2 A2 K3
A1 1M1 A2 1M2 2M1
12 14 .8 22 24 32 34 42 44
11 21 31 41
12 14 .7 22 24 32 34 42 44
11 21 31 41
12 14 .6 22 24 32 34 42 44
A-111
Fault Break in earthing wire of relay K1 (current path 2)
Effect of fault
Break in signal line of sensor 2B2 (current path 4)
Break in supply line of relay K3 (current path 5)
Break in supply line of relay contact 14 at K2 (current path 7) Break in earthing wire 2M1 (current path 8)
A-112
Exercise 12: Eliminating a fault on the pallet loading station Name: Fault finding: Determining the required status Date: Sheet 1 of 9
Create the displacement-step diagram with the help of the documentation given out.
Components
Time Step 1 Designation Identification Signal 2 3 4 5 6 7 8 9 10
A-113
Exercise 12: Eliminating a fault in the pallet loading station Name: Fault finding: Setpoint/actual comparison Date: Sheet 2 of 9
Determine the ACTUAL status of the system with the help of the following documentation: Positional sketch with problem description Graphic representation If the correct function is not given (REFERENCE/ACTUAL comparison), clearly mark the area in the diagram where the fault occurs.
Components
Time Step 1 Designation Identification Signal 2 3 4 5 6 7 8 9 10
A-114
Exercise 12: Eliminating a fault on the pallet loading station Name: Fault finding: Description of faults Date: Sheet 3 of 9
You have marked the area where a fault occurs in the diagram of the worksheet REFERENCE/ACTUAL comparison. Describe the process up the point where the station or system stops. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________
A-115
Exercise 12: Eliminating a fault on the pallet loading station Name: Fault finding: Definition of faults - pneumatics Date: Sheet 4 of 9
Once you have established the ACTUAL status of the system, consider what the causes of the faults could be. In which pneumatic tubing connections could the fault occur? Enter all the possibilities and indicate components at the start and end of the tubing connection in order to ensure clear identification.
Potential fault No. Tubing connection Start
End
Potential faults
A-116
Exercise 12: Eliminating a fault on the pallet loading station Name: Fault finding: Definition of faults electrics Date: Sheet 5 of 9
Once you have established the ACTUAL status of the system, consider what the causes of the faults could be. In which current paths could the fault be located? What is the function of the current path? Enter all the possibilities.
Potential fault No. Current path No. Function of current path
Potential faults
A-117
Exercise 12: Eliminating a fault on the pallet loading station Name: Fault finding: Localisation of faults - pneumatics Date: Sheet 6 of 9
Investigate the potential causes of errors you have found in the pneumatics. Use the same fault numbering that you have used for the worksheet Definition of faults pneumatic. Document the procedure used to investigate the tubing connections. Enter the results of your investigation.
Measuring and test protocol Potential fault No. Tubing connection Start Inspection End Result
Measuring and test protocol
A-118
Exercise 12: Eliminating a fault on the pallet loading station Name: Fault finding: Localisation of faults Date: Sheet 7 of 9
Investigate the potential error causes you have found. Use the same fault numbering that you have used in the worksheet Definition of faults - electrics. Document the procedure you have used to check the line connection. Enter the result of the investigation.
Measuring and test protocol Potential fault No. Current path No. Measuring points Inspection Result
Measuring and test protocol
A-119
Exercise 12: Eliminating a fault on the pallet loading station Name: Fault finding: Elimination of fault Date: Sheet 8 of 9
Once you have localised the failure location, your procedure for the elimination of the fault must be documented on this worksheet. Describe each of the steps carried out in detail. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________
Note In the event of the system not fulfilling the intended function return to the first worksheet and repeat the fault finding. Ask for new worksheet s to do so.
A-120
Exercise 12: Eliminating a fault on the pallet loading station Name: Fault finding: Re-starting Date: Sheet 9 of 9
Once you have identified, localised and eliminated the fault, re-start the system in accordance with the required status. Reset the specified required times. Briefly document the procedure followed in note form. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________
A-121
A-122
Part B Fundamentals
The theoretical fundamentals for the electropneumatics training package are summarised in the textbook: Electropneumatics, Basic Level This textbook represents an impressive synthesis of years of experience gained in Festo Didactic courses and the requirements of company and college training. It explains basic equipment and modern installation-saving components that require little maintenance. A comprehensive description of methods of representation showing motion sequences and operating states makes complex circuits easy to understand. A detailed example provides students with the necessary knowledge for the planning and implementation of an electropneumatic circuit. G. Prede, D. Scholz, 2001 edition, 296 pages, bound Order No.: 091181
B-1
B-2
Contents
Part C Solutions
Exercise 1: Realising a sorting device ____________________________________C-3 Exercise 2: Realising a shut-off device___________________________________C-15 Exercise 3: Realising a lid press ________________________________________C-23 Exercise 4: Realising the operation of a hinged lid _________________________C-33 Exercise 5: Realising a diverting device __________________________________C-41 Exercise 6: Actuation of a stacking magazine _____________________________C-49 Exercise 7: Sorting of packages ________________________________________C-59 Exercise 8: Actuation of a sliding platform _______________________________C-67 Exercise 9: Expanding a diverting device ________________________________C-75 Exercise 10: Designing a stamping device________________________________C-85 Exercise 11: Realising a pallet loading station ____________________________C-95 Exercise 12: Eliminating a fault on the pallet loading station________________C-101
C-1
Contents
C-2
Exercise 1: Realising a sorting device Solutions
Exercise 1: Realising a sorting device Name: Fundamentals: Function of pneumatic working components Date: Sheet 1 of 7
Pneumatic working components can be divided into two groups: Working components using linear movement Working components using rotary movement Describe the function of the working components shown.
Description: Function Symbol 1 Single-acting cylinder, return spring in piston chamber, return stroke via compressed air, forward stroke via return spring. Function The piston rod of this single-acting cylinder is moved into the retracted end position by means of switching on the compressed air. Once the compressed air is switched off the piston reverses into the forward end position via a return spring in the piston chamber (2 operating positions). Symbol 2 Single-acting cylinder, return spring in piston chamber, forward stroke via compressed air, return stroke via return spring Function The piston rod of the single-acting cylinder is moved into the forward end position by means of switching on the compressed air. Once the compressed air is switched off the piston reverses into the retracted end position (2 operating positions). Symbol 3 Pneumatic semi-rotary drive (swivelling drive), with limited swivel range Function This semi-rotary drive is double-acting and is reversed by means of alternating connection of compressed air (2 operating positions).
C-3
Exercise 1: Realising a sorting device Name: Fundamentals: Completing solenoid valve symbols Date: Sheet 2 of 7
Complete the individual symbols with the help of the corresponding component descriptions.
Description Pilot actuated 3/2-way solenoid valve, normally open, with manual override, with spring return Pilot actuated 3/2-way solenoid valve, normally closed, with manual override, with spring return Symbol
2 10 1M1
1 2
12 1M1
C-4
Exercise 1: Realising a sorting device Name: Fundamentals: Normal positions of directional control valves Date: Sheet 3 of 7
An electrically actuated 3/2-way solenoid valve has two switching positions. It can be in the normal position (unactuated), or in the switching position (actuated). In the normal position the valve can be closed or open. Describe the effects on the motion sequence of the following application arising as a result of the different normal positions: The single-acting cylinder shown is controlled by one of the represented 3/2-way solenoid valves respectively.
2 12 1M1 10 1M1 2
Description: 3/2-way solenoid valve, normally closed The solenoid valve used is reversed via the application of voltage at the solenoid coil; flow is released from pressure port 1 to working port 2. When the signal is cancelled, the valve is returned to the initial position via a return spring; pressure port 1 (and consequently flow) is closed. If the solenoid coil of the directional control valve is de-energised, the cylinder chamber is exhausted via the directional control valve (exhaust port 3), and the piston rod is retracted. If the solenoid coil is energised, the directional control valve switches. The cylinder chamber is pressurised and the piston is advanced. If the solenoid coil is de-energised, the valve reverses. The cylinder chamber is exhausted and the piston rod retracts. Consequently the motion sequence is: 1A1+ 1A1-
Description: 3/2-way solenoid valve, normally open The solenoid valve used is reversed by applying voltage at the solenoid coil; port 1 (and consequently flow) is closed. If the signal is cancelled the valve is returned to the initial position via a return spring and flow is released from pressure port 1 to working port 2. If the solenoid coil of the directional control valve is de-energised, the cylinder chamber is pressurised via the directional control valve and the piston rod is advanced. If the solenoid coil is energised the directional control valve switches and the cylinder chamber is exhausted via the directional control valve (exhaust port 3), causing the piston rod to retract. The valve reverses if the solenoid coil is de-energised. The cylinder chamber is pressurised and the piston rod advances. Consequently the motion sequence is: 1A1- 1A1+
C-5
Exercise 1: Realising a sorting device Name: Fundamentals: Direct and indirect actuation Date: Sheet 4 of 7
An electrically actuated solenoid valve can be actuated either directly or indirectly. Describe the difference with the help of the following application: Electrical actuation of a spring returned 3/2-way solenoid valve using a pushbutton.
Description: Direct actuation Current flows through the solenoid coil of the valve if the pushbutton is actuated. The solenoid is energised and the valve switches into the actuated position. The current flow is interrupted if the pushbutton is released. The solenoid is de-energised and the directional control valve returns to the initial position. Description: Indirect actuation In the case of indirect control, current flows through a relay coil if a pushbutton is actuated. The relay contact closes and the valve switches. The switching position is retained for as long as current flows through the solenoid or relay coil (in the case of self-latching loops also after the pushbutton is released). The relay is deenergised if the current flow is interrupted via the relay coil and the valve switches into the initial position. More complex, indirect actuation is always used if the control circuit and primary circuit operate using different voltages, the current through the coil of the directional control valve exceeds the permissible current for the pushbutton, if several valves are switched using one pushbutton or extensive logic functions are required between the signals of various pushbuttons.
C-6
Exercise 1: Realising a sorting device Name: Design and function of an electrical switch Date: Sheet 5 of 7
Switches are basically divided into pushbutton and control switch designs and perform the function of a normally closed contact, normally open contact or changeover switch. Describe the design and function of the switches shown.
3 4
Description: Design/function Symbol Pushbutton with normally open function Function
1 2
4 1
With a pushbutton, the selected switching position is only retained for as long as it is actuated. The pushbutton shown performs the function of a normally open contact. In the case of a normally open contact, the circuit is interrupted in the normal position of the pushbutton, i.e. in the unactuated state. Actuation of the switching stem causes the circuit to be closed and current to flow to the consuming device. Once the switching stem is released, the pushbutton returns to the normal position as a result of the spring force, thereby interrupting the circuit. Symbol Detent switch with normally closed contact Function In the case of a detent switch both switching positions are mechanically locked. A switching position is therefore always retained until the switch is re-actuated. The detent switch shown performs the function of a normally closed contact. With a normally closed contact the circuit is closed in the normal position of the detent switch due to the spring force. Actuation of the detent switch causes the circuit to be interrupted and renewed actuation closes the circuit again. Symbol Pushbutton with changeover function Function In the case of this pushbutton, the selected switching position is retained only for as long as this is actuated. The pushbutton shown performs the function of a changeover switch, where the functions of a normally closed and normally open contact are combined in one device. A switching action causes one circuit to be closed and another circuit to be opened. Both circuits are briefly interrupted during switching.
C-7
Exercise 1: Realising a sorting device Name: Fundamentals: Mode of operation of different valve types Date: Sheet 6 of 7
Electrically actuated directional control valves are switched with the help of solenoids and can basically be divided into two groups: Spring return valves Double solenoid valves Describe how these two groups differ with regard to function and behaviour in the event of a power failure.
Valve type Spring return valve Mode of operation The actuated switching position is maintained only for as long as current flows through the solenoid coil. The normal position is clearly defined by the return spring. In the event of a power failure the valve switches to the normal position via the spring and this may trigger dangerous machine movements, e.g. causes the piston rod of a pneumatic cylinder to move into the initial position and release the clamping of a workpiece. Double-solenoid valve Switching of the valve merely requires a brief signal; due to the static friction, the last assumed switching position is retained even in the de-energised state. All solenoid coils are de-energised in the normal position and the normal position cannot be clearly defined. In the event of a power failure, the valve retains its last switching position; no dangerous movements are triggered, e.g. the piston rod of a pneumatic cylinder maintains its operating position and retains a workpiece.
C-8
Exercise 1: Realising a sorting device Name: Fundamentals: Port designations of valves Date: Sheet 7 of 7
In order to prevent incorrect tubing of directional control valves, valve ports (working and pilot lines) are identified to ISO 5599 3, both on the valve itself and in the circuit diagram. Describe the meaning or function of the designations below.
Designation 3 12 Meaning or function Working line, exhaust port Pilot line, with pilot actuated or pneumatically actuated directional control valves; Function on actuation: Connection of supply port 1 and working port 2 Pilot line, with pilot actuated or pneumatically actuated directional control valves; Function on actuation: Closing of supply port 1
10
C-9
Exercise 1: Realising a sorting device Name: Completing the pneumatic and electrical circuit diagrams Date: Sheet 1 of 2
Design the pneumatic and electrical circuit diagrams for the sorting device.
1A1
1V2
1 1V1 1M1 2
3 0Z2
0Z1
1 2 3
C-10
Exercise 1: Realising a sorting device Name: Completing the pneumatic and electrical circuit diagrams Date: Sheet 2 of 2
+24 V
13 S1 14
1M1
0V
C-11
Exercise 1: Realising a sorting device Name: Process description Date: Sheet 1 of 1
Initial position The cylinder is in the retracted end position. Steps 1-2 Actuation of pushbutton S1 (normally open contact), causes the solenoid coil 1M1 of the 3/2-way solenoid valve 1V1 to be energised. The valve 1V1 reverses and cylinder 1A1 advances. Steps 2-3 As soon as pushbutton S1(normally open contact) is no longer actuated, the coil 1M1 is de-energised, the valve 1V1 is returned into the initial position via the return spring, the cylinder 1A1 is exhausted and the spring returns the cylinder into the retracted end position.
C-12
Exercise 1: Realising a sorting device Name: Compiling the equipment list Date: Sheet 1 of 1
Quantity 1 1 1 1 1 1 1 1 Description Cylinder, single-acting One-way flow control valve 3/2-way solenoid valve, normally closed Pushbutton (normally open contact) Manifold Start-up valve with filter control valve Compressed air supply Power supply unit 24 V DC
Equipment list
C-13
C-14
Exercise 2: Realising a shut-off device Solutions
Differentiation is made between directly actuated and pilot actuated directional control valves with regard to the type of actuation. Compare these two valve types and describe the respective advantages and disadvantages.
Directly actuated valve Flow is releases to the consuming device via the armature of the solenoid. In order to obtain a sufficient cross section of opening, a comparably large armature is required. This consequently requires a powerful return spring and the solenoid to generate a high force. It is therefore of a large design with high power consumption. Pilot actuated valve Flow to the consuming device is switched via the main stage. The valve piston is moved via an air duct from pressure port 1. This only requires a low flow so that a comparatively small armature with minimal actuating force can be used. A minimum supply pressure is required in order to actuate the piston against the spring force. Compared to a directly actuated valve, the solenoid can be configured in a small design and the power consumption and heat emission is thus reduced.
C-15
In order to prevent incorrect tubing up of directional control valves, valve ports (working and pilot lines) are identified in accordance with ISO 5599-3, both on the valve itself and in the circuit diagram. Describe the meaning and function of the designations below
Designation 4 14 Meaning, function Working line, working port Power line, with pilot actuated or pneumatically actuated directional control valves Function on actuation: Connection of supply port 1 and working port 4 Pilot line, with pilot actuated or pneumatically actuated directional control valves Function on actuation: Auxiliary pilot air exhausting
82/84
C-16
Exercise 2: Realising a shut-off device Name: Fundamentals: Mode of operation of a solenoid valve Date: Sheet 3 of 5
A valve symbol provides information regarding the function of the valve, i.e. the number of ports, switching positions and type of actuation, but not about the constructional design. Describe the mode of operation of the directional control valve shown.
4 1M1 5 1 3 2
Description: Mode of operation of directional control valve Pilot actuated 5/2-way solenoid valve, with manual override, with spring return Mode of operation: In the normal position, the piston is positioned at the lefthand stop, the ports 1 (supply port) and 2 (working port), as well as the ports 4 (working port) and 5 (exhaust port) are connected. If the solenoid coil is energised, the valve piston moves up to the righthand stop. In this position, ports 1 and 4 as well as 2 and 3 (exhaust port) are connected (the designation of the internal line of the pilot control is 14; function on actuation: Connection of supply port 1 and working port 4). If the solenoid is de-energised, the valve piston switches back into the normal position due to the spring force and the pilot air is exhausted. In the de-energised state the valve can be switched by means of a manual override.
C-17
Exercise 2: Realising a shut-off device Name: Fundamentals: IP classification Date: Sheet 4 of 5
Depending on the installation and ambient conditions, electrical equipment is protected by means of a housing or cover. The required protection class against dust, humidity and foreign objects is to be identified. Protection class IP 65 is shown on a valve. Describe the meaning of this classification.
Description: IP 65 classification In accordance with DIN-VDE 470-1, the protection classification code is composed of the two letters IP (for International Protection) and two digits. The first digit indicates the scope of protection against the ingress of dust or foreign objects and the second digit the scope of protection against the penetration of humidity or water. Protection class IP 65 therefore means protection against the ingress of dust . (i.e. complete protection against contact with energised or internally moving parts, protection against the ingress of dust) and hose-water (i.e. strong jets of water aimed from any direction against the housing/enclosure must not have any harmful effect).
C-18
Exercise 2: Realising a shut-off device Name: Fundamentals: Symbols of pneumatic cylinders Date: Sheet 5 of 5
Piston rod cylinder with linear action can be divided into two groups: Single-acting cylinders Double-acting cylinders Describe the meaning of the cylinder symbols shown.
Symbol 1 Symbol 2
Description: Symbolic representation Symbol 1 Double-acting multi-position cylinder; reversal via alternating supply of compressed air. By series connecting two cylinders of identical piston diameter and different stroke length, it is possible to approach three positions. The third position can be approached directly or via the second intermediate position from the first position. However, to do so the subsequent cylinder stroke must always be greater than the previous stroke. With the return stroke, an intermediate position is only possible with the appropriate actuation (3 working positions). The shorter stroke length is half of the longer one. Symbol 2 Double-acting cylinder, reversal via alternating supply of compressed air, adjustable end position cushioning (2 working positions) Cushioning is used in the end position if large loads are to be moved by a cylinder. Prior to reaching the end position, a cushioning piston interrupts the direct exhaust path of air to atmosphere. The restricted exhaust air causes the piston speed to be reduced during the last part of the stroke travel.
C-19
Exercise 2: Realising a shut-off device Name: Completing the pneumatic and electrical circuit diagrams Date: Sheet 1 of 1
Design the pneumatic and electrical circuit diagrams for the shut-off device.
1A1
1V2
1V3
2 1V1 1M1 5 1 3 4 2
+24 V
13 S1 14
1M1
0V
C-20
Exercise 2: Realising a shut-off device Name: Process description Date: Sheet 1 of 1
Initial position The cylinder is in the retracted end position. Steps 1-2 Actuation of pushbutton S1(normally open contact) causes the solenoid coil 1M1 of the 5/2-way solenoid valve 1V1 to be energised and the valve 1V1 to reverse. The piston side of cylinder 1A1 is now filled with compressed air whilst the piston rod side is exhausted. Cylinder 1A1 advances. Steps 2-3 As soon as pushbutton S1 (normally open contact) is no longer actuated, the coil 1M1 is de-energised and the valve 1V1 is returned to the initial position again via the return spring. The piston side of cylinder 1A1 is exhausted whilst the piston rod side is filled with compressed air. The cylinder returns into the retracted end position.
C-21
Exercise 2: Realising a shut-off device Name: Compiling the equipment list Date: Sheet 1 of 1
Quantity 1 2 1 1 1 1 1 1 Description Cylinder, double-acting One-way flow control valve 5/2-way solenoid valve Pushbutton (normally open contact) Manifold Start-up valve with filter control valve Compressed air supply Power supply unit 24 V DC
Equipment list
C-22
Exercise 3: Realising a lid press Solutions
Exercise 3: Realising a lid press Name: Fundamentals: Mode of operation of relays Date: Sheet 1 of 4
Relays form part of the components of the electrical signal control section. The main components are: Coil with core Coil winding Contact set Return spring Armature Terminal lugs The illustration below represents a sectional view of a relay. Allocate the component designations.
2 3
1 4 5
A1 A2
4 2
The relay consists of (1) Coil with core (2) Return spring (3) Coil winding (4) Armature (5) Contact set (6) Terminal lugs (7) Terminal lugs
C-23
Describe the mode of operation of a relay.

