Documente Academic
Documente Profesional
Documente Cultură
Basic level
Workbook
TP 101
With CD-ROM
1A1
1B1
1Z1
1Z2
1V3
2
1V2
14
1V1
1
12
2
1
1S1
1V4
1B1
1S2
Festo Didactic
541088 en
Order no.
Status:
Authors:
Editor:
Graphics:
Layout:
541088
03/2012
W. Haring, M. Metzger, R.-C. Weber
Frank Ebel
Doris Schwarzenberger
03/2012
Festo Didactic GmbH & Co. KG, D-73770 Denkendorf, Germany, 2013
Internet: www.festo-didactic.com
E-mail: did@de.festo.com
The purchaser shall receive a single right of use which is non-exclusive, non-time-limited and limited
geographically to use at the purchaser's site/location as follows.
The purchaser shall be entitled to use the work to train his/her staff at the purchaser's site/location and
shall also be entitled to use parts of the copyright material as the basis for the production of his/her own
training documentation for the training of his/her staff at the purchaser's site/location with
acknowledgement of source and to make copies for this purpose. In the case of schools/technical colleges
and training centres, the right of use shall also include use by school and college students and trainees at
the purchaser's site/location for teaching purposes.
The right of use shall in all cases exclude the right to publish the copyright material or to make this available
for use on intranet, Internet and LMS platforms and databases such as Moodle, which allow access by a
wide variety of users, including those outside of the purchaser's site/location.
Entitlement to other rights relating to reproductions, copies, adaptations, translations, microfilming and
transfer to and storage and processing in electronic systems, no matter whether in whole or in part, shall
require the prior consent of Festo Didactic GmbH & Co. KG.
Table of contents
Preface _________________________________________________________________________________ V
Introduction ____________________________________________________________________________ VII
Technology module for pneumatics (TP100) ____________________________________________________X
Learning objectives for the basic level (TP101) _________________________________________________ XI
Overview of learning objectives per exercise __________________________________________________ XII
Equipment set for the basic level (TP101) ____________________________________________________ XIV
Allocation of equipment per exercise _______________________________________________________ XVIII
Practical tools for the trainer _______________________________________________________________ XIX
Structure of the exercises _________________________________________________________________ XIX
Designations of the components____________________________________________________________ XIX
CD ROM contents ________________________________________________________________________ XX
Equipment set for the advanced level (TP102) ________________________________________________ XXII
Learning objectives for the advanced level (TP102)____________________________________________ XXIII
Solutions
Exercise 1: Pressing cheeses _________________________________________________________________1
Exercise 2: Opening a fodder silo _____________________________________________________________9
Exercise 3: Clamping boards to a saw bench __________________________________________________ 15
Exercise 4: Sorting packages _______________________________________________________________ 21
Exercise 5: Stopping milk bottles ___________________________________________________________ 31
Exercise 6: Opening and closing a pipeline ___________________________________________________ 37
Exercise 7: Shutting off a pipeline ___________________________________________________________ 45
Exercise 8: Actuating a shut-off device _______________________________________________________ 51
Exercise 9: Expanding the control system for pressing cheeses ___________________________________ 59
Exercise 10: Clamping a workpiece __________________________________________________________ 65
Exercise 11: Loading wire baskets __________________________________________________________ 73
Exercise 12: Actuating a sliding door ________________________________________________________ 79
Exercise 13: Feeding wooden boards ________________________________________________________ 87
Exercise 14: Compacting beverage cans ______________________________________________________ 93
Exercise 15: Packaging of brochures ________________________________________________________ 99
Exercise 16: Mounting locking pins_________________________________________________________ 105
Exercise 17: Labelling paint pots___________________________________________________________ 111
Exercise 18: Cleaning workpieces __________________________________________________________ 117
Exercise 19: Pressing labels into place ______________________________________________________ 123
III
IV
Preface
Festo Didactics training system for automation and technology is geared towards various educational
backgrounds and vocational requirements. The training packages are therefore broken down as follows:
Basic modules impart basic, interdisciplinary, technological knowledge.
Technology modules address the important topics of open and closed-loop control technology.
Function modules explain the fundamental functions of automated systems.
Application modules enable training and further education that is aligned with real-life practice.
The technology modules deal with various technologies including pneumatics, electro-pneumatics,
programmable logic control systems, automation using a personal computer, hydraulics, electrohydraulics,
proportional hydraulics, sensor technology, electric drives and applications technology (handling).
The modular design of the training system makes it possible to focus on applications above and beyond
those covered in the individual modules, such as, for example, PLC actuation of pneumatic, hydraulic and
electric drives.
All training modules have the same structure:
Hardware
Teachware
Software
Seminars
The hardware is comprised of industrial components and systems that are specially designed for training
purposes.
The structure of the teachware corresponds to that of the training hardware. It includes:
Textbooks (with exercises and examples)
Workbooks (with practical exercises, supplementary instructions and solutions)
Transparencies and videos (for dynamic instruction)
The working materials for TP101 consist of 19 exercises and a workbook. Each exercise has its own set of
ready-to-use worksheets. The solutions are included in the workbook, which also has the worksheets and a CD
ROM. The exercises can be purchased without the workbook and are used as consumables. They can thus be
easily made available to trainees. Data sheets for the hardware components are made available along with the
training module and on the CD ROM.
The teaching and learning media are available in several languages. Theyre intended for use in classroom
instruction, but are also suitable for self-study.
Where software is concerned, computer training programs and programming software are made available
for programmable logic controllers.
A wide range of seminars covering the contents of the technology module round off the programme for
training and further education.
VI
Introduction
This workbook is part of the training system for automation and technology from Festo Didactic GmbH & Co.
KG. The system provides a solid basis for practical training and further education. The TP100 technology
module only includes pneumatic control systems.
The TP101 basic level is suitable for basic training in the field of pneumatic control technology. It covers the
fundamentals of pneumatics as well as the function and use of pneumatic equipment. The equipment can be
used to set up simple pneumatic control systems.
The TP102 advanced level comprises vocational training in the field of pneumatic control technology. The
equipment can be used to set up extensive combinatory circuits with linking of the input and output signals
as well as control systems with stepper modules.
A permanent workstation equipped with a Festo Didactic profile plate is a prerequisite for setting up the
control systems. The profile plate has 14 parallel T-slots at 50 mm intervals. A portable compressor with
silencer (230 V, max. 8 bar = 800 kPa) can be used for compressed air supply.
Working pressure should not exceed 6 bar (600 kPa).
Ideal control sequence reliability can be achieved by operating the control system at a working pressure of 5
bar (500 kPa) without oil.
All the control systems for the 19 exercises are set up using the equipment set for the TP101 basic level. The
theoretical fundamentals for understanding this series of exercises are included in the textbook:
Data sheets for the individual components are also available (cylinders, valves, measuring instruments etc.).
VII
General
Trainees should only work with the control systems under the supervision of a trainer.
Observe specifications included in the data sheets for the individual components and in particular all
safety instructions!
Mechanical
Mount all the components securely onto the profile plate.
Limit switches must not be actuated frontally.
Danger of injury during troubleshooting!
