Electroneumatica Avanzada

Learning System for Automation and Technology
Electropneumatics
Workbook Advanced level
094467
Authorised applications and liability The Learning System for Automation and Technology has been developed and prepared exclusively for training in the field of automation and technology. The training organization and / or trainee shall ensure that the safety precautions described in the accompanying Technical documentation are fully observed. Festo Didactic hereby excludes any liability for injury to trainees, to the training organization and / or to third parties occurring as a result of the use or application of the station outside of a pure training situation, unless caused by premeditation or gross negligence on the part of Festo Didactic. Order no.: Description: Designation: Edition: Layout: Graphics: Authors: 094467 TEACHW.E-PNEUM. D.S202-C-SIBU-GB 05/2002 06.05.2002, OCKER Ingenieurbro OCKER Ingenieurbro D. Waller, H. Werner, Th. Ocker
Copyright by Festo Didactic GmbH & Co., D-73770 Denkendorf 2002 The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design registrations. Parts of this training documentation may be duplicated, solely for training purposes, by persons authorised in this sense.
Preface
The Festo Didactic Learning System for Automation and Technology has been formulated according to various prerequisites and vocational requirements. It has been divided into the following categories of training packages: Basic packages which convey basic knowledge spanning a wide range of technologies Technology packages which deal with important subjects of open and closed-loop control technology Function packages to explain the basic functions of automated systems Application packages to facilitate practice-orientated vocational and further training The technology packages deal with the technologies of pneumatics, electropneumatics, programmable logic controllers, hydraulics, electrohydraulics, proportional hydraulics and handling technology.
Mounting frame
Profile plate
U = 230V~
Storage tray
TP202 Festo Didactic
The modular design of the Learning System permits applications beyond the scope of the individual packages. It is, for instance, possible to design PLC controlled systems with pneumatic, hydraulic and electrical actuators. All training packages are based on an identical structure: Hardware Teachware Software Seminars The hardware consists of industrial components and systems which have been adapted for didactic purposes. The courseware has been designed in line with didactic methods and coordinated for use with the training hardware. The courseware comprises: Textbooks (with exercises and examples) Workbooks (with practical exercises, explanatory notes, solutions and data sheets) Transparencies and videos (to create a lively training environment) The training and learning media is available in several languages, which has been designed for use in the classroom as well as for self-tuition. The software sector serves as a basis for providing computer training program, simulation program and programming software for programmable logic controllers. A comprehensive range of seminars on the subject of the various technology packages completes our program of vocational and further training.
Latest information about the technology package pneumaticTP 202 New in Pneumatic 2000: Industrial components on the profile plate. Fostering of key qualifications: Technical competence, personal competence and social competence form professional competence. Training of team skills, willingness to co-operate, willingness to learn, independence and organisational skills. Aim Professional competence Content Part A Part B Part C Part D Course Fundamentals Solutions Appendix Exercises Reference to the text book Function diagrams, circuits, descriptions of solutions and quipment lists Storage tray, mounting technology and datasheets
Table of contents
Introduction Notes on safety and operation Training contents of basic level and advanced level Equipment set for the basic level (TP201) Equipment set for the advanced level (TP202) Component and exercise allocation (table) Methodical structure of the exercises Designation of components 9 11 13 15 18 20 21 22
Part A Course
Basic exercises Exercise 1: Exercise 2: Exercise 3: Exercise 4: Exercise 5: Exercise 6: Exercise 7: Bench drill Feed unit for sheet metal strip Filling device Stamping device Drilling jig Clamping unit for grinding Forming press A-3 A-5 A-7 A-9 A-11 A-15 A-19
Consolidating exercises Exercise 8: Exercise 9: Exercise 10: Exercise 11: Exercise 12: Exercise 13: Exercise 14: Exercise 15: Exercise 16: Exercise 17: Exercise 18: Exercise 19: Exercise 20: Embossing device Handling device Drilling and reaming machine Loading station Internal grinding machine Assembly unit Moulding press Pick-and-place unit Galvanising process Loading station Rotary indexing station Checking station Handling device A-21 A-23 A-25 A-29 A-33 A-37 A-41 A-45 A-49 A-53 A-57 A-63 A-67
Part B Fundamentals
Part C Solutions
Solution 1: Solution 2: Solution 3: Solution 4: Solution 5: Solution 6: Solution 7: Solution 8: Solution 9: Solution 10: Solution 11: Solution 12: Solution 13: Solution 14: Solution 15: Solution 16: Solution 17: Solution 18: Solution 19: Solution 20: Bench drill Feed unit for sheet metal strip Filling device Stamping device Drilling jig Clamping unit for grinding Forming press Embossing device Handling device Drilling and reaming machine Loading station Internal grinding machine Assembly unit Moulding press Pick-and-place unit Galvanising process Loading station Rotary indexing station Checking station Handling device C-3 C-9 C-17 C-21 C-27 C-35 C-41 C-45 C-49 C-55 C-59 C-63 C-69 C-75 C-81 C-87 C-95 C-103 C-111 C-117
Part D Appendix
Storage tray Mounting technology Plastic tubing Data sheets D-2 D-3 D-5 ...
Introduction
This workbook forms part of Festo Didactics Learning System for Automation and Technology. The system provides a solid basis for practiceorientated vocational and further training. Technology package TP200 is concerned exclusively with electro-pneumatic control systems. The basic level TP201 is suitable for basic training in electro-pneumatic control technology. It conveys knowledge concerning the physical fundamentals of electropneumatics as well as the function and use of electro-pneumatic components. The equipment set permits the construction of simple electro-pneumatic control systems. The advanced level TP202 is intended for further training in electropneumatic control technology. The equipment set permits the construction of a wide range of combinatorial circuits with logic operations of the input and output signals as well as program controls. Prerequisites for assembling control circuits are a fixed workstation and a Festo Didactic profile plate. The profile plate has 14 parallel T-grooves arranged at intervals of 50 mm. A short-circuit proof power supply unit provides a constant power supply (Input: 230 V, 50 Hz, Output: 24 V, max. 5 A). A mobile, silenced compressor may be used for compressed air supply (230 V, maximum 8 bar = 800 kPa). Working pressure should be a maximum of p = 6 bar (= 600 kPa) Optimum operational safety is achieved by operating the control system with unlubricated air at a pressure of p = 5 bar = 500 kPa. The training hardware of both equipment sets (TP201 and TP202) will be required for the practical assembly of the controls documented here. The theoretical fundamentals required to understand this book of exercises can be found in the following textbook: Learning System for Control Technology Introduction to Electropneumatics Also available are data sheets on the various components (cylinders, valves, measuring devices, etc.).
10
11
Notes on safety and operation

In the interests of your own safety, the following advice should be observed: Pressurised air lines that become detached can cause accidents. Switch off supply immediately. Lines must be connected up and secured before the compressed air is switched on. Warning! Cylinders may advance or retract as soon as the compressed air is switched on. Do not operate the electrical limit switches manually during fault finding (use a suitable tool). Observe general safety regulations (DIN 58126 and VDE 100). Distinction is to be made between the two different designs of the electrical limit switches Actuation from the left Actuation from the right Limit switches should be placed so that they contact only the side of the trip cam and never the front at high piston speeds. In the pneumatic circuits cylinders are shown without magnetic pistons, since these are only required when magnetic end-position switches are used. Festo Didactic training sets only contain cylinders with magnetic pistons. Do not exceed permissible operating pressure (observe data sheets). Only use extra-low voltage 24 V. All components are provided with 4 mm safety sockets respectively safety plugs