Description: Mode of operation of a relay A relay is an electromagnetically operated switch. An electromagnetic field is created if voltage is applied at the coil of the solenoid, which causes the movable armature to be attracted to the coil core. The armature acts on the relay contacts which, depending on configuration either open or close. If the current flow through the coil is interrupted, a spring causes the armature to return into the initial position.
C-24
One or several contacts can be switched by a relay coil. Depending on the required function, a relay with normally open, normally closed or changeover contact(s) is used. Additional designs of electromagnetically operated switches are for instance the remanence relay, time relay with switch-on delay and the contactor. Describe the design and contact line-up of the relays shown.
Description: Design/contact line-up Design: Relay with two normally closed contacts and two normally open contacts Function: If the relay coil is energised, two of the four contacts are opened and two contacts are closed. Design: Relay with four changeover contacts Function: If the relay coil is energised, up to four current paths are opened or closed via the four relay contacts. High flexibility, wide range of different contact combinations possible. Symbol
A1
13
23
31
41
A2
14
12 14
24
22 24
32
32 34
42
42 44
A1
A2
11
21
31
41
C-25
Exercise 3: Realising a list press Name: Fundamentals: Design and mode of operation of relays Date: Sheet 4 of 4
Name possible applications of relays in electrical or electropneumatic control systems.