Use a tool to actuate the limit switches, for example a screwdriver.
Only reach into the set-up when its at a complete standstill.
Electrical
Electrical connections must only be established and interrupted in the absence of voltage!
Only use connector cables with safety plugs for electrical connections.
Only use low-voltage (max. 24 V DC).
Pneumatics
Do not exceed the maximum permissible pressure of 6 bar (600 kPa).
Do not switch on the compressed air until all of the tubing connections have been completed and
secured.
Do not disconnect tubing while under pressure.
Danger of injury when switching compressed air on!
Cylinders may advance and retract automatically.
Danger of accident due to tubing slipping off!
Use shortest possible tubing connections.
Wear safety glasses.
In the event that tubing slips off:
Switch compressed air supply off immediately.
Pneumatic circuit set-up:
Connect the components using plastic tubing with an outside diameter of 4 or 6 mm. Push the tubing
into the push-in connector as far as it will go.
Switch compressed air supply off before dismantling the circuit.
Dismantling the pneumatic circuit:
Press the blue release ring down, after which the tubing can be pulled out.
VIII
The mounting boards for the components are equipped with mounting variant A, B or C:
Variant A, snap-in system
Lightweight components that are not load-bearing (e.g. directional control valves). Simply clip the
components into the slot on the profile plate. Release the component from the slot by actuating the blue
lever.
Variant B, bolt-on system
Components with medium load capacity (e.g. actuators). These are clamped onto the profile plate using
T-head bolts. The blue knurled nut is used for clamping and loosening.
Variant C, screw system
For components with high load capacity and components that are seldom removed from the profile plate (for
example on-off valve with filter regulator). These components are secured with socket head screws and
T-head bolts.
Observe specifications in the data sheets regarding the individual components.
A stopwatch is required in order to evaluate the control systems once they have been set up. The stopwatch is
used to:
Adjust the one-way flow control valves so that the cylinder stroke times comply with the specified
values
Adjust time delay valves
IX
Workbooks
Optional teachware
Seminars
P100
P111
P121
P-OP
P-NEU
IW-PEP
Repair and maintenance in the field of control technology pneumatic and electropneumatic systems
P-AL
P-AZUBI
Please refer to the current seminar planner for locations, dates and prices.
Youll find further training materials in our catalogue and on the Internet. The training system for automation
and technology is continuously updated and expanded. Transparencies, videos, CD ROMs and DVDs, as well
as textbooks, are offered in several languages.
Become familiar with the set-up and mode of operation of a single-acting cylinder.
Become familiar with the set-up and mode of operation of a 3/2-way valve.
Be able to recognise and sketch the various types of actuation for directional control valves.
Be able to explain and set up direct actuation.
Be able to analyse and evaluate circuits.
Become familiar with the set-up and mode of operation of a double-acting cylinder.
Become familiar with the set-up and mode of operation of a 5/2-way valve.
Be able to explain and set up indirect actuation.
Become familiar with the mode of operation of a 5/2-way valve with pneumatic actuation.
Become familiar with the difference between a signalling element and a control element.
Be able to measure pressure in pneumatic control systems.
Be able to differentiate between the various types of flow control and use them in accordance with
specifications.
Be able to adjust cylinder advancing and retracting speeds.
Become familiar with one type of signal storage in pneumatic control systems.
Be able to explain and implement AND/OR/NOT logic operations.
Be able to explain and set up latching circuits.
Become familiar with one option for end-position sensing in cylinders.
Be able to combine logic operations.
Become familiar with the set-up and mode of operation of a magnetic proximity switch.
Be able to differentiate between 5/2-way valves and to select and use them in accordance with
specifications.
Be able to further develop existing circuits.
Become familiar with the set-up and mode of operation of a pressure sequence valve.
Be able to set up pressure-dependent control systems.
Become familiar with the set-up and mode of operation of a pressure regulator.
Be able to analyse existing circuits and optimise them in accordance with specifications.
Become familiar with the set-up and mode of operation of a time delay valve.
Be able to set up circuits with oscillating motion.
Be able to use time delay valves in accordance with specific constraints.
Be able to analyse and set up circuits with two cylinders.
XI
10
11
12
13
14
15
16
17
18
19
Learning Objective
Become familiar with the set-up
and mode of operation of a
single-acting cylinder.
Become familiar with the set-up
and mode of operation of a 3/2way valve.
Be able to recognise and sketch
the various types of actuation for
directional control valves.
Be able to explain and set up
direct actuation.
Be able to analyse and evaluate
circuits.
XII
Exercise
10
11
12
13
14
15
16
17
18
19
Learning Objective
Become familiar with one type of
signal storage in pneumatic
control systems.
Be able to explain and implement
AND/OR/NOT logic operations.
latching circuits.
Become familiar with one option
XIII
XIV
Quantity
Designation
Order no.
152866
152861
152860
152863
576302
576303
152862
576307
Double-acting cylinder
152888
193967
Pressure gauge
152865
539756
152884
Single-acting cylinder
152887
540691
151496
539775
540694
539772
10
Push-in sleeve
153251
10
Push-in T-connector
153128
Distributor block
152896
539771
539770
Symbol
Pressure gauge
1
Pneumatic proximity switch
2
12
14
5
XV
Designation
Symbol
Shuttle valve
2
1
Dual-pressure valve
2
1
2
t
1
2
1
12
Single-acting cylinder
Double-acting cylinder
XVI
Designation
Symbol
1
2
Distributor block
Connectors
XVII
10
11
12
13
14
15
16
17
18
19
Equipment
Cylinder, single-acting
Cylinder, double-acting
1
1
Pressure gauge
3/2-way valve, pushbutton,
normally closed
1
2
2
1
1
normally open
3/2-way valve, selector
switch, normally closed
switch
5/2-way pneumatic valve
Shuttle valve
Dual-pressure valve
1
1
1
2
1
2
pressure gauge
Time delay valve, normally
closed
Distributor block
regulator
XVIII
XIX
CD ROM contents
The CD ROM provides you with additional media. The worksheets and solutions have been saved as PDF
files on the CD ROM that is included with the trainers manual.
The CD ROM contains the following folders:
Operating instructions
Demo
Festo catalogue
FluidSIM circuit diagrams
Industrial applications
Presentations
Product information
Videos
Operating instructions
Operating instructions for the various components included in the technology module are available. These
instructions are helpful when using and commissioning the equipment.
FluidSIM demo version
A demo version of the FluidSIM pneumatics software package is included on the CD ROM. Even this demo
version is suitable for testing control systems developed by the user.
XX
Festo catalogue
The relevant pages from the Festo catalogue will be provided with selected components. The
representations and descriptions of the components are intended to demonstrate how the components are
presented in an industrial catalogue. Additional information regarding the components is also included.
FluidSIM circuit diagrams
The FluidSIM circuit diagrams for all 19 exercises included in the technology module are contained in this
directory.
Industrial applications
Photos and graphics representing industrial applications are made available. These can be used to illustrate
individual tasks. Project presentations can also be supplemented with these illustrations.
Presentations
Contains short presentations of the components included in the technology module. These can be used, for
example, to create project presentations.