Description: Possible applications Signal multiplication Voltage or current amplification Delaying or converting of signals Logic operations of information Isolation of control and primary circuits Isolation of DC and AC circuits in purely electrical control systems
C-26
Design the pneumatic and electrical circuit diagrams for the lid press.
1A1
1V2
1V3
2 1V1 1M1 5 1 3 4 2
C-27
+24 V
13 S1 14
12 K1
14 11
A1 K1 A2 0V
11 21 31 41
1M1
12 14 .2 22 24 32 34 42 44
C-28
Exercise 3: Realising a lid press Name: Process description Date: Sheet 1 of 1
Initial position Cylinder 1A1 is in the retracted end position. Steps 1-2 Actuation of pushbutton S1 (normally open contact) causes the relay K1 to be energised, the changeover contact K1 (connected in the form of a normally open contact) also closed and the solenoid coil 1M1 of the 5/2-way valve 1V1 is energised. The valve 1V1 reverses and causes the rear chamber of cylinder 1A1 to be filled with compressed air whilst the front chamber if exhausted. Cylinder 1A1 advances. Steps 2-3 As soon as pushbutton S1 (normally open contact) is no longer actuated, relay K1 is de-energised and the changeover contact K1(connected in the form of a normally open contact) opens. This causes the coil 1M1 to be de-energised and the valve 1V1 to be returned into the initial position via the return spring. The rear chamber of cylinder 1A1 is exhausted whilst the front chamber is filled with compressed air. the cylinder returns into the retracted end position.
C-29
Exercise 3: Realising a lid press Name: Completing the pneumatic and electrical circuit diagrams, alternative solution Date: Sheet 1 of 2
Indirect actuation does of course function equally with a 3/2-way solenoid valve and single-acting cylinder.
1A1
1V2
1 1V1 1M1 2
C-30
Exercise 3: Realising a lid press Name: Completing the pneumatic and electrical circuit diagrams, alternative solution Date: Sheet 2 of 2
+24 V
13 S1 14
12 K1
14 11
A1 K1 A2 0V
11 21 31 41
1M1
12 14 .2 22 24 32 34 42 44
C-31
Exercise 3: Realising a lid press Name: Compiling the equipment list 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 1 2 1 1 1 1 1 1 1 Designation Cylinder, double-acting One-way flow control valve 5/2-way solenoid valve Pushbutton (normally open) Relay Manifold Start-up valve with filter control valve Compressed air supply Power supply unit 24 V DC
Equipment list
C-32
Exercise 4: Realising the operation of a hinged lid Solutions
Exercise 4: Realising the operation of a hinged lid Name: Fundamentals: Converting solenoid valves Date: Sheet 1 of 3
In industrial practice there are numerous different requirements placed on a valve. If a valve with the desired characteristics is not available, it is often possible to use a valve with a different number of ports to obtain the required function. The table below lists a selection of directional control valves frequently in use in industrial applications. Describe the valve types shown. Designate all the solenoid valves that can be replaced by using a 5/2-way solenoid valve of the type shown. If conversion measures need to be taken in order to obtain the desired function, then please describe thee. Note By the term conversion measures we understand the simplest of conversions, such as the closing of working ports 2 or 4 using a blanking plug.
4 14 1M1 5 1 3 2
Symbol
Description: Valve type
Replacement possible
Description: Necessary conversions
2 12 1M1
2 12 1M1
Pilot actuated, spring return 2/2-way solenoid valve, with manual override Pilot actuated, spring return
3
Replacement possible, no conversion required? X
1 2
3/2-way solenoid valve, normally closed, with manual override Pilot actuated, spring return
Replacement possible, conversion by closing working port 2 using a blanking plug
10 1M1
1 4
3 2
3/2-way solenoid valve, normally open, with manual override Pilot-actuated, spring return 4/2-way solenoid valve, with manual override
Replacement possible, conversion by closing working port 4 using a blanking plug
Replacement possible, no conversion required X
14 1M1
C-33
Exercise 4: Realising the operation of hinged lid Name: Fundamentals: Selecting solenoid valves Date: Sheet 2 of 3
The choice of a valve is made according to the following criteria: Problem definition, Required behaviour in the event of a power failure, Lowest possible overall costs The following choice of valves is available for the actuation of a single-acting cylinder: A pilot actuated, spring return 3/2-way solenoid valve with manual override A pilot actuated, spring return 5/2-way solenoid valve with manual override Make your choice and explain your reasons for this. Note Apart from the costs of the actual valve, the above mentioned overall costs of a valve also include the costs for installation, maintenance and storage of replacement parts.
Valve type Pilot actuated, spring return 5/2-way solenoid valve with manual override Reason As can be seen from question 1, the 5/2-way solenoid valve has a broad spectrum of possible applications. In practice this means that only one valve type is required for different requirements or applications. This in turn means a considerable cost reduction thanks to more alternatives when it comes to the procurement of the valve and storage of replacement parts. The maintenance of different valves entails considerable higher expenditure compared to maintaining a single valve type. A 3/2-way valve can only actuate single-acting cylinders whereas a 5/2-way valve can actuate singleacting and double-acting cylinders. This is why the choice should be a 5/2way solenoid valve. The fact that the costs of a 3/2-way solenoid valve are usually 5 % below that of a 5/2-way double solenoid valve is immaterial in view of the above mentioned advantages.
C-34
Exercise 4: Realising the operation of a hinged lid Name: Fundamentals Date: Sheet 3 of 3
Triggering the advance of the cylinder piston rod is to be possible using two pushbuttons S1 and S2. If at least one of the two pushbuttons is actuated, the valve coil 1M1 is energised, the solenoid valve 1V1 switches into the actuated position and the piston rod advances. If both pushbuttons are released, the valve switches into the initial position and the piston rod retracts. Create the appropriate function table and the logic symbol. Note 0 means: Pushbutton not actuated, i.e. piston rod does not advance 1 means: Pushbutton actuated, i.e. piston rod advances
S1 0 (not actuated) 0 (not actuated) 1 (actuated) 1 (actuated) S2 0 (not actuated) 1 (actuated) 0 (not actuated) 1 (actuated) 1M1 0 (not actuated) 1 (actuated) 1 (actuated) 1 (actuated) 1V1 0 (not actuated) 1 (actuated) 1 (actuated) 1 (actuated)
Function table
S1 S2
<=1
1M1
Logic symbol
C-35
Design the pneumatic and electrical circuit diagrams for the hinged lid.
1A1
1V2
1 1V1 1M1 5 1 3 4 2
C-36
Exercise 4: Realising the operation of a hinged lid Name: Complete the pneumatic and electrical circuit diagrams Date: Sheet 2 of 2
+24 V
13 S1 14 S2
13 14
12 K1
14 11
A1 K1 A2 0V
11 21 31 41
1M1
12 14 .3 22 24 32 34 42 44
C-37
Exercise 4: Realising the operation of a hinged lid Name: Process description Date: Sheet 1 of 1
Initial position In the initial position cylinder 1A1 is in the forward end position and the rear cylinder chamber is filled with compressed air. Steps 1-2 Actuation of pushbutton S1 or pushbutton S2 (both in the form of normally open contacts), causes the relay K1 to be energised, the changeover contact K1 (connected in the form of a normally open contact) closes and the solenoid coil 1M1 of the 5/2-way valve 1V1 is energised. The valve 1V1 reverses and the rear chamber of cylinder 1A1 is exhausted; the spring presses the cylinder into the retracted end position. Steps 2-3 As soon as the pushbutton S1 or S2 (both in the form of normally open contacts), are no longer pressed, the relay K1 is de-energised, the changeover switch K1 (connected in the form of a normally open contact) opens. This causes the coil 1M1 to be de-energised and the valve 1V1 to be returned into the initial position via the return spring. The rear chamber of cylinder 1A1 is filled with compressed air and the cylinder returns into the forward end position.
C-38
Exercise 4: Realising the operation of a hinged lid Name: Compiling the equipment 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 1 1 1 2 1 1 1 1 1 Description Cylinder, single-acting One-way flow control valve 5/2-way solenoid valve Pushbutton (normally open contact) Relay Manifold Start-up valve with filter control valve Compressed air supply Power supply unit 24 V DC
Equipment list
C-39
C-40
Exercise 5: Realising the operation of a diverting device Solutions
Exercise 5: Realising the operation of a diverting device Name: Fundamentals: Use of solenoid valves Date: Sheet 1 of 4
Two factors are to be taken into consideration with regard to the question as to which valve type is to be used for a particular application: Duration, i.e. time frame, Quantity or frequency of required switching operations. In order to utilise a directional control valve as efficiently as possible, you will need to decide in each case whether a double-solenoid valve or a spring-return directional control valve is more cost effective for the required application. Decide whether a double soleoid or a spring-return valve seems more cost effective for the applications listed and explain the reasons for your choice. Application 1 The clamping cylinder of a milling device is to firmly hold in position a workpiece for the duration of a milling operation (duration of approx. 10 min, 60 clamping operations per day).
Valve type Double solenoid valve Reason An applied signal needs to be stored for lengthy switching operations. In the case of double solenoid valve this occurs via static friction and with spring return directional control valves via continuously energising the solenoid coil. Clamped workpieces must not be released in the event of EMERGENCYSTOP, hence the use of spring-return solenoid valves is not permissible in this case.
Application 2 The ejecting cylinder of a sorting device is to push defective workpieces from a conveyor (duration of approx. 1s, 600 ejecting operations per day).
Valve type Spring-returned solenoid valve Reason For short switching operations an applied signal does not need to be stored. Spring-return solenoid valves have the advantage: Only one valve coil needs to be actuated, i.e. energised to switch the valve.
C-41
Exercise 5: Realising the operation of a diverting device Name: Fundamentals: Mode of operation of a solenoid valve Date: Sheet 2 of 4
Describe the mode of operation of the directional control valve shown.
4 1M1 5 1
2 1M2 3
Description: Mode of operation of a directional control valve Pilot actuated 5/2-way double solenoid valve, with manual override Mode of operation: If the piston is at the lefthand stop, ports 1 (compressed air supply) and 2 (working port), as well as port 4 (working port) and port 5 (exhaust port)are connected. If the lefthand solenoid coil is energised, the piston moves to the righthand stop and ports 1 and 4 as well as port 2 and port 3 (exhaust port) are connected (power line, 14 and 12, function during actuation: Connection of compressed air supply 1 and working port 4, i.e. 2). If the valve is to return into the initial position, it is not sufficient to interrupt the current to the lefthand solenoid coil since the righthand solenoid coil also needs to be energised. If neither of the two solenoids is actuated the piston, owing to friction, remains in its last assumed position (signal control in the power section). This also applies if both solenoids are simultaneously energised since they then act against one another with identical force. The valve can be switched via a manual override in the de-energised state .
C-42
Exercise 5: Realising the operation of a diverting device Name: Fundamentals: Calculating the current consumption of a valve coil Date: Sheet 3 of 4
A spring-return solenoid valve is to be switched via pushbutton S1. Calculate the current consumption of the valve coil 1M1 at a voltage supply of 24 V DC and a coil resistance of 48 (Ohm).
+24 V 1
13 S1 14
1M1
0V
Current consumption in 1M1 According to Ohms law R=UI A current consumption of 0.5 A (ampere) is calculated via Capacity of 1M1 According to P = U I = 24 V 0.5 A = 12 W a power consumption of 12 W (Watt) is calculated
I=
U 24V = = 0.5 A R 48
C-43
Exercise 5: Realising the operation of a diverting device Name: Fundamentals: Calculating the current consumption of a valve coil Date: Sheet 4 of 4
Would the current consumption in S1 be the same, higher or lower if the above valve coil is connected to a 24V AC voltage? Explain the reasons for your answer.
Identical
Higher
Lower
Reason The magnetic fields of the AC voltage create an induction voltage in the coil windings which acts against the voltage applied and which increases the coil resistance. This resistance of the AC coil (impedance) is made up of the ohmic resistance and the so-called inductive reactance, thereby reducing the effective current.
C-44
Exercise 5: Realising the operation of a diverting device Name: Completing the pneumatic and electrical circuit diagrams Date: Sheet 1 of 2
Design the pneumatic and electrical circuit diagrams for the diverting device.
1A1
1V2
1V3
2 1V1 1M1 5 1 3 4 2
1M2
C-45
Exercise 5: Realising the operation of a diverting device Name: Completing the pneumatic and electrical circuit diagrams Date: Sheet 2 of 2
+24 V
13 S1 14 S2
13 14
12 K1
14 11
12 K2
14 11
A1 K1 A2 0V
11 21 31 41
A1 K2 A2 1M1 1M2
12 14 .3 22 24 32 34 42 44
11 21 31 41
12 14 .4 22 24 32 34 42 44
C-46
Exercise 5: Realising the operation of a diverting device Name: Process description Date: Sheet 1 of 1
Initial position In the initial position, cylinder 1A1 is in the retracted end position. Steps 1-2 Actuation of pushbutton S1 (normally open contact) causes the relay K1 to be energised, the changeover contact K1 (connected in the form of a normally open contact) to close and the solenoid coil 1M1 of the 5/2-way double solenoid valve 1V1 to be energised. The valve 1V1 reverses and the rear chamber of cylinder 1A1 is filled with compressed air whilst the front chamber is exhausted. Cylinder 1A1 advances. As soon as pushbutton S1 (normally open contact) is no longer actuated, the relay K1 is de-energised and the changeover contact K1 (connected in the form of a normally open contact) opens, thereby causing the coil 1M1 to be de-energised. Steps 2-3 Actuation of pushbutton S2 (normally open contact) causes the relay K2 to be energised and the changeover contact K2 (connected in the form of a normally open contact) to be closed. This causes the coil 1M2 to be energised and the valve 1V1 to return into the initial position. The front chamber of the cylinder 1A1 is filled with compressed air whilst the rear chamber is exhausted. The cylinder 1A1 returns into the retracted end position. As soon as pushbutton S2 (normally open contact) is no longer actuated, relay K2 is de-energised and changeover contact K2 (connected in the form of a normally open contact) opens. This causes the coil 1M2 to be de-energised.
C-47
Exercise 5: Realising the operation of a diverting device Name: Compiling the equipment list Date: Sheet 1 of 1
Quantity 1 2 1 2 2 1 1 1 1 Description Cylinder, double-acting One-way flow control valve 5/2-way double solenoid valve Pushbutton (normally open contact) Relay Manifold Start-up valve with filter control valve Compressed air supply Power supply unit 24 V DC
Equipment list
C-48
Exercise 6: Actuation of a stacking magazine Solutions
The components of an electropneumatic system are represented in a pneumatic circuit diagram and/or in an electrical circuit diagram. Determine where the components below are to be represented.
Component Pneumatic circuit diagram Electrical circuit diagram X X X X X X X X X X X
Manually operated pushbutton Cylinder Valves Valve coils Relay Electromechanical limit switch Electronic proximity sensor Indicating devices
C-49
The function of sensors in electropneumatic control systems is to acquire information and transmit this for signal processing. What function(s) can an electromechanical limit switch fulfill in an electropneumatic control system?
Description: Function (s) of electromechanical limit switches To detect the forward and retracted end positions of the piston rod of drive cylinders To establish the availability and position of a workpiece
C-50
Exercise 6: Actuation of a stacking magazine Name: Fundamentals: Representation of limit switches Date: Sheet 3 of 6
Limit switches can be actuated in different ways, via the function of a normally closed or normally open contact or changeover switch and, in the normal position of the system, can be either actuated or unactuated. Describe the appropriate design or function of the symbols shown.
Description: Design/ function Roller actuated limit switch with normally closed function, unactuated Symbol
2 1
Roller actuated limit switch with normally open function, unactuated
4 1
C-51
One possibility of recording the allocated contacts of a relay is by means of listing these in a logic element table. Create the logic element table for the relays K6 and K9.
+24 V 12 K5 11 12 K1 11 14 10 14 12 K6 11 11 14 12 K2 11 12 14 12 K7 11 13 14 12 K4 11 14 14 12 K8 11 15 14 12 K3 11 16 14 12 K9 11 17 14 32 K6 31 18 34 32 K7 31 19 34 ...
22 K9
24 21 A1
22 K6
24 21 A1
22 K7
24 21 A1
22 K8
24 21 A1
32 K9
34 31
32 K8
34 31
K6 A2 ... 0V
K7 A2
K8 A2
K9 A2
1M1
2M1
Logic elementtable K6
Description: Logic element table
1 Normally open contact in current path 11 1 Normally open contact in current path 12 1 Normally open contact in current path 18
11 12 18
K9 1 Normally open contact in current path 17 1 Normally closed contact in current path 10 1 Normally closed contact in current path 18
10 17 18
C-52
Another method of recording the allocated contact sets of a relay can be seen in the electrical circuit diagram below.
+24 V 1 21 NA EMERGENCY 22 STOP 2 3 4 5 6 7 8 9 10 12 K11 11 12 14 12 K6 11 12 K1 11 14 11 11 13 14 12 14 12 K7 11 14 12 K4 11 16 14 12 K8 11 17 14 12 K3 11 18 14 12 K9 11 19 14 22 K1 21 20 24 12 K10 11 21 14 32 K6 31 22 34 32 K7 31 23 34 32 K8 31 24 34 11 14 25 22 K11 21 26 34 22 K3 31 21 24 27 32 K11 31 34
1B1
1B2
2B1
2B2 S1 Start
13 14
12 K5
32 K9
24
22 K10
24 21
22 K6
24 21 A1
22 K7
24 21 A1
22 K8
24 21 A1
22 K9
24 21 A1
42 K7
44 41
42 K8
44 41
42 K9
44 41
32 K10
34 31
A1 K11 A2 0V
11 21 31 41
A1 K1 A2 K2
A1 K3 A2
A1 K4 A2
A1 K5 A2
A1 K6 A2
A1 K7 A2
1M1
2M1
2M2
1M2
K8 A2 A2
K9 A2
K10 A2 1A1+ 2A1+ 2A11A1-
12 14 .11 22 24 .25 32 34 .27 42 44
11 21 31 41
12 14 .12 22 24 .20 32 34 42 44
11 21 31 41
12 14 .14 22 24 32 34 42 44
11 21 31 41
12 14 .18 22 24 .27 32 34 42 44
11 21 31 41
12 14 .16 11 22 24 32 34 42 44 21 31 41
12 14 .12 22 24 32 34 42 44
11 21 31 41
12 14 .13 22 24 .14 32 34 .22 42 44
11 21 31 41
12 14 .15 22 24 .16 32 34 .23 42 44 .22
11 21 31 41
12 14 .17 22 24 .18 32 34 .24 42 44 .23
11 21 31 41
12 14 .19 22 24 .20 32 34 .26 42 44 .24
11 21 31 41
12 14 .21 22 24 .12 32 34 .26 42 44
C-53
Exercise 6: Actuation of a stacking magazine Name: Fundamentals Date: Sheet 6 of 6
Complete the information regarding the relays shown by: Indicating the current path in which the respective contact is used. Specifying the function fulfilled by the contact set (normally open or normally closed contact).
Relay Current path Function: Normally open contact Function: Normally closed contact
Relay K9
Current path 19 Current path 20 Current path 24 Current path 26
X X X X X X X
Relay K10
Current path 12 Current path 21 Current path 26
C-54
Design the pneumatic and electrical circuit diagrams.

1A1 1B2
1V2
1V3
2 1V1 1M1 5 1 3 4 2
1M2
C-55
+24 V
13 S1 14
2 1B2
4 1
12 K1
14 11
12 K2
14 11
A1 K1 A2 0V
11 21 31 41
A1 K2 A2 1M1 1M2
12 14 .3 22 24 32 34 42 44
11 21 31 41
12 14 .4 22 24 32 34 42 44
C-56
Exercise 6: Ansteuerung eines Schachtmagazins Name: Process description Date: Sheet 1 of 1
Initial position Cylinder 1A1 is in the retracted and position in the initial position. Steps 1-2 Actuation of pushbutton S1 (normally open contact) causes the relay K1 to be energised; the changeover contact K1 (connected in the form of a normally open contact) closes and the solenoid coil 1M1 of the 5/2-way double solenoid valve 1V1 is energised. The valve 1V1 reverses. The rear chamber of the cylinder 1A1 is filled with compressed air whilst the front chamber is exhausted. The cylinder 1A1 advances. If pushbutton S1 (normally open contact) is no longer actuated, the relay K1 is deenergised and the changeover switch K1 (connected in the form of a normally open contact) opens. This also causes the coil 1M1 to be de-energised. Steps 2-3 Once the cylinder has reached its forward end position, the piston rod actuates the electrical limit switch 1B2. The changeover switch 1B2 (connected in the form of a normally open contact) closes and the relay K2 is energised. The changeover contact K2 (connected in the form of a normally open contact) closes and the solenoid coil 1M2 is energised. The valve 1V1 reverses into the initial position again. The front chamber of the cylinder 1A1 is filled with compressed air whilst the rear chamber is exhausted. The cylinder returns into the retracted end position again. As soon as the electrical limits switch 1B2 is no longer actuated (changeover contact, connected in the form of a normally open contact), the relay K2 is deenergises and the changeover contact K2 (connected in the form of a normally open contact) opens. This also causes the coil 1M2 to be de-energised.
C-57
Exercise 6: Actuation of a stacking magazine Name: Compiling the equipment list Date: Sheet 1 of 1
Quantity 1 2 1 1 1 2 1 1 1 1 Description Cylinder, double-acting One-way flow control valve 5/2-way double solenoid valve Pushbutton (normally open contact) Limit switch (normally open contact) Relay Manifold Start-up valve with filter control valve Compressed air supply Power supply unit 24 V DC
Equipment list
C-58
Exercise 7: Sorting of packages Solutions
Exercise 7: Sorting of packages Name: Fundamentals: Calculation of piston force Date: Sheet 1 of 3
The piston of a double-acting cylinder is of a diameter of 20 mm and the piston rod of a diameter of 8 mm. The frictional losses within the cylinder are 10 %. Calculate the effective piston force in the advance and return stroke at an operating pressure of 6 bar (600 kPa).
To be calculated Advance stroke Return stroke Solution F = 188 N F = 158 N
C-59
Exercise 7: Sorting of packages Name: Fundamentals: Calculation of electrical characteristic values Date: Sheet 2 of 3
A relay of an electropneumatic circuit is designated as follows: 580 , 1 W Calculate the permissible operating voltage which ensures that no overload occurs on the relay.
To be calculated Max. Operating voltage Solution approach A maximum operating voltage of 24 volts is calculated on the basis of the formula
P = V I = I2 R =
V2 R
C-60
Exercise 7: Sorting of packages Name: Fundamentals Date: Sheet 3 of 3
Triggering of the advancing movement of a cylinder piston rod is to be achieved by means of two pushbuttons S1 and S2. The valve coil 1M1 is energised if both pushbuttons are actuated simultaneously and the solenoid valve 1V1 switches into the actuated position causing the piston rod to advance. If at least one of the pushbuttons is released, the valve switches into the initial position and the piston rod retracts. Create an appropriate function table and the logic symbol. Note 0 means: Pushbutton not actuated, i.e. piston rod not advancing 1 means: Pushbutton actuated, i.e. piston rod advances
S1 0 (not actuated) 0 (not actuated) 1 (actuated) 1 (actuated) S2 0 (not actuated) 1 (actuated) 0 (not actuated) 1 (actuated) 1M1 0 (not actuated) 0 (not actuated) 0 (not actuated) 1 (actuated) 1V1 0 (not actuated) 0 (not actuated) 0 (not actuated) 1 (actuated)
Function table
S1 S2
&
1M1
Logic symbol
C-61
Exercise 7: Sorting of packages Name: Completing the pneumatic and electrical circuit diagrams Date: Sheet 1 of 2