Product information
This directory contains product information and data sheets from Festo for the components included in the
technology module. This is intended to demonstrate which information and data are available for industrial
components.
Videos
Several videos of industrial applications complete the media provided with the technology module. Short
clips demonstrate the applications in their actual industrial environments.
XXI
XXII
Quantity
Designation
Order no.
152867
152860
152864
576302
576303
Double-acting cylinder
152888
193967
151496
539759
540715
152868
10
Push-in sleeve
153251
Stepper module
152886
20
Push-in T-connector
153128
152877
539771
152882
152883
XXIII
XXIV
Layout
Cheese production
Parameters
Use a double-acting cylinder.
Pneumatically control the cylinder using a manually actuated valve.
1.
2.
3.
4.
5.
6.
7.
Project assignment
Describe the mode of operation of a single-acting cylinder.
Describe the mode of operation of a normally closed 3/2-way valve.
Complete the pneumatic circuit diagram for the pressing tool.
Set up the control system.
Double-check the control system configuration.
Describe the mode of operation of the control system.
Create an equipment list.
1.
2.
3.
4.
5.
Procedure
The cheeses are placed into the tool manually.
When the pushbutton is activated, the cylinder advances and presses the cover onto the tool.
The pushbutton is pressed and held until the pressing operation has been completed.
When the pushbutton is released, the cylinder is retracted and the tool can be accessed.
The cheese can be removed.
Safety note
Limit pressure at the service unit for this exercise to a maximum of3.5 bar (350 kPa). Immediately
deactivate compressed air supply if the tubing slips off.
Compare the circuit symbol shown above with the schematic diagram of the single-acting cylinder.
Determine whether or not the two representations coincide with each other.
The two representations coincide with each other.
Match up each component with the corresponding number from the above drawing.
Component
Designation
Cylinder barrel
End cap
Bearing cap
Piston rod
Piston
Spring return
Supply port
Exhaust port
=
=
=
=
p
D
=
=
Ap
theoretical piston force (N)
effective piston surface (sq. metres)
D2
)
4
working pressure (Pa)
(
Piston force Feff is important in actual practice. Frictional resistance has to be taken into consideration when
calculating piston force. Under normal operating conditions (pressure range of 4 to 8 bar or 400 to 800 kPa),
it is assumed that friction forces (FR) amount to roughly 10% of the theoretical piston force.
The following applies to the effective piston force of single-acting cylinders:
Feff
Feff
FR
FF
=
=
=
=
A p (FR + FF)
effective piston force (N)
friction force (approx. 10% of Fth ) (N)
return spring force (N)
Calculate the effective piston force for the advance stroke of the used cylinder with a working pressure
of 6 bar (600 kPa).
A= (
0.022 3.14
) = 0.000314
4
Feff = 0.9 A p FF
Feff = 0.9 (0.000314) 600,000 13.6
Feff = 169.56 13.6 = 155.96 N
Note
TThe piston diameter of the used cylinder is 20 mm and spring return force is 13.6 N.
Complete the circuit symbol of a manually actuated, normally closed 3/2-way valve with spring return.
3
2
Complete the pneumatic circuit diagram for the control system and enter the port designations.
1A1
1S1
3
0Z2
0Z1
1
2
Sequence description
Step 1-2
When the pushbutton on 3/2-way valve 1S1 is pressed, compressed air flows into the piston chamber of
cylinder 1A1 and the piston rod is advanced.
Step 2-3
When the pushbutton is released, valve 1S1 is exhausted and cylinder 1A1 returns to its initial position
due to force applied by the return spring.
Create an equipment list by entering the required components and their quantities in the table below.
Quantity
Designation
Cylinder, single-acting
Distributor block
Equipment list
Layout
Fodder silo
Parameters
A single-acting cylinder is to be used.
The cylinder will be pneumatically controlled using a pushbutton.
1.
2.
3.
4.
5.
6.
Project assignment
Answer the questions on the normally open 3/2-way valve.
Create the pneumatic circuit diagram for controlling the slide.
Set up the control system.
Double-check the control system configuration.
Describe the mode of operation of the control system.
Create the equipment list.
Procedure
1. When the pushbutton is activated, the cylinder is retracted to the retracted end position.
2. The pushbutton is pressed and held for as long as the slide is to remain open.
3. When the pushbutton is released, the cylinder is advanced and the slide closes the opening in the silo.
Safety note
Limit pressure at the service unit to a maximum of 3.5 bar (350 kPa) for this exercise.
10
Complete the circuit symbol of the 3/2-way valve. It needs to include the following functions: manual
actuation, spring return, normally open.
2
1
3
11
Change the pneumatic circuit diagram for the control system and enter the port designations.
1A1
1S1
3
0Z2
0Z1
1
2
Circuit diagram
Note
Please note that control systems must be represented in their initial positions.
12
Sequence description
Step 1-2
If pushbutton 1S1 is activated, the piston is exhausted via the 3/2-way valve and cylinder 1A1 is
retracted.
Step 2-3
When the pushbutton is released, the spring forces the 3/2-way valve into its initial position, the piston
chamber is once again pressurised and cylinder 1A1 advances again.
Safety note
Limit pressure at the service unit for this control system to a maximum of 3.5 bar (350 kPa).
13
Change the equipment list shown below such that it corresponds with the requirements for this control
system.
Quantity
Designation
Distributor block
Tubing material
Single-acting cylinder
Equipment list
Quantity
Designation
Distributor block
Tubing material
Single-acting cylinder
Equipment list
14
Layout
Sawing fixture
15
Parameters
Use one of the control systems from the previous exercises and modify it for this task.
Use, by way of example, only one single-acting cylinder to design the control system.
1.
2.
3.
4.
5.
Project assignment
Complete the pneumatic circuit diagram for the clamping tool.
Set up the control system.
Double-check the control system configuration.
Describe the mode of operation of the control system.
Change the equipment list.
1.
2.
3.
4.
Procedure
A board is manually laid on the saw bench.
After activating a switch, the cylinder advances and clamps the board.
The cylinder remains in the advanced position, even when the switch has been released.
After turning the switch back to its initial position, the cylinder is retracted to the retracted end position,
where it remains until the switch is activated again.
Safety note
Limit pressure at the service unit to a maximum of 3.5 bar (350 kPa) for this exercise.
16
Complete the circuit diagrams shown below by entering the required type of actuation.
a)
b)
Circuit diagram
17
Sequence description
Step 1-2
When selector switch 1S1 is activated, compressed air flows into the piston chamber and the cylinder is
advanced.
Step 2-3
When the selector switch is reset, the valve is exhausted and the cylinder returns to its initial position
due to force applied by the return spring.
Safety note
Limit pressure at the service unit for this control system to a maximum of 3.5 bar (350 kPa).
18
Change the equipment list by entering the required components in the table below.
Quantity
Designation
Cylinder, single-acting
Distributor block
19
20
Layout
Sorting station
21
Parameters
A double-acting cylinder will be used, because work is carried out during both the advance and the
return strokes.
1.
2.
3.
4.
5.
6.
7.
Project assignment
Describe the set-up of a double-acting cylinder.