1A1 1B1 1B2
1V2
1V3
2 1V1 1M1 5 1 3 4 2
1M2
C-62
Exercise 7: Sorting of packages Name: Completing the pneumatic and electrical circuit diagrams Date: Sheet 2 of 2
+24 V
13 S1 14 1B1
4 1
2 1 B2
4 1
12 K1
14 11
12 K3
14 11
12 K2
14 11
A1 K1 A2 0V
11 21 31 41
A1 K2 A2 K3 1M1 1M2
12 14 .4 22 24 32 34 42 44
11 21 31 41
12 14 .4 22 24 32 34 42 44
11 21 31 41
12 14 .5 22 24 32 34 42 44
C-63
Exercise 7: Sorting of packages Name: Process description Date: Sheet 1 of 1
Initial position The cylinder 1A1 is in the retracted end position in the initial position. If the cylinder is in the retracted end position, then the electrical limit switch 1B1 is actuated (changeover contact, connected in the form of a normally open contact) and the changeover switch 1B1 closed and the relay K2 energised. Steps 1-2 Actuation of pushbutton S1 (normally open contact) causes the relay K1 to be energise. The changeover contact K1 (in the form of a normally open contact) closes and the solenoid coil 1M1 of the 5/2-way double solenoid valve 1V1 is energised. The double solenoid valve 1V1 reverses. The piston end of cylinder 1A1 is filled with compressed air whilst the piston rod end is exhausted and cylinder 1A1 advances. As soon as the cylinder 1A1 moves out of the retracted end position, limit switch 1B1 is no longer actuated and the changeover switch 1B1 opens. This causes the normally open contact K2 to open and the solenoid coil 1M1 to be no longer energised. However the double solenoid valve still remains in the righthand switching position. Steps 2-3 Once the cylinder reaches its forward end position, the piston rod actuates the electrical limit switch 1B2 (changeover contact, connected in the form of a normally open contact). The changeover switch 1B2 closes and the relay K3 is energised. The closing of the changeover contact K3 (connected in the form of a normally open contact), also causes the solenoid coil 1M2 to be energised. The valve 1V1 reverses. The piston rod chamber of cylinder 1A1 is filled with compressed air whilst the piston end is exhausted. The cylinder moves into the retracted end position again. As soon as the electrical limit switch 1B2 is no longer actuated (changeover contact, connected in the form of a normally open contact), the relay K3 is de-energised and the changeover contact K3 (connected in the form of a normally open contact) opens. This also causes the coil 1M2 to be de-energised. The cylinder remains in the retracted end position.
C-64
Exercise 7: Sorting of packages Name: Compiling the equipment list Date: Sheet 1 of 1
Quantity 1 2 1 1 2 3 1 1 1 1 Description Cylinder, double-acting One-way flow control valve 5/2-way double solenoid valve Pushbutton (normally open contact) Limit switch (normally open contact) Relay Manifold Start-up valve with filter control valve Compressed air supply Power supply unit 24 V DC
Equipment list
C-65
C-66
Exercise 8: Actuation of a sliding platform Solutions
Exercise 8: Actuation of a sliding platform Name: Fundamentals: Signal storage Date: Sheet 1 of 3
The actuation of the pushbutton must be stored if the piston rod of a double-acting cylinder is to advance even if the pushbutton is only briefly actuated. This signal storage can be effected either in the power section or in the signal control section of a circuit. Describe how signal storage is devised in the power section or signal control section respectively.
Place of signal storage Signal storage in the power section Description: Signal storage A double solenoid valve is to be used for signal storage. Owing to the static friction of the valve piston, the double solenoid valve maintains its switching position even when the corresponding solenoid coil is no longer energised. Signal storage in the signal control section By means of a spring-return solenoid valve with self-latching loop . The relay coil is energised and a contact closes. Once the ON pushbutton is released, current continues to flow through the coil via the closed contact. The relay remains in the actuated position and therefore also the spring-returned solenoid valve. Actuation of an OFF pushbutton causes the current to be interrupted. Depending on the configuration of the two pushbuttons, differentiation is made between dominant setting or dominant resetting self-latching loops.
C-67
Exercise 8: Actuation of a sliding platform Name: Fundamentals: Analysing circuits Date: Sheet 2 of 3
Describe the behaviour of the circuit specified (pilot actuated, spring-return 5/2way solenoid valve with manual override, double-acting cylinder) in the event of Power failure Pressure failure Pressure and power failure.
Power failure The spring-return solenoid valve switches into the normal position, the double-acting cylinder moves into the retracted end position. The solenoid valve and consequently the cylinder can be switched manually using the manual override. Pressure failure The solenoid valve switches into the normal position due to the reduced operating pressure, the double-acting cylinder is without pressure and assumes an undefined position.
C-68
Exercise 8: Actuation of a sliding platform Name: Fundamentals: Logic functions Date: Sheet 3 of 3
The lamp P1 is to be illuminated whenever pushbutton S1 is not actuated. Draw up the appropriate function table and the logic symbol. Note 0 means: Pushbutton S1 not actuated, i.e. lamp P1 off 1 means: Pushbutton S1 actuated, i.e. lamp P1 illuminated
S1 0 (not actuated) 1 (actuated) P1 1 (actuated) 0 (not actuated)
Function table
S2
P1
Logic symbol
C-69

1A1
1V2
1V3
2 1V1 1M1 5 1 3 4 2
C-70
+24 V
13 S1 14
12 K1
14 11
22 K1
24 21
31 S2 32
A1 K1 A2 0V
11 21 31 41
1M1
12 14 .2 22 24 .3 32 34 42 44
C-71
Exercise 8: Actuation of a sliding platform Name: Process description Date: Sheet 1 of 1
Initial position Cylinder 1A1 is in the retracted end position in the initial position. Steps 1-2 Actuation of pushbutton S1 (normally open contact) causes the relay K1 to be energised; the changeover contact K1 (connected in the form of a normally open contact) in current path 2 closes and activates the self-latching loop of relay K1. In addition, the changeover contact K1 in current path 3 closes and the solenoid coil 1M1 of the 5/2-way solenoid valve 1V1 is energised. The valve 1V1 reverses. The piston end of cylinder 1A1 is then filled with compressed air whilst the piston rod side is exhausted. Cylinder 1A1 advances. Steps 2-3 Actuation of pushbutton S2 (normally closed contact) cancels the self-latching loop of relay K1. The changeover contact K1 (connected in the form of a normally open contact) in current path 3 opens and the relay K1 is de-energised. The valve 1V1 reverses via the return spring. The piston rod end of cylinder is filled with compressed air whilst the piston end is exhausted. the cylinder returns into the retracted end position.
C-72
Exercise 8: Actuation of a sliding platform Name: Compiling the equipment list Date: Sheet 1 of 1
Quantity 1 2 1 1 1 1 1 1 1 1 Description Cylinder, double-acting One-way flow control valve 5/2-way solenoid valve Pushbutton (normally open contact) Pushbutton (normally closed contact) Relay Manifold Start-up valve with filter control valve Compressed air supply Power supply unit 24 V DC
Equipment list
C-73
C-74
Exercise 9: Expanding a diverting device Solutions
A latching relay circuit is required in order to store a signal in the signal control section. The relay coil is to be energised by pressing pushbutton S1. Complete the electrical circuit diagram below so that the relay latches after the pushbutton S1 is released.
+24 V 1 2
13 S1 14
12 K1
14 11
A1 K1 A2 0V
11 21 31 41
12 14 .2 22 24 32 34 42 44
C-75
An additional normally closed contact is required in order to cancel a set latching circuit. Differentiation is made between two groups depending on the configuration of this normally closed contact: Dominant setting self-latching loop Dominant resetting self-latching loop Complete the electrical circuit diagram so that the self-latching loop is reliably cancelled via the actuation of a pushbutton S2.
+24 V 1 2 +24 V 1 12 13 S1 14 12 K1 11 S1 31 S2 32 14 13 S2 32 14 K1 11 31 2 14
A1 K1 A2 0V
11 21 31 41
A1 K1 A2 0V
11 21 31 41
12 14 .2 22 24 32 34 42 44
12 14 .2 22 24 32 34 42 44
Electrical circuit diagram; left: Dominant resetting self-latching loop; right: Dominant setting self-latching loop
C-76
Exercise 9: Expansion of a diverting device Name: Fundamentals: Latching circuits Date: Sheet 3 of 4
The various circuits for signal storage exhibit different behaviour: with simultaneously applicable set and reset conditions in the event of power failure or cable fracture Complete the table and enter the behaviour of the respective valve. Valve position unchanged/valve is actuated/valve switches to normal position
Signal storage via double solenoid valve Signal storage via electrical latching circuit combined with spring-return valve Dominant setting Valve is actuated Dominant resetting Valve switches to normal position Valve switches to normal position
Set and reset signal shared
Valve position unchanged Valve position unchanged
Power failure
Valve switches to normal position
C-77
Exercise 9: Expansion of a diverting device Name: Fundamentals: Limit switches and proximity sensors Date: Sheet 4 of 4
The function of limit switches and proximity sensors is to acquire information and to transmit this for signal processing. These include: Mechanical position switches (limit switches), magnetic proximity sensors (reed switches), optical proximity sensors, capacitive proximity sensors, inductive proximity sensors Allocate the designations to the corresponding symbols in the table.
Designation Magnetic proximity sensor (reed switch) Symbol
BN BK BU
Optical proximity sensor
BN BK BU
Inductive proximity sensor
BN BK BU
Mechanical position switch (limit switch)

2 4 1
Capacitive proximity sensor
BN BK BU
C-78
Exercise 9: Expansion of a diverting device Name: Completing the pneumatic and electrical circuit diagrams Date: Sheet 1 of 2

1B1 1A1 1B2
1V2
1V3
2 1V1 1M1 5 1 3 4 2
1M2
C-79
Exercise 9: Expansion of a diverting device Name: Completing the pneumatic and electrical circuit diagrams Date: Sheet 2 of 2
+24 V
13 S1 14
12 K1
14 11
1B1
BN BK BU
1B2
BN BK BU
12 K2
14 11
12 K3
14 11
22 K1
24 21
31 S2 32
A1 K1 A2 0V
11 21 31 41
A1 K2 A2 K3
A1 1M1 A2 1M2
12 14 .2 22 24 .7 32 34 42 44
11 21 31 41
12 14 .7 22 24 32 34 42 44
11 21 31 41
12 14 .8 22 24 32 34 42 44
C-80
Exercise 9: Exansion of a diverting device Name: Process description Date: Sheet 1 of 2
Initial position Cylinder 1A1 is in the retracted end position in the initial position. If cylinder 1A1 is in the retracted end position, then the proximity sensor 1B1 is actuated, and the relay K2 is energised; the changeover contact K2 (connected in the form of a normally open contact) in current path 7 closes. Steps 1-2 Actuation of pushbutton S1 (normally open contact) causes the relay K1 to be energised; the changeover contact K1 (connected in the form of a normally open contact) in current path 2 closes and activates the self-latching loop of relay K1. In addition the changeover contact K1 (connected in the form of a normally open contact in current path 7 closes and the solenoid coil 1M1 of the 5/2-way double solenoid valve 1V1 is energised. The double solenoid valve 1V1 reverses. The rear chamber of the cylinder 1A1 is now filled with compressed air whilst the front chamber is exhausted. Cylinder 1A1 advances. As soon as the cylinder 1A1 moves out of the retracted end position, proximity sensor 1B1 is no longer actuated. This also causes the changeover contact K2 (connected in the form of a normally open contact) in current path 7 to open and current no longer flows through the solenoid coil 1M1. The double solenoid valve nevertheless remains in the righthand switching position. Steps 2-n The proximity sensor 1B2 is actuated when the cylinder reaches the forward end position and the relay K3 is energised. The changeover contact K3 (connected in the form of a normally open contact) in current path 8 closes and the solenoid coil 1M2 is energised. This causes the valve 1V1 to return into the initial position and the cylinder 1A1 to return into the retracted end position. The relay K3 is de-energised as soon as proximity sensor 1B2 is no longer actuated; the changeover contact K3 (connected in the form of a normally open contact) in current path 8 opens, causing the coil 1M2 to be de-energised. Since the electrical latching circuit of relay K1 is still active, the solenoid coil 1M1 receives another switching pulse as soon as the retracted end position is reached so that the cylinder 1A1 immediately advances again.
C-81
Exercise 9: Expanding a diverting device Name: Process description Date: Sheet 2 of 2
Step n-(n+1) The oscillating movement of cylinders 1A1 can be interrupted by means of pressing pushbutton S2 (normally closed contact), thereby cancelling the self-latching loop of relay K1. The cylinder moves into the retracted end position and remains there.
C-82
Exercise 9: Expanding a diverting device Name: Compiling the equipment list Date: Sheet 1 of 1
Quantity 1 2 2 1 1 1 3 1 1 1 1 Description Cylinder, double-acting One-way flow control valve Proximity sensor, electronic 5/2-way double solenoid valve Pushbutton (normally open contact) Pushbutton (normally closed contact) Relay Manifold Start-up valve with filter control valve Compressed air supply Power supply unit 24 V DC
Equipment list
C-83
C-84
Exercise 10: Designing a stamping device Solutions
In contrast with limit switches proximity sensors are switched contactlessly and without an external mechanical actuating force. Describe the design and function of a magnetic proximity sensor (reed switch).
Description: Design and function Reed switches are magnetically actuated proximity sensors, which consist of two contact blades located inside an inert gas filled glass tube. The effect of a magnet causes the two blade contacts to be closed thereby enabling an electrical current to flow. In the case of reed switches in the form of normally closed contacts, the contact blades are pretensioned by means of small magnets. This pretension is overcome by a much stronger switching magnet. Reed switches have a long service live and minimal switching time (approx. 0.2 ms). They are maintenance-free, but must not be used in areas subject to strong magnetic fields, (e.g. in the proximity of resistance welders). Symbol Schematic representation
C-85
As regards polarity there are two different designs of electronic proximity sensors, i.e. PNP or NPN Describe the differences between these two types.
PNP In the case of negative switching sensors a supply voltage is applied at the output in the absence of a part within the response range of the sensor. The approaching of a workpiece or machine part causes the output to switch to 0V voltage. NPN In the case of positive switching sensors, zero voltage is applied at the output in the absence of a part within the response range of the sensor. The approaching of a workpiece or machine part causes the output to switch so that supply voltage is applied.
C-86
Exercise 10: Designing a stamping device Name: Fundamentals: Pressure switches Date: Sheet 3 of 5
Pressure sensitive sensors, so-called PE converters, are used to monitor pressure in a system. Describe the mode of operation of a PE converter.
Description of mode of operation With a PE converter, a pneumatic pressure signal switches an electrical signal generator (generally in the form of a changeover switch); consequently a pneumatic input signal is output as an electrical signal. If the switching pressure is adjustable, this is known as a pressure sensor.
C-87
Exercise 10: Designing a stamping device Name: Fundamentals: Pressure sensor Date: Sheet 4 of 5
Pressure sensors can be divided into two groups whereby differentiation is made between: Pressure sensors with mechanical contact (mechanical principle of action) Pressure sensors with electronic switching (electronic principle of action) Describe the purpose and function of the pressure sensor shown below.
Description: Purpose and function Pressure sensors are used in order to generate an electrical output signal at a defined pressure. With this mechanically operating pressure sensor, the pressure acts on a piston surface. The piston moves, if the force resulting from the pressure exceeds the spring force, and actuates the changeover contact. The switching pressure can be set by pretensioning the spring, hence this pressure sensor is knows as a pressure switch. Symbol Schematic representation
C-88
Exercise 10: Designing a stamping device Name: Fundamentals: Choice of proximity sensors Date: Sheet 5 of 5
The end positions of a drive cylinder are to be sensed by means of proximity sensors. The following requirements apply regarding the proximity sensors: The end positions of the piston rod are to be sensed contactlessly The proximity sensors are to be insensitive to dust The piston rod and trip cam of the cylinder are made of metal Choose which proximity sensors meet the specified requirements and explain your reasons for this.
Proximity sensor Inductive proximity sensor or magnetic proximity sensor Reason Both proximity sensors operate contactlessly and without mechanical actuation. Both proximity sensors are insensitive to dirt. Since the trip cam is made of metal, both inductive as well as magnetic proximity sensors are feasible.
C-89

1B1 1A1 1B2
1V2 1B3 p
1V3
2 1V1 1M1 5 1 3 4 2
1M2
C-90
+24 V
1B1
BN BK BU
1B2 BN BK BU
1B3 p
BN BK BU S1
13 14 12 K1 11 14
12 K2
14 11
12 K3
14 11
A1 K1 A2 0V
11 21 31 41
A1 K2 A2 K3
A1 1M1 A2 1M2
12 14 .7 22 24 32 34 42 44
11 21 31 41
12 14 .8 22 24 32 34 42 44
11 21 31 41
12 14 .8 22 24 32 34 42 44
C-91
Exercise 10: Designing a stamping device Name: Process description Date: Sheet 1 of 1
Initial position Cylinder 1A1 is in the retracted end position in the initial position. The proximity sensor 1B1 is actuated if the cylinder 1A1 is in the retracted end position. This causes the relay K1 to be energised and the changeover contact K1 (connected in the form of a normally open contact) in current path 7 to be closed. Steps 1-2 Actuation of pushbutton S1 (normally open contact) causes the solenoid coil 1M1 of the 5/2-way double solenoid valve 1V1 to be energised. The double solenoid valve 1V1 reverses and cylinder 1A1 advances. As soon as the cylinder 1A1 moves out of the retracted end position, the proximity sensor 1B1 is no longer actuated. This causes the changeover contact K1 (connected in the form of a normally open contact) in current path 7 to open and the solenoid coil 1M1 is no longer currentcarrying. The double solenoid coil nevertheless remains in the righthand switching position. Steps 2-3 When the cylinder reaches the forward end position, the proximity sensor 1B2 is actuated and the relay K2 energised. The changeover contact K2 (connected in the form of a normally open contact) in current path 8 closes. In the meantime, the pressure sensor 1B3 measures the pressure applied at cylinder 1A1. The pressure sensor (programmed as a normally open contact) switches if the pressure is identical or greater than the set required value and the relay K3 is energised; the changeover contact K3 (connected in the form of a normally open contact) in current path 8 closes and the solenoid coil 1M2 is now energised. This causes the valve 1V1 to reverse and the cylinder 1A1 to move into the retracted end position. As soon as the proximity sensor 1B2 is no longer actuated, the relay K2 is deenergised and the changeover contact K2 (connected in the form of a normally open contact) opens. The pressure sensor (programmed as normally open contact) switches off if the set required value is not met and the relay K3 is de-energised; the changeover contact K3 (connected in the form of a normally open contact) in current path 8 opens thereby also causing the coil 1M2 to be de-energised.
C-92
Exercise 10: Designing a stamping device Name: Compiling the equipment list Date: Sheet 1 of 1
Quantity 1 2 2 1 1 1 3 1 1 1 1 Description Cylinder, double-acting One-way flow control valve Proximity sensor, electronic 5/2-way double solenoid valve Pressure sensor Pushbutton (normally open contact) Relay Manifold Start-up valve with filter control valve Compressed air supply Power supply unit 24 V DC
Equipment list
C-93
C-94
Exercise 11: Realising a pallet loading station Solutions
Exercise 11: Realising a pallet loading station Name: Fundamentals: Designing the displacement-step diagram Date: Sheet 1 of 3
Design the displacement-step diagram for the problem definition described.