Describe the mode of operation of a 5/2-way valve.
Create a pneumatic circuit diagram for the package blocking slide.
Set up the control system.
Double-check the control system configuration.
Describe the mode of operation of the control system.
Create an equipment list.
Procedure
1. When the selector switch is activated, the cylinder advances and pushes the slide into the flow of
material.
2. The cylinder remains in this position after releasing the selector switch and the material flow remains
interrupted.
3. After turning the selector switch to its initial position, the cylinder moves to its retracted end position
and the material flow is resumed. The cylinder remains in this position until the selector switch is
activated again.
Safety note
Limit pressure at the service unit to a maximum of 3.5 bar (350 kPa) for this exercise.
22
Compare the circuit symbol shown above with the schematic diagram of the double-acting cylinder.
Determine whether or not the two illustrations are the same.
The two illustrations are the same.
Make a note of the characteristics of a single-acting and a double-acting cylinder designs that are the
same as well as those that are different.
Both cylinder designs include cylinder barrel, piston and piston rod.
The double-acting cylinder doesnt have a return spring.
The double-acting cylinder has 2 supply ports.
Match the numbers from the schematic drawing with the individual components of the double-acting
cylinder.
Component
Designation
Piston
Cylinder barrel
Piston rod
Bearing cap
End cap
23
Forward stroke
Compressed air flows into the cylinder through the piston chamber supply port. Pressure is built up in the
chamber and force is applied to the surface of the piston as a result. If this force exceeds static friction,
the piston is advanced. Air in the piston rod chamber escapes through the port at the piston rod end.
Pressure is not built up to full force until the piston is fully advanced.
Return stroke
After reversing, air flows through the supply port at the piston rod chamber where it builds up pressure
until the piston rod is retracted. Air escapes from the piston chamber through the piston chamber port.
24
Calculate the piston force for the advance and return strokes
Theoretical piston force is calculated using the following formula:
Fth
Ap
A'
=
=
=
p
FR
D
d
=
=
=
=
D2
)
4
(D 2 d 2 )
Calculate the effective piston force for the advance and return strokes of the cylinder with a working
pressure of 6 bar (600 kPa).
Forward stroke
Feff
Feff
Feff
=
=
=
(A p) FR
0.9 A p
0.9 0.000314 600,000
Feff
169.66 N
Return stroke
Feff
Feff
Feff
=
=
=
(A' p) FR
0.9 (0.000314 0.00005024) 600,000
0.9 0.00026376 600,000
Feff
142.4 N
Note
The piston diameter of the cylinder is 20 mm and the piston rod diameter is 8 mm.
25
Indicate why the directional control valve has to be actuated with a switch.
A switch has to be used because a pushbutton cannot be held in the activated position for as long as it
takes to replace the containers.
26
Complete the circuit symbol of a manually actuated, 5/2-way valve with spring return and locking
function, and enter the port designations.
3
5
Describe the mode of operation of a 5/2-way valve when valve port 2 is connected to the piston rod end
of a double-acting cylinder.
Mode of operation of a 5/2 way valve, unactuated
When the 5/2-way valve is not actuated, the return spring holds the valve in its initial position. The piston
rod end of the cylinder is pressurised and the piston rod is retracted.
27
1S1
3
0Z2
0Z1
1
2
28
Create an equipment list by entering the required components in the table below.
Quantity
Designation
Cylinder, double-acting
Distributor block
29
30
Layout
31
Parameters
Stopping of the material flow will be carried out at a central control panel.
As compressed air is available at the control panel, a pneumatic solution will be used.
The control valve for the cylinder will be pneumatically actuated.
Project assignment
1. Determine the requirements for the control system with regard to actuating components and the control
element.
2. Complete the pneumatic circuit diagram for stopping the material flow.
3. Set up the control system.
4. Double-check the control system configuration.
5. Describe the mode of operation of the control system.
6. Create an equipment list.
Procedure
1. When the selector switch is activated, the cylinder advances and pushes the slide into the flow of
material, thus stopping the bottles.
2. After setting the selector switch back to its initial position, the cylinder is in its retracted end position
and once again enables material flow.
3. The cylinder remains in this position until the selector switch is activated again.
Additional task
Explain the term indirect control.
32
Complete the circuit diagram shown below and enter the missing connection and component
designations.
1A1
1V1
14
5
1S1
3
0Z2
0Z1
1
2
Note
The on-off valve with filter regulator and the distributor block are not shown. These components are
required in order to set up the control system.
33
Sequence description
Explain the mode of operation of the control system by describing its operating sequence.
Initial position
The signalling element and the control element are in the position generated by the return spring.
Step 1-2
When the selector switch at the 3/2-way valve 1S1 is actuated, pneumatic control port 14 at 5/2-way
valve 1V1 is pressurised with compressed air. The 5/2-way valve is reversed as a result. The left-hand
port (piston end) of the double-acting cylinder is pressurised with compressed air, and the right-hand
port (piston rod end) is exhausted. The cylinder advances.
Step 2-3
When the selector switch is returned to its initial position, the compressed air supply to the 3/2-way
valve is blocked, the 5/2-way valve looses pressure at control port 14 and the valve piston is returned to
its initial position by the return spring. The piston end of the cylinder is thus exhausted and the piston
rod end is pressurised with compressed air. The cylinder travels to its retracted end position.
34
Create an equipment list by entering the required components in the table below.
Quantity
Designation
Cylinder, double-acting
Distributor block
35
Additional task
36
Layout
Wastewater treatment
37
Parameters
The gate must be opened and closed slowly because the pipeline would otherwise be overloaded (the
forming of waves should be avoided).
The speed of the opening and closing strokes should be steady.
1.
2.
3.
4.
5.
6.
Project assignment
Create a pneumatic circuit.
Set up the control system.
Double-check the control system configuration.
Describe the mode of operation of the control system.
Create an equipment list.
Observe pressure conditions upstream and downstream of the flow control and document them.
Procedure
1. When the selector switch is activated, the cylinder is advanced and opens the gate.
2. When the selector switch is returned to its initial position, the cylinder is retracted to its initial position
and the gate is closed.
Additional tasks
At which pressure level do you observe jerking motion?
Explain how jerking motion occurs.
Safety note
Limit pressure at the service unit to a maximum of 3.5 bar (350 kPa) for this exercise.
38
2
Circuit symbol and schematic diagram of a one-way flow control valve
Explain how a one-way flow control valve is tested for correct functioning.
A one-way flow control valve is tested for correct functioning by means of two pressure gauges. The
pressure gauges are connected directly upstream and downstream from the valve under test.
39
Complete the circuit diagram shown below. Complete the symbols for the one-way flow control valves..
Observe the specified basic conditions when doing so.
1A1
1Z2
1V1
1Z1
1S1
1V2
40
Create an equipment list by entering the required components and their quantities in the table below.
Quantity
Designation
Cylinder, double-acting
Pressure gauge
Distributor block
41
Sequence description
Step 1-2
When the 5/2-way valve is reversed, the piston chamber in the cylinder is pressurised via the one-way
flow control valve. The cylinder travels to its advanced end position.