S1
1 1
4=1
1A1
0
1B2
2B2
2A1
0
C-95
Design the pneumatic and electrical circuit diagrams for the pallet loading station.
1A1 1B2 2A1 2B2
1V2
1V3
2V2
2 1V1 1M1 5 1 3 4 2
2 2V1 1M2 2M1
1 2
C-96
Exercise 11: Realising a pallet loading station Name: Completing the pneumatic and electrical circuit diagrams
+24 V 1 3 5
Date: Sheet 2 of 2
6 7 8
1B2
BN BK BU
2B2
BN BK BU S1
13 14
12 K3
14 11
12 K2
14 11
12 K1
14 11
A1 K1 A2 0V
11 21 31 41
A1 K2 A2 K3
A1 1M1 A2 1M2 2M1
12 14 .8 22 24 32 34 42 44
11 21 31 41
12 14 .7 22 24 32 34 42 44
11 21 31 41
12 14 .6 22 24 32 34 42 44
C-97
Exercise 11: Realising a pallet loading station Name: Process description Date: Sheet 1 of 1
Initial position Cylinders 1A1 and 2A1 are in the retracted end position in the initial position. Steps 1-2 Actuation of pushbutton S1(normally open contact) causes the relay K3 to be energised. The changeover contact K3 (connected in the form of a normally open contact) closes and the solenoid coil 1M1 of the 5/2-way double solenoid coil 1V1 is energised. The double solenoid valve 1V1 reverses and the cylinder 1A1 advances. As soon as pushbutton S1 (normally open contact) is no longer actuated, the relay K3 is de-energised and the changeover contact K3 (connected in the form of a normally open contact) opens. Consequently, the coil 1M1 is also de-energised. Steps 2-3 As soon as the cylinder 1A1 reaches the forward end position, the proximity sensor 1B2 switches and the relay K1 is energised. The changeover contact K1 (connected in the form of a normally open contact) in current path 8 closes and the solenoid coil 2M1 of the 3/2-way solenoid valve 2V1 is energised. The valve 2V1 reverses and the cylinder 2A1 advances. Steps 3-4 The proximity sensor 2B2 is actuated when the cylinder 2A1 reaches the forward end position and the relay K2 is energised. The changeover contact K2 (connected in the form of a normally open contact) in current path 7 closes. The solenoid coil 1M2 is now energised, thereby causing the valve 1V1 to reverse and the cylinder 1A1 to move into the retracted end position. Relay K1 is de-energised as soon as the cylinder 1A1 moves out of the forward end position. The normally open contact K1 in current path 8 opens and the solenoid coil 2M1 is de-energised. The return spring switches the valve 2V1 into the initial position again and the cylinder 2A1 moves into the retracted end position.
C-98
Exercise 11: Realising a pallet loading station Name: Compiling the equipment list Date: Sheet 1 of 1
Quantity 1 1 3 1 1 2 1 3 1 1 1 1 Description Cylinder, double-acting Cylinder, single-acting One-way flow control valve 5/2-way double solenoid valve 3/2-way solenoid valve Proximity sensor, electronic Pushbutton (normally open contact) Relay Manifold Start-up valve with filter control valve Compressed air supply Power supply unit 24 V DC
Equipment list
C-99
C-100
Exercise 12: Eliminating a fault on the pallet loading station Solutions
Exercise 12: Eliminating a fault on the pallet loading station Name: Fault finding in simple electropneuamtic circuits Date: Sheet 1 of 4
The following fault occurs in the circuit shown below: The piston rod of cylinder 1A1 and the piston rod of cylinder 2A1 advance and remain in the forward end position. Describe what the potential cause of the fault could be.
1A1 1B2 2A1 2B2
1V2
1V3
2V2
2 1V1 1M1 5 1 3 4 2
2 2V1 1M2 2M1
1 2
C-101
Exercise 12: Eliminating a fault in the pallet loading station Name: Fault finding in simple electropneumatic circuits
+24 V 1 3 5
Date: Sheet 2 of 4
6 7 8
1B2
BN BK BU
2B2
BN BK BU S1
13 14
12 K3
14 11
12 K2
14 11
12 K1
14 11
A1 K1 A2 0V
11 21 31 41
A1 K2 A2 K3
A1 1M1 A2 1M2 2M1
12 14 .8 22 24 32 34 42 44
11 21 31 41
12 14 .7 22 24 32 34 42 44
11 21 31 41
12 14 .6 22 24 32 34 42 44
List of potential causes of faults Sensor 2B2 at cylinder 2A1 maldjusted, sensor faulty Line interruption in current path 3 (e.g. cable break or loose connection) Line interruption in signal line of sensor 2B2, current path 4(e.g. cable break or loose connection) Line interruption in earthing wire of 1M2, current path 7 (e.g. cable break or loose connection), valve coil 1M2 faulty Line interruption in earthing wire of relay K2, current path 4 (e.g. cable break or loose contact), relay K2 faulty Line interruption in current path 7, supply line of relay contact 14 (relay K2) or supply line of relay contact 11 (relay K2) after valve coil 1M2 (e.g. cable break or loose contact)
C-102
Exercise 12: Eliminating a fault in the pallet loading station Name: Fault finding in simple electropneumatic circuits Date: Sheet 3 of 4
A cable break occurs at the points marked in the circuit shown below. Describe what the effects of a cable break at these respective points are on the functioning of the circuit.
+24 V 1 2 3 4 5 6 7 8
1B2
BN BK BU
2B2 BN BK BU S1
13 14
12 K3
14 11
12 K2
14 11
12 K1
14 11
A1 K1 A2 0V
11 21 31 41
A1 K2 A2 K3
A1 1M1 A2 1M2 2M1
12 14 .8 22 24 32 34 42 44
11 21 31 41
12 14 .7 22 24 32 34 42 44
11 21 31 41
12 14 .6 22 24 32 34 42 44
C-103
Exercise 12: Eliminating a fault in the pallet loading station Name: Fault finding in simple electropneumatic circuits Date: Sheet 4 of 4
Fault Break in earthing wire of relay K1, current path 2
Effect of fault Piston rod of cylinder 1A1 advances, sensor 1B2 is actuated => Relay K1 is not energised => Relay contact in current path 8 (changeover contact, connected in the form of normally open contact) does not switch => Piston rod of cylinder 2A1 does not move into the forward end position (remains retracted), sensor 2B2 is not actuated => Piston rod of cylinder 1A1 remains advanced since 1M2 is not actuated.
Break in signal wire of sensor 2B2, current path 4
Piston rod of cylinder 1A1 advances, sensor 1B2 is actuated => Piston rod of cylinder2A1 moves into the forward end position, sensor 2B2 is actuated => Relay K2 is not energised => Relay contact in current path 7 (changeover contact, connected in the form of a normally open contact) does not switch => Piston rod of 1A1 and piston rod of cylinder 2A1 remain advanced. Current path 5 is not closed, relay K3 is not energised, no reaction in response to start signal => Piston rod of cylinder 1A1 and piston rod of cylinder 2A1 remain retracted. Piston rod of cylinder 1A1 advances, sensor 1B2 is actuated => Piston rod of cylinder 2A1 moves into the forward end position, sensor 2B2 is actuated => Relay K2 is energised, relay contact in current path 7 (changeover contact, connected in the form of a normally open contact) switches, but valve coil 1M2 is not energised due to cable break => Piston rod of cylinder 1A1 and piston rod of cylinder 2A1 remain advanced. Piston rod of cylinder 1A1 advances => Sensor 1B2 is actuated => Relay K1is energised, relay contact in current path 8 (changeover contact, connected in the form of a normally open contact) switches, but valve coil 2M1 is not energised due to cable break => Piston rod of cylinder 2A1 remains retracted, piston rod of 1A1 remains advanced.
Break in supply line of relay K3, current path 5 Break in supply line of relay contact 14 (relay K2), current path 7
Break in earthing wire 2M1, current path 8
C-104
Exercise 12: Eliminating a fault in the pallet loading station Name: List of faults Date: Sheet 1 of 1
Simulation of faults Displace sensor 1B2 on cylinder 1A1 in the retracted end position direction
Cause of fault Sensor 1B2 at cylinder 1A1 maladjusted
Effect of fault Piston rod of cylinder 1A1 advances, sensor 1B2 is briefly actuated => Piston rod of cylinder 2A1 does not move up to the forward end position, sensor 2B2 is not actuated => Piston rod of cylinder 1A1 remains advanced since 1M2 is not actuated.
Remove sensor 1B2 signal line or displace sensor at forward end position Remove sensor 2B2 signal line or displace sensor at forward end position
Cable break in signal line of sensor 1B2, or sensor maladjusted Cable break in signal line of sensor 2B2, or sensor maladjusted
Piston rod of cylinder 1A1 advances => No sensor signal, i.e. sensor 1B2 is not actuated => Piston rod of cylinder 2A1 remains retracted, piston rod of cylinder 1A1 remains advanced. Piston rod of cylinder 1A1 advances, sensor 1B2 is actuated => Piston rod of cylinder 2A1 advances into the forward end position, no sensor signal, i.e. sensor 2B2 is not actuated => Piston rod of cylinder 1A1 and piston rod of cylinder 2A1 remain advanced. Piston rod of cylinder 1A1 advances => Piston rod of cylinder 2A1 remains retracted since current path 2 or current path 8 is interrupted.
Interrupt current path 2 (e.g. earthing wire of relay K1, signal line or current path 8, e.g. supply lines of relay contact 14 or relay contact 11 (relay K1), remove earthing wire of 2M1 Interrupt earthing wire of relay K2, current path 4 or current path 7, or remove relay K2 or supply lines of relay contact 14 or relay contact 11 (relays K2), earthing wire of 1M2 Interrupt earthing wire of relay K3, current path 5 or current path 6 Remove 1M1 or K3 or supply line of relay contact 14 at K3
Cable break in earthing wire of 2M1, K1 or supply lines of relay contact 14/11 (relay K1)
Cable break in earthing wire of 1M2, K2 or supply lines of relay contact 14/11 (relay K2)
Piston rod of cylinder 1A1 and piston rod of cylinder 2A1 advance and remain in the forward end position.
Cable break in earthing wire 1M1, K3 or supply line of relay contact 14 at K3
No reaction to start signal => Piston rod of cylinder 1A1 and piston rod of cylinder 2A1 remain retracted.
C-105
Exercise 12: Eliminating a fault in the pallet loading station Name: Notes for the trainer Date: Sheet 1 of 1
Notes for the trainer It is advisable to deal with this exercise after solving exercise 11 of TP 201, since the correct configuration of circuit will then be available and in tested form. The fault can be directly built into the circuit by the trainer (see list of simulation of faults). It is important to make sure that trainees proceed systematically during fault finding. Alternative If the circuit of exercise 11 is not available fully assembled, it is also possible to carry out the fault finding theoretically: The trainer explains the fault (cylinder 1A1 advances, the circuit then comes to a stop.) Trainees then localise the fault with the help of the function chart. Trainees draw up a list of potential causes of faults and describe how they proceed during the fault finding (where do you need to measure, what needs to be checked).
C-106
Part D Appendix
Organiser __________________________________________________________ D-2 Assembly technology ________________________________________________ D-3 Plastic tubing_______________________________________________________ D-4 Data sheets Single-acting cylinder _____________________________________________ 152887 Double-acting cylinder ____________________________________________ 152888 Manifold________________________________________________________ 152896 Relay, 3 off______________________________________________________ 162241 Signal input plate, electrical ________________________________________ 162242 Proximity sensor, optical __________________________________________ 178577 Limit switch, electrical, actuated from the left__________________________ 183322 Limit switch, electrical, actuated from the right ________________________ 183345 Pressure sensor with display _______________________________________ 539757 One-way flow control valve_________________________________________ 539773 2 x 3/2-way solenoid valve with LED, normally closed ___________________ 539776 5/2-way solenoid valve with LED ____________________________________ 539777 5/2-way double solenoid valve with LED______________________________ 539778 Start-up valve with filter control valve ________________________________ 540691 Proximity sensor, electronic, with cylinder mounting ____________________ 540695
D-1
Organiser
Equipment set in the organiser All components of the equipment set for the technology package TP201 are stored in an organiser within a 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 14parallel T-slots, 50 mm apart. 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 disc and T-head bolts, vertical or 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 plate either lengthwise or diagonally to the slot. Once the desired locking disc position is set, the device is mounted on the profile plate. By turning the knurled nut in a clockwise direction, the T-head bolt is 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 using 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 Outer diameterr Inner diameter Minimum bending radius within temperature range of -35 to +60C Maximum operating pressure within temperature range of -35 to +30C within temperature range of +30 to +40C within temperature range of +40 to +60C Subject to change 10 bar (1000 kPa) 9 bar (900 kPa) 7 bar (700 kPa) Silver metallic 4 mm 2.6 mm
17 mm
D-4
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 Operating pressure max. Piston diameter Max. stroke length Thrust at 600 kPa (6 bar) Spring return force min. Connection Compressed air, filtered (lubricated or unlubricated) Piston cylinder 1000 kPa (10 bar) 20 mm 50 mm 139 N 13.6 N QS-G1/8-4 fittings for plastic tubing PUN 4 x 0.75
Festo Didactic GmbH & Co. KG, 07/2005
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 Operating pressure max. Piston diameter Max. stroke length Thrust at 600 kPa (6 bar) Return force at 600 kPa (6 bar) Connection Compressed air, filtered (lubricated or unlubricated) Piston cylinder 1000 kPa (10 bar) 20 mm 100 mm 189 N 158 N 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
162241
Relay, 3-off
A1
12 14
22 24
32 34
42 44
A2 A1
11 12 14
21 22 24
31 32 34
41 42 44
A2 A1
11 12 14
21 22 24
31 32 34
41 42 44
A2
11
21
31
41
Design
This component consists of three relays with connections and two bus-bars for the power supply. All electrical connections are in the form of 4 mm sockets. The unit can be mounted in a mounting frame or on the profile plate using four plug-in adapters.
Subject to change
1/4
162241
Relay, 3-off
1 4 5
A1 A2
4 2
Function
The relay consists of a coil with a core (1) and winding (3) with connection lugs (7), an armature (4), a return spring (2) and a contact assembly with four changeover contacts (5) and connection lugs (6). When power is applied to the coil connections, current flows through the winding, creating a magnetic field. The armature is pulled onto the coil core and the contact assembly is actuated. Electrical circuits are opened or closed via this assembly. When the electrical current is removed, the magnetic field collapses and the armature and contact assembly are returned to their original position by a return spring.
Note
The switching status of the relays is indicated by LEDs, which are protected against incorrect polarity. The four changeover contacts of the contact assembly can be used as normally-open contacts (1), normally-closed contacts (2) or changeover contacts (3).
2/4
Subject to change
162241
Relay, 3-off
+24 V
13 S1 14
12 K1
14 11
A1 K1 A2 0V
11 21 31 41
1M1
12 14 .2 22 24 32 34 42 44
Example of application: Circuit diagram, electrical
+24 V
+24 V
A1 K1 A2
12
14 K1 11
A1 A2
12
14
11
Changeover switch connected as normally-open contact
Changeover switch connected as normally-closed contact
Normally-open contacts, normally-closed contacts: Allocation of contacts on relay plate
Subject to change
3/4
162241
Relay, 3-off
Technical data
Electrical Voltage Contact assembly Contact rating Contact interrupt rating Pichup time Drop-off time Connections Electromagnetic compatibility Emitted interference Noise immunity tested to EN 500 81-1 tested to EN 500 82-1 24 V DC 4 changeover contacts Max. 5 A Max. 90 W 10 ms 8 ms For 4 mm safety connector plug
4/4
Subject to change
162242
Signal input plate, electrical
13
23
31
41
14 13
24 23
32 31
42 41
14 13
24 23
32 31
42 41
14
24
32
42
Design
This component consists of two illuminated pushbuttons in the form of momentarycontact switches and one illuminated pushbutton in the form of a detented switch. All electrical connections are in the form of 4 mm safety connectors. The unit can be mounted in a mounting frame or on the profile plate using four plug-in adapters.
Function
The illuminated pushbutton in the form of a detented switch consists of a contact assembly with two normally-open contacts and two normally-closed contacts, together with a colourless transparent pushbutton cap with a miniature lamp. The contact assembly is actuated by pressing this cap. Electrical circuits are opened or closed via the contact assembly. When the cap is released, the switching status is maintained. The contact assembly is returned to its initial position by pressing the pushbutton a second time. The illuminated pushbuttons in the form of momentary-contact switches consist of a contact assembly with two normally-open contacts and two normally-closed contacts, together with a colourless transparent pushbutton cap with a miniature lamp. The contact assembly is actuated by pressing this cap. Electrical circuits are opened or closed via the contact assembly. When the cap is released, the contact assembly returns to its initial position.
Subject to change
1/2
162242
Signal input plate, electrical
Note
When power is applied to the connections of the visual indicator, the switching status is displayed by the built-in miniature lamp in the pushbuttons.
+24 V
13 S1 14
12 K1
14 11
A1 K1 A2 0V
11 21 31 41
1M1
12 14 .2 22 24 32 34 42 44
Example: Circuit diagram, electrical
Technical data
Electrical Voltage Contact assembly Contact rating Power consumption (miniature lamp) Connections Electromagnetic compatibility 24 V DC 2 normally-open contacts, 2 normally-closed contacts Max. 1 A 0.48 W For 4 mm safety connector plug
Emitted interference Noise immunity
tested to EN 500 81-1 tested to EN 500 82-1
2/2
Subject to change
178577
Design
The optical proximity sensor with LED and electrical connections is assembled on a polymer assembly base. The electrical connection is effected by means of safety connectors or via a 3-pin plug socket. The unit is mounted on the profile plate via a quick release detent system with blue triple grip nut (mounting alternative B).
Function
Optical proximity sensors consist of two main modules, the emitter and the receiver. In the case of diffuse sensor, these are built into one housing. The emitter of the diffuse sensor emits a pulsating, red light which is within the visible spectral range. The object to be detected reflects part of the light emitted. This light is detected by a semiconductor device in the receiver which is also built into the sensor housing and causes a change in the switching status. The object to be detected may be reflective, matt, transparent or opaque. All that is needed is for a sufficiently high proportion of light to be reflected directly or diffusely. The operational switching distance may be varied by means of a potentiometer. The proximity sensor has a PNP output, i.e. the signal line is switched to the positive potential in the switched status. The switch is designed as a normally closed contact. The connection of the load takes place between the signal output of the proximity sensor and the load. The switching status is indicated by a yellow LED. The sensor is protected against polarity reversal, overload and short circuit.
Subject to change
1/2
178577
+24V-
BN + BK BU
S
Note The correct polarity of the applied voltage is necessary for proper functioning. The connections for the operating voltage are colour coded as follows: red for positive, blue for negative and black for the signal output. The load is connected to the switching output and the negative terminal of the current supply.
Technical Data
Electrical Switching voltage Residual ripple Nominal switching distance Switching frequency Output function Output current Protection class Connections Cable Electromagnetic compatibility 10 30 V DC maximum 10% 0 to 100 mm (adjustable) maximum 200 Hz Normally open contact, positive switching maximum 100 mA IP65 for 4 mm safety connector plug or 3-pin socket with 4 mm safety connector plug
Eitted interference Noise immunity
2/2
Subject to change
183322
Limit switch, electrical, actuated from the left
4 1
The two electrical limit switches, order no. 183322 for actuation from the left and order no. 183345 for actuation from the right, have the same symbol in the circuit diagram.
Design
A microswitch with roller lever and electrical connections is installed in a plastic housing. The electrical connection is effected by means of safety connectors or via a 3-pin plug socket. The component is mounted on the profile plate using the rotary system by means of two blue grip nuts (mounting variant B).
Function
This electrical limit switch consists of a mechanically-actuated microswitch. It is actuated when the roller lever is pressed, for example by the trip cam of a cylinder. The switch contacts are used to open or close a circuit. The microswitch returns to its original position when the roller lever is released.
Subject to change
1/2
183322
Limit switch, electrical, actuated from the left
Note
The microswitch can be connected up to act as a normally-open contact (1), normally-closed contact (2) or changeover contact (3). In cases where piston speeds are high, the limit switch should be actuated by the trip cam of a cylinder only in the specified direction. The limit switch must not be actuated from the front.
Technical data
Electrical Design Mechanically-actuated electrical microswitch in limit-switch housing 24 V DC Max. 5 A Max. 200 Hz 0.2 mm 2.7 mm 5N For 4 mm safety connector plug or 3-pin plug socket
Voltage Contact rating Switching frequency Reproducible switching accuracy Switch travel Actuation force Connection Electromagnetic compatibility
2/2
Subject to change
183345
Limit switch, electrical, actuated from the right
4 1
The two electrical limit switches, order no. 183322 for actuation from the left and order no. 183345 for actuation from the right, have the same symbol in the circuit diagram.
Design
A microswitch with roller lever and electrical connections is installed in a plastic housing. The electrical connection is effected by means of safety connectors or via a 3-pin plug socket. The component is mounted on the profile plate using the rotary system by means of two blue grip nuts (mounting variant B).
Function
This electrical limit switch consists of a mechanically-actuated microswitch. It is actuated when the roller lever is pressed, for example by the trip cam of a cylinder. The switch contacts are used to open or close a circuit. The microswitch returns to its original position when the roller lever is released.
Subject to change
1/2
183345
Limit switch, electrical, actuated from the right
Note
The microswitch can be connected up to act as a normally-open contact (1), normally-closed contact (2) or changeover contact (3). In cases where piston speeds are high, the limit switch should be actuated by the trip cam of a cylinder only in the specified direction. The limit switch must not be actuated from the front.
Technical data
Electrical Design Mechanically-actuated electrical microswitch in limit-switch housing 24 V DC Max. 5 A Max. 200 Hz 0.2 mm 2.7 mm 5N For 4 mm safety connector plug or 3-pin plug socket
Voltage Contact rating Switching frequency Reproducible switching accuracy Switch travel Actuation force Connection Electromagnetic compatibility
2/2
Subject to change
539757
Pressure sensor with display
Design
The pressure sensor with display is screwed onto the adapter plate plate. The unit is attached via the grid system with the blue lever (assembly variant A).
Function
The pressure sensor is a piezoresistive relative pressure transducer with integrated amplifier and built-in temperature compensation. The pressure to be measured is transferred onto a silicone coated piezoresistive element. The signal change generated therein is output as a voltage or switching signal at the connector plug via an intergrated amplifer.
Subject to change
1/2
539757
Pressure sensor with display
+24V-
BN p BU BK
Note
The polarity of the applied voltage is to be observed for the correct functioning of the device. The connections for the operating voltage are to be identified by colour: Red for positive and blue for negative. The signal output is black. The load is to be connected to the switch output and to the negative pole of the power supply.
Technical data
Electrics Switching voltage Residual ripple Operating pressure Analogue output Output function Switching current Protection class Connection Cable Electromagnetic compatibility Emitted interference Noise immunity Tested to EN 500 81-1 Tested to EN 500 82-1 15 30V DC Max. 10% 0 to 10 bar (0 to 1000 kPa) 0 to 10 V Normally open contact, positive switching Max. 150 mA IP65 Plug M8x1 With 4 mm jack plug
2/2
Subject to change
539773
One-way flow control valve
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 Design Pressure range Standard nominal flow rate Compressed air, filtered, (lubricated or unlubricated) One-way flow control valve 20 to 1000 kPa (0.2 to 10 bar) in throttled direction: free flow direction: 0 110 l/min 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
1/1
539776
2 x 3/2-way solenoid valve with LED, normally closed
2 1M1
1M1
Design
This 3/2-way single solenoid valve with push-in fittings is attached to a function plate which is equipped with a P port and silencer. The two electrical connections are equipped with safety connectors. The unit is mounted on the profile plate using a quick release detent system with a blue lever (mounting alternative "A").
Function
The solenoid valve is reversed when voltage is applied to the solenoid coil (1 2) and brought back into its initial position (1 0) by a return spring when the signal is removed. The switching status is displayed via an LED in the terminal housing. The valve is equipped with a manual override.
Note
The solenoid coil is characterised by very low power consumption and low heat generation. The electrical connection incorporates protection against incorrect polarity for the LED and a protective circuit.
Subject to change
1/2
539776
2 x 3/2-way solenoid valve with LED, normally closed
Technical Data
Pneumatic Medium Design Pressure range Switching time at 600 kPa (6 bar) Compressed air, filtered (lubricated or unlubricated) Spool valve, pilot-actuated, with return spring 300 to 800 kPa (3 to 8 bar) On: 20 ms Off: 33 ms 1000 l/min QS 3 for plastic tubing PUN 4 x 0.75
Standard nominal flow rate Connection
Electrical Voltage Duty cycle Protection class Connection 24 V DC 100 % IP65 M8x1 central plug, cable with socket and 4 mm safety plugs
2/2
Subject to change
539777
5/2-way single solenoid valve with LED
4 1M1 5 1M1 1
Design
This 5/2-way single solenoid valve with push-in fittings is bolted onto a function plate which is equipped with a P port and silencer. The two electrical connections are equipped with safety connectors. The unit is mounted on the profile plate using a snap-lock system with a blue lever (mounting variant "A").
Function
The solenoid valve is reversed when voltage is applied to the solenoid coil (1 4) and brought back into its initial position (1 2) by a return spring when the signal is removed. The switching status is shown by an LED in the terminal housing. The valve is equipped with a manual override.
Note
The solenoid coil is characterised by very low power consumption and low heat generation. The electrical connection incorporates protection against incorrect polarity for the LED and a protective circuit.
Subject to change
1/2
539777
5/2-way single solenoid valve with LED
Technical Data
Pneumatic Medium Design Pressure range Switching time at 600 kPa (6 bar) Compressed air, filtered (lubricated or unlubricated) Spool valve, pilot-actuated, with return spring 300 to 800 kPa (3 to 8 bar) On: 25 ms OFF: 40 ms 1000 l/min QS-1/8-4-I fittings for plastic tubing PUN 4 x 0.75
Standard nominal flow rate Connection
2/2
Subject to change
539778
5/2-way double solenoid valve with LED
4 1M1 5 1M1 1M2 1
2 1M2 3
Design
This 5/2-way double solenoid valve with push-in fitting is bolted onto a function plate which is equipped with a P port and silencer. The four electrical connections are equipped with safety connectors. The unit is mounted on the profile plate using a snap-lock system with a blue lever (mounting variant "A").
Function
The double solenoid valve is reversed when voltage is applied to a solenoid coil and remains in this switching position after the signal is removed until an opposed signal is applied. The presence of switching signals is shown by the LEDs in the terminal housings. The valve is equipped with a manual override.
Note
The solenoid coil is characterised by very low power consumption and low heat generation. The electrical connections incorporate protection against incorrect polarity for the LEDs and protective circuits.
Subject to change
1/2
539778
5/2-way double solenoid valve with LED
Technical Data
Pneumatic Medium Design Pressure range Switching time at 600 kPa (6 bar) Standard nominal flow rate Connection Compressed air, filtered (lubricated or unlubricated) Spool valve, pilot-actuated 300 to 800 kPa (3 to 8 bar) 15 ms 1000 l/min 3 QS-1/8-4-I fittings for plastic tubing PUN 4 x 0.75
2/2
Subject to change
540691
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
Note
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.
Technical Data
Pneumatic Medium Design Assembly position Standard nominal flow rate * Upstream pressure Operating pressure Connection Compressed air Sintered filter with water separator, diaphragm control valve Vertical 5 110 l/min 100 to 1000 kPa (1 to 10 bar) 50 to 700 kPa (0.5 to 7 bar) 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
540695
Proximity sensor, electronic, with cylinder mounting
Design
The proximity sensor consists of the sensor, mounting kit and cable . The cable is equipped with a socket and three jack plugs.
Function
This proximity sensor emits an electrical signal when approaching a magnetic field (e.g. permanent magnet on a cylinder piston). The electrical connections are moulded into the cable. The switching status is indicated via an LED. The yellow LED is illuminated when actuated.
+24V-
BN + BK BU
Note
The polarity of the applied voltage is to be observed for the correct functioning of the device. The wires inside the socket cable must therefore be allocated by colour: Red (BN) for positive, blue (BU) for negative and black (BK) for the signal output. In this case, the load (relay) is connected to the sensor and to the negative pole. The switch is protected against reverse polarity but not against short circuit.
Subject to change
1/2
540695
Proximity sensor, electronic, with cylinder mounting
Technical data
Electrics Switching voltage Switching current Switching accuracy Switching time 10 to 30 V DC Max. 200 mA 0.1 mm On: 0.5 ms Off: 0.5 ms M 8x1 plug socket for socket with cable With 4 mm jack plug
Connection Cable Electromagnetic compatibility Emitted interference Noise immunity
Tested to EN 500 81-1 Tested to EN 500 82-1
2/2
Subject to change