Step 2-3
After resetting the switch, the cylinders piston rod chamber is pressurised via the one-way flow control
valve and the 5/2-way valve. The cylinder travels to its retracted end position.
The required retraction time is adjusted with the one-way flow control valve. Use a stopwatch to this end.
42
Additional tasks
43
44
Layout
45
Basic condition
Speed control should enable a smooth opening process.
1.
2.
3.
4.
5.
6.
Project assignment
Select the appropriate type of flow control.
Create a pneumatic circuit diagram for the shut-off mechanism.
Set up the control system.
Double-check the control system configuration.
Describe the mode of operation of the control system.
Create an equipment list.
Procedure
1. A gate valve is opened slowly after activating a selector switch.
2. The gate valve is closed quickly when the selector switch is returned to its initial position.
Safety note
Limit pressure at the service unit to a maximum of 3.5 bar (350 kPa) for this exercise.
46
47
Complete the circuit diagram shown below. Observe the specific constraints when doing so.
1A1
1V1
1S1
48
Create an equipment list by entering the required components and their quantities in the table below.
Quantity
Designation
Cylinder, double-acting
Distributor block
49
Sequence description
Step 1-2
When the 5/2-way valve is reversed, the piston chamber in the cylinder is pressurised with compressed
air. The piston rod chamber is exhausted via 5/2-way valve 1S1. The cylinder travels slowly to its
advanced end position. The required advancing time is adjusted with the one-way flow control valve.
Step 2-3
After resetting the switch, the cylinders piston rod chamber is pressurised via the one-way flow control
valve and the 5/2-way valve is pressurised without flow control. The piston chamber is exhausted via
5/2-way valve 1S1. The cylinder travels to its retracted end position.
Note
This control system works with exhaust air flow control. Use a stopwatch in order to set the required time
value. The setting can be secured with a lock nut.
50
Layout
51
Parameters
A double-acting cylinder will be used.
The closing operation should be executed by the cylinders forward stroke.
1.
2.
3.
4.
5.
6.
7.
Project assignment
Describe the mode of operation of a quick exhaust valve.
Describe the mode of operation of a 5/2-way double pilot valve.
Draw a pneumatic circuit diagram for the shut-off mechanism.
Set up the control system.
Double-check the control system configuration.
Describe the mode of operation of the control system.
Create an equipment list.
Procedure
1. A shut-off mechanism (ball valve) is opened slowly after activating a pushbutton.
2. The shut-off mechanism is closed quickly after activating a second pushbutton.
Safety note
Limit pressure at the service unit to a maximum of 3.5 bar (350 kPa) for this exercise.
52
2
1
53
14
12
Describe the performance of the valve depicted above when port 14 is briefly pressurised with
compressed air.
When port 14 is pressurised, the valve piston is moved to the right and directs compressed air from port
1 to port 4. Port 2 is exhausted via port 3. When port 14 is once again unpressurised, the valve position
remains in this position by compressed air from port 1.
54
1Z1
1V3
1V2
1V1
2
12
1S2
14
1S1
55
Sequence description
Step 1-2
After actuating 3/2-way valve 1S1, the 5/2-way double pilot valve is reversed and the cylinders piston
chamber is pressurised via the one-way flow control valve. The double-acting cylinder travels to its
advanced end position. The piston rod chamber is vented via the quick exhaust valve. The piston remains
in this end position, even when 1S1 is released again.
Step 2-3
The 5/2-way double pilot valve is reversed by actuating 3/2-way valve 1S2. The cylinders piston rod
chamber is pressurised via the quick exhaust valve. The cylinders piston chamber is exhausted via the
one-way flow control valve and the 5/2-way double pilot valve. The cylinder travels to its retracted end
position.
Retracting time
The required retraction time is adjusted using the one-way flow control valve. Use a stopwatch to this
end. This setting can be secured with the lock nut.
56
Create an equipment list by entering the required components to the table below.
Quantity
Designation
Cylinder, double-acting
Pressure gauge
Distributor block
57
58
Layout
Cheese production
59
Parameters
Design pneumatic control of the cylinder using an additional manually actuated valve.
Operation should be possible using either of the valves.
1.
2.
3.
4.
Project assignment
Analyse the proposed solution.
Complete the pneumatic circuit diagram for the pressing device.
Set up the control system.
Update the equipment list.
1.
2.
3.
4.
5.
Procedure
The cheeses are placed into the press manually.
After actuating a pushbutton at the loading or unloading end of the system, the cylinder advances and
presses the lid onto the press.
The pushbutton is pressed and held until the pressing operation has been completed.
When the pushbutton is released, the cylinder is retracted and the press can be accessed.
The cheese can be removed.
Safety note
Limit pressure at the service unit for this exercise to a maximum of 3.5 bar (350 kPa).
60
Analyse the control system depicted above and explain why the required piston force is not achieved.
The required piston force is not reached because part of the operating pressure escapes via the exhaust
port of the unactuated valve.
61
2
1
62
1V1
1
1S1
1S2
63
Designation
Cylinder, single-acting
Distributor block
Quantity
Designation
Cylinder, single-acting
Shuttle valve
Distributor block
64
Layout
65
Parameters
The clamping process can only be started when the cylinder is in the retracted end position.
After activating a second pushbutton, the cylinder returns to the retracted end position and releases the
workpiece.
Pressure gauges will be installed between the one-way flow control valve and each of the cylinders two
working ports in order to indicate pressure.
1.
2.
3.
4.
5.
6.
7.
Project assignment
Describe the mode of operation of a dual-pressure valve.
Describe the mode of operation of a 3/2-way roller lever valve.
Complete the pneumatic circuit.
Set up the control system.
Double-check the control system configuration.
Describe the mode of operation of the control system.
Create an equipment list.
Procedure
1. A double-acting cylinder can only be advanced when a pushbutton is activated and the cylinder is in the
retracted end position; otherwise its not possible to insert a workpiece for machining.
2. The clamping cylinder should be held in the advanced end position until the workpiece has been
machined. Machining time may vary.
3. The workpiece is released by pressing a second pushbutton.
Safety note
Limit pressure at the service unit to a maximum of 3.5 bar (350 kPa) for this exercise.
Additional task
What happens if the 3/2-way roller lever valve is readjusted?
66
2
1
1
1
67
Explain how the roller lever valve has to be mounted in order to ensure correct functioning of the control
system.
The roller lever valve must be mounted so that its actuated when the cylinder piston is in the retracted
end position. If the valve is mounted in front of or underneath the cylinder cam, the roller lever is not
actuated and the AND operation cannot be fulfilled. The control system is not started.
68
1B1
1Z1
1Z2
1V3
1V2
14
1V1
1
1S1
12
5
1B1
1V4
1S2
69
Sequence description
Step 1-2
When 3/2-way valve 1S1 is actuated, compressed air is applied to both inputs at dual-pressure valve
1V1. Compressed air is now also present at the output of the dual-pressure valve. 5/2-way double pilot
valve 1V2 is reversed by the signal at pilot port 14. The cylinder is thus also reversed and the piston
advances. 3/2-way roller lever valve 1B1 is switched to its normal position and the output signal at the
dual-pressure valve is deactivated. The cylinder is held in the advanced end position by the self-locking
loop.
Step 2-3
After activating the pushbutton at 3/2-way valve 1S2, 5/2-way double pilot valve 1V3 is reversed again
(signal at pilot port 12). The cylinders piston rod chamber is pressurised. The cylinder travels to its
retracted end position. 3/2-way roller lever valve 1B1 is actuated again.
70
Create an equipment list by entering the required components in the table below.
Quantity
Designation
Cylinder, double-acting
Pressure gauge
Distributor block
71
72
Layout
73
Parameters
Material flow will be controlled by two valves with pushbutton, one for disabling and one for enabling. Due to
the fact that the pushbutton signals are of short duration, a control system must be set up which stores the
signal.
1.
2.
3.
4.
5.
6.
1.
2.
3.
4.
74
Project assignment
Describe the mode of operation of a shuttle valve.
Complete the pneumatic circuit.
Set up the control system.
Double-check the control system configuration.
Describe the mode of operation of the control system.
Create an equipment list.
Procedure
When the pushbutton is activated, the cylinder advances and pushes the deflector into the flow of
material.
The cylinder remains in this position after the pushbutton has been released and the material flow is
diverted.
After activating the second pushbutton, the cylinder is retracted to the retracted end position and the
material flow reverts to the original supply point.
The cylinder remains in this position until the pushbutton is activated again.
Develop the required latching circuit and complete the circuit diagram shown below.
1A1
1V4
1V3
1V5
14
5
1V2
12
1
1S2
1
1V1
1
1S1
2
1
75
If the pushbutton at valve 1S1 is activated, shuttle valve 1V1 allows compressed air to flow. As valve 1S2
is normally open, the compressed air actuates input 12 at 3/2-way valve 1V2. As a result, input 14 at 5/2way valve 1V3 is also actuated. Directional control valve 1V3 is reversed, and the cylinders piston
advances. However, valve 1V2 is held in the actuated state at the same time by the return line to shuttle
valve 1V1.
When 3/2-way valve 1S2 is actuated, the self-latching loop is interrupted. Theres no longer a signal at
input 12 at valve 1V2, and the valve is switched to its normal position. Input 14 at 5/2-way valve 1V3 and
the return line to the shuttle valve are exhausted. Valve 1V3 is switched to its normal position and the
cylinder piston returns to its initial position.
In the event that pushbuttons 1S1 and 1S2 are both activated at the same time, theres no signal at the
output either. This type of control system is called an RS flip-flop.
76
Create an equipment list by entering the required components in the table below. Take all components
into consideration that are required for the set-up.
Quantity
Designation
Cylinder, double-acting
Distributor block
77
78
Layout
Sliding door
79
Parameters
Either process can only be started when the door is in one of its end positions.
Pressure must be limited to 3 bar (300 kPa) for safety reasons (danger of pinching).
1.
2.
3.
4.
5.
Project assignment
Create a pneumatic circuit diagram for the sliding doors control system.
Set up the control system.
Double-check the control system configuration.
Describe the mode of operation of the control system.
Create an equipment list.
Procedure
When the sliding door is in one of its defined end positions, it can be moved to the other end position by
pressing the pushbutton. The door can thus be opened and closed.
The opening and closing processes cannot be started as long as the door is not in one of its end positions.
Safety note
Limit pressure at the service unit to a maximum of 3 bar (300 kPa) for this exercise.
80
Additional tasks
What happens if compressed air supply fails during advance or return motion?
How can the control system be put back into operation, what must be done?
S
N
N
S
81
1V5
1V4
1B2
14
12
5
1V2
1V3
1
1V1
1S1
1B2
1S2
1B1
1V6
82
Step 1-2
If one of the two pushbuttons is activated, shuttle valve 1V1 generates an output signal. A signal is now
applied to pilot port 14 at the 5/2-way double pilot valve and the valve is switched. The cylinder
advances.
When the cylinder reaches the advanced end position, pneumatic proximity switch 1B2 is attenuated.
Step 2-3
If one of the two pushbuttons is activated, shuttle valve 1V1 generates an output signal. A signal is now
applied to pilot port 12 at the 5/2-way double pilot valve and the valve is switched. The cylinder is
retracted. When the cylinder reaches the retracted end position, pneumatic proximity switch 1B1 is
attenuated.
83
84
Create an equipment list by entering the required components in the table below.
Quantity
Designation
Cylinder, double-acting
Distributor block
Describe the consequences of a pressure failure and explain how the control system can be placed back
into service.
The door remains in its current position. It must be manually pushed into one of its end-positions in order
to restart the control system, because otherwise the start condition is not fulfilled (door is in one of its
two end-positions).
85
86
Layout
Stacking magazine
87
1.
2.
3.
4.
5.
Parameters
A roller lever valve is used to mechanically determine whether or not a board is located in the picking
area. The cylinder is throttled while advancing and retracting.
Project assignment
Complete the pneumatic circuit.
Set up the control system.
Double-check the control system configuration.
Describe the mode of operation of the control system.
Create an equipment list.
Procedure
1. The ejecting process is started by means of a pushbutton when the cylinder is in its retracted end
position. The ejecting cylinder only pushes a workpiece out of the magazine when the roller lever valve
in the picking area indicates that the picking area is NOT occupied.
2. If the picking area is empty, the cylinder advances to the advanced end position with restricted exhaust
air, pushes the workpiece out and immediately returns to its retracted end position with restricted
exhaust air.
Additional task
How would you have to change the control system if the ejecting process could only start when a workpiece
is in the magazine AND the picking area is empty?
88
1V4
1V3
1B2
14
12
5
1V2
1V1
1B1
1S1
1V5
1S2
1B2
Note
You can use a 3/2-way valve with selector switch in the control system instead of a 3/2-way roller lever
valve, if you want to simulate whether the picking area is empty or occupied.
89
Sequence description
Step 1-2
If the picking area is occupied, 3/2-way roller lever valve 1S2 is not actuated. Dual-pressure valve 1V1
does not generate an output signal and the 5/2-way double pilot valve cannot be reversed.
If the picking area is empty, 3/2-way roller lever valve 1S2 is actuated. Dual-pressure valve 1V1
generates an output signal. If the pushbutton at 3/2-way valve 1S1 is activated, dual-pressure valve 1V2
generates an output signal. A signal is applied to pilot port 14 at 5/2-way double pilot valve 1V3. The
5/2-way double pilot valve is reversed and the cylinder advances.
Step 2-3
Pneumatic proximity switch 1B2 is attenuated and switches to the free-flow direction. A signal is applied
to pilot port 12 at the 5/2-way double pilot valve. 5/2-way double pilot valve 1V3 is switched and the
cylinder travels to its retracted end position. Pneumatic limit switch 1B1 is attenuated and switches to
the free-flow direction.
Step 3-1
Same as step 1
90
Create an equipment list by entering the required components in the table below.
Quantity
Designation
Cylinder, double-acting
Distributor block
91
Explain how the control system has to be changed in order to meet this requirement.