Elektropneumatika Seminari

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541090 EN 04/05

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

541090 04/2005 M. Pany, S. Scharf Frank Ebel Doris Schwarzenberger 09/2005

Festo Didactic GmbH & Co. KG 541090

Festo Didactic GmbH & Co. KG 541090

Festo Didactic GmbH & Co. KG 541090

Festo Didactic GmbH & Co. KG 541090

Festo Didactic GmbH & Co. KG 541090

Festo Didactic GmbH & Co. KG 541090

Festo Didactic GmbH & Co. KG 541090

Notes on safety and operation

Festo Didactic GmbH & Co. KG 541090

Notes on safety and operation

Festo Didactic GmbH & Co. KG 541090

Technology package for electropneumatics (TP200)

Important elements of TP200

Festo Didactic GmbH & Co. KG 541090

Technology package for electropneumatics (TP200)

Festo Didactic GmbH & Co. KG 541090

Training aims of Basic Level (TP201)

Festo Didactic GmbH & Co. KG 541090

Training aims of Basic Level (TP201)

Festo Didactic GmbH & Co. KG 541090

Allocation of training aims and exercises

Festo Didactic GmbH & Co. KG 541090

Allocation of training aims and exercises

Festo Didactic GmbH & Co. KG 541090

Equipment set Basic Level (TP201)

Festo Didactic GmbH & Co. KG 541090

Equipment set Basic Level (TP201)

Equipment set symbols

Description Relay, 3-off

Festo Didactic GmbH & Co. KG 541090

Equipment set Basic Level (TP201)

Description 5/2-way solenoid valve

5/2-way double solenoid valve

4 1M1 5 1M1 1M2 1

Proximity sensor, electronic

Proximity sensor, optical

Limit switch, electrical

One-way flow control valve

Festo Didactic GmbH & Co. KG 541090

Equipment set Basic Level (TP201)

Description Single-acting cylinder

Start-up valve with filter control valve

Festo Didactic GmbH & Co. KG 541090

Allocation of equipment and exercises

Festo Didactic GmbH & Co. KG 541090

Allocation of equipment and exercises

Festo Didactic GmbH & Co. KG 541090

Methodological help for the trainer

Festo Didactic GmbH & Co. KG 541090

Methodological help for the trainer

Festo Didactic GmbH & Co. KG 541090

Methodological structure of the exercises

Festo Didactic GmbH & Co. KG 541090

Festo Didactic GmbH & Co. KG 541090

Contents of the CD-ROM

FluidSIM circuit diagrams

Festo Didactic GmbH & Co. KG 541090

Contents of the CD-ROM

Festo Didactic GmbH & Co. KG 541090

Equipment set Advanced Level (TP202)

Festo Didactic GmbH & Co. KG 541090