An additional sensor will have to be connected for workpiece sensing. A suitable sensor is therefore
required (roller lever valve) as well as a dual-pressure valve (AND). An AND operation will be added for
the two sensors instead of using 3/2-way valve 1S2.
92
Layout
Can press
93
Parameters
The initial position of the compacting cylinder is the retracted end position.
The compacting process should only be started when system pressure is greater than 6 bar (600 kPa).
The return stroke can be triggered manually if the compacting cylinder does not fully reach the
advanced end position due to the quantity of cans to be compacted.
1.
2.
3.
4.
5.
Project assignment
Complete the pneumatic circuit diagram for the can press.
Set up the control system.
Double-check the control system configuration.
Describe the mode of operation of the control system.
Create an equipment list.
Procedure
1. A pressure sequence valve is switched when the specified pressure value is reached and supplies
compressed air to the control system. The control system should not be operable at a pressure of less
than 4.5 bar (450 kPa).
2. It should only be possible to start the compacting process using a start button when the compacting
cylinder is in the retracted end position. The compacting cylinder moves to the advanced end position or
as far as it can depending on the amount of material to be compacted.
3. The return stroke is triggered either by a limit switch or a pushbutton.
Note
The required protective guard is not shown.
94
12
3 2 1
12
95
1V6
1B2
2
1V5
14
12
5
1V3
3
1V4
2
1
1B1
1V7
1S1
1S2
1V2
1B2
12
1V1
96
Create an equipment list by entering the required components in the table below.
Quantity
Designation
Cylinder, double-acting
Distributor block
97
Sequence description
Set up the control system and put it into operation.
Step 1-2
The pushbutton at valve 1S1 is activated. The condition at dual-pressure valve 1V3 (AND) is changed to
TRUE as a result. 5/2-way double pilot valve 1V5 is switched to the operating position. The double-acting
cylinder advances.
Step 2-3
Pneumatic limit switch 1B2 is actuated and switches to the operating position. 5/2-way double pilot
valve 1V5 is reset by shuttle valve 1V4 (OR).
Alternatively, this process can be started using the pushbutton at valve 1S2. The 5/2-way double pilot
valve is reset by shuttle valve 1V4 (OR).
The double-acting cylinder returns to its initial position. The process is finished when pneumatic limit
switch 1B1 is actuated.
98
Layout
Brochure production
99
Parameters
The process can only be started when the clamping cylinder is in the retracted end position.
The operating pressure has to be greater than 6 bar (600 kPa) before the control system can be started up.
The return stroke is triggered manually, because the duration of the packaging process varies.
1.
2.
3.
4.
5.
Project assignment
Complete the pneumatic circuit diagram for the packaging unit.
Set up the control system.
Double-check the control system configuration.
Describe the mode of operation of the control system.
Create an equipment list.
Procedure
1. A pressure sequence valve is switched when the specified pressure value is reached and supplies
compressed air to the control system.
2. The tensioning process starts when the clamping cylinder is in the retracted end position and a
pushbutton is activated. The cylinder is advanced and remains in the advanced position.
3. The process ends when a second pushbutton is activated and the cylinder returns to the retracted end
position.
100
p1
p2
1 3
If pressure at the secondary side is increased, for example due to a load change at the cylinder, the
diaphragm is pressed against the spring and the outlet cross-section of the valve seat is reduced or
closed. The valve seat of the diaphragm is opened and compressed air is able to escape into the
atmosphere through the relief ports in the housing.
If pressure drops at the secondary side, the valve is opened by the force of the spring. Thus regulating air
pressure to the pre-selected operating pressure means that the valve seat is continuously opened and
closed, which is triggered by the volume of air that flows through. Operating pressure is indicated by a
measuring instrument.
101
1V7
1V6
1V5
1
2
1V4
14
12
5
1V3
1
1B1
1
1S1
1S2
1V2
1V1
12
102
Create an equipment list by entering the required components in the table below.
Quantity
Designation
Cylinder, double-acting
Distributor block
103
Describe the function of the one-way flow control valve which is connected in parallel to the pressure
regulator.
One-way flow control valve 1V5 functions as a bypass for the pressure regulator. The flow control is fully
closed. Compressed air can escape via the non-return valve when the cylinder is retracted, because its
unable to escape via the pressure regulator.
104
Layout
105
Parameters
Pressure at the working port of the assembly cylinder must have a value of at least 3.5 bar (350 kPa), in
order to ensure that the locking pins are securely mounted.
It should not be possible to start the process if pressure is greater than 3.8 bar (380 kPa).
The return stroke of the assembly cylinder is started automatically when it reaches the advanced end
position.
1.
2.
3.
4.
5.
1.
2.
3.
4.
Project assignment
Complete the pneumatic circuit diagram for the automated assembly machine.
Set up the control system.
Double-check the control system configuration.
Describe the mode of operation of the control system.
Create an equipment list.
Procedure
The process will be started with a pushbutton when the assembly cylinder is in the retracted end
position.
The cylinder should move to the advanced end position with minimal force.
It actuates a limit switch in this position.
It should then quickly return to the retracted end position.
Analyse the circuit diagram shown below and determine whether or not its suitable for the required task.
The circuit diagram is suitable.
What are the advantages or disadvantages of the characteristics of the required control system?
There is a danger that pressure can be incorrectly set at the pressure regulator in the supply line to the
cylinder which would result in the pins being damaged.
106
1A1
1B1
1V7
1V6
1V5
1
2
1V4
14
12
5
1V3
1
1B1
1
1S1
1S2
1V2
1V1
12
107
Complete the pneumatic circuit diagram shown below, taking all required conditions into consideration.
1A1
1B1
1V7
1B2
2
1V6
14
12
5
1V5
1V4
1V3
1V8
12
1
1V2
12
1V1
2
1B1
1S1
1B2
2
1
3
1
108
Create an equipment list by entering the required components in the table below.
Quantity
Designation
Cylinder, double-acting
Pressure regulator
Distributor block
Equipment list
109
Sequence description
Step 1-2
Pushbutton 1S1 is activated and pneumatic proximity switch 1B1 is attenuated; the condition at the first
dual-pressure valve, 1V3 (AND), thus becomes TRUE. After the pressure sequence valve has been
switched with sufficient pressure, the 3/2-way valve is switched to the operating position. The condition
at the second 2-way valve, 1V5 (AND), thus becomes TRUE and the 5/2-way double pilot valve is
switched to the operating position. The double-acting cylinder advances.
Step 2-3
Pneumatic proximity switch 1B2 is attenuated and switches to the operating position. The 5/2-way
double pilot valve is switched. The double-acting cylinder returns to its initial position. The process is
finished when pneumatic proximity switch 1B1 is attenuated.
110
Layout
Farbe rau
lichtg 35
0
RAL 7
Farbe au
lichtgr 35
RAL 70
Labelling fixture
111
Parameters
As the label has to be glued to the paint pot with minimal pressure, working pressure must be
adjustable.
The cylinder should be retracted as quickly as possible.
Working pressure must be adjustable within a range of 3 to 7 bar (300 and 700 kPa).
Pressure should be indicated by a pressure gauge upstream of the cylinder.
1.
2.
3.
4.
5.
Project assignment
Complete the pneumatic circuit.
Set up the control system.
Double-check the control system configuration.
Describe the mode of operation of the control system.
Create an equipment list.
1.
2.
3.
4.
112
Procedure
The process will be started using a pushbutton when the cylinder is in the retracted end position.
The cylinder should advance to the advanced end position with minimal force and speed and remain in
this position for an adjustable period of time.
It should then quickly return to the retracted end position.
Pressure during the forward stroke should be indicated at a pressure gauge.
Describe the mode of operation of a time delay valve and enter the most important technical data in the
table.
The time delay valves switches input pressure applied to port 1 to port 2 after the preset delay time has
expired. If the supply of compressed air is interrupted at port 1, working port 2 is once again switched to
the unpressurised state. The time delay valve is automatically reset within 200 ms. Delay time is infinitely
adjustable via an adjusting knob.
Technical data
Pressure range
Switch-on pressure
50 l/min.
Delay time
2 to 30 sec. (adjustable)
Setting accuracy
0.6 sec.
> 200 ms
113
1B2
1Z1
1V6
3
1V5
1
1V4
14
12
5
1V2
3
1V3
1
t
1V1
2
1B1
1S1
1B2
2
1
3
1
114
Create an equipment list by entering the required components in the table below.
Quantity
Designation
Cylinder, double-acting
Pressure gauge
Distributor block
Equipment list
115
Sequence description
Step 1-2
Pushbutton 1S1 is activated and pneumatic proximity switch 1B1 is attenuated; the condition at the first
dual-pressure valve, 1V2 (AND), thus becomes TRUE and 5/2-way double pilot valve 1V4 is switched to
the operating position. The double-acting cylinder is advanced with minimal pressure and with flow
control.
Step 2-3
Pneumatic proximity switch 1B2 is attenuated and switches to the operating position. Compressed air is
fed to time delay valve 1V3 as a result, which then switches through after a preset period of time. The
5/2-way double pilot valve is reset. The double-acting cylinder returns to its initial position with minimal
pressure. The piston chamber is vented via the quick exhaust valve. The process is finished when
pneumatic proximity switch 1B1 is attenuated.
116
Layout
117
Parameters
A roller lever valve will be used in order to detect the retracted end position.
The cleaning process should be limited to a period of 20 seconds.
1.
2.
3.
4.
5.
6.
Project assignment
Convert a 5/2-way double pilot valve to a 3/2-way double pilot valve.
Complete the pneumatic circuit diagram for the automatic cleaning system.
Set up the control system.
Double-check the control system configuration.
Describe the mode of operation of the control system.
Create an equipment list.
Procedure
1. The process is started using a pushbutton when the lifting cylinder is in its retracted end position.
2. The cylinder for the lifting device moves to the advanced end position. It then goes back to the midposition and returns to the advanced end position. This motion sequence is repeated until the process
is stopped by the time delay valve.
3. The cylinder then returns to its retracted end position.
118
14
12
5
119
1B2
1A1
1V6
2
1V5
2
1V4 4
14
12
5
1V3
2
1
1
1B1 2
1B3
1B2 2
1V2 2
10
12
1
1V1
3
1S1
t
1
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Sequence description
Step 1-2
After activating start button 1S1, signal latch 1V2 is switched. Compressed air is fed to the input at time
delay valve 1V1. The 5/2-way double pilot valve 1V4 is switched by 3/2-way roller lever valve 1B1 and
shuttle valve 1V3 (OR) and the cylinder is advanced. Travel beyond pneumatic proximity switch 1B3 at
the mid-position has no effect, because the same control port of the final control element is actuated.
Step 2-3
Pneumatic proximity switch 1B2 is actuated in the advanced end position. The final control element (5/2way double pilot valve) is switched. The cylinder is retracted and actuates pneumatic proximity switch
1B3 at the mid-position.
Step 3-4
The cylinder is once again reversed when pneumatic proximity switch 1B3 at the mid-position is actuated.
Reversing only takes a few milliseconds, and thus the trip cam does not travel beyond pneumatic
proximity switch 1B3.
Step 4-5
Oscillating motion
The cylinder moves back and forth between pneumatic proximity switches 1B3 and 1B2 until time
specified at time delay valve 1V1 has elapsed.
121
Create an equipment list by entering the required components in the table below.
Quantity
Designation
Cylinder, double-acting
Distributor block
Note
A pneumatic 5/2-way double pilot valve is converted to a pneumatic 3/2-way double pilot valve.
122
Layout
Labelling fixture
123
Parameters
A single-acting cylinder will be used to clamp the valve housings.
A roller lever valve will be used to detect whether or not the clamping cylinder has reached its advanced
end position.
A double-acting cylinder will be used as a pressing cylinder.
The feed speeds of both the clamping and the pressing cylinders should be adjustable.
1.
2.
3.
4.
5.
Project assignment
Analyse the pneumatic circuit diagram for the pressing fixture.
Set up the control system.
Double-check the control system configuration.
Describe the mode of operation of the control system.
Create an equipment list.
1.
2.
3.
4.
Procedure
The pressing process is started using a pushbutton.
A limit switch will be used to detect whether or not the clamping cylinder has reached its position.
The pressing cylinder should not advance until the clamping cylinder has reached its advanced end
position.
After the plastic cap has been pressed into place, both cylinders are retracted.
Note
Necessary protective guards are not taken into consideration.
124
1A1
1V3
2V2
1
1V2
2
2V1
12
10
1
1V1
1
1S1
14
12
5
2
1
1B2
2B1 2
2B2
1B2
2B2
125
Create an equipment list by entering the required components in the table below.
Quantity
Designation
Cylinder, double-acting
Cylinder, single-acting
Distributor block
Equipment list
Note
A pneumatic 5/2-way double pilot valve is converted to a pneumatic 3/2-way double pilot valve.
126
Sequence description
Step 1-2
When pushbutton 1S1 is activated, the condition at dual-pressure valve 1V1 (AND) becomes TRUE. The
3/2-way double pilot valve 1V2 is reversed. The single-acting cylinder advances with restricted supply air.
Step 2-3
When the single-acting cylinder reaches its advanced end position, roller lever valve 1B2 is actuated and
reverses 5/2-way double pilot valve 2V1. The double-acting cylinder moves to its advanced end position
where it attenuates pneumatic proximity switch 2B2, which is switched to the free-flow direction.
Step 3-4
5/2-way double pilot valve 2V1 and 3/2-way double pilot valve 1V2 are reversed. Both cylinders are
retracted. The process is finished when the piston in the double-acting cylinder attenuates pneumatic
proximity switch 2B1, which then switches to the free-flow direction.
Note
Single-acting cylinder 1A1 is retracted slightly earlier than double-acting cylinder 2A1. This is due to
overlapping of the control signals at pilot ports 14 and 12 at 5/2-way double pilot valve 2V1. The 5/2-way
double pilot valve 2V1 can only reverse when single-acting cylinder 1A1 has left its advanced end
position and 3/2-way roller lever valve 1B2 is no longer actuated.
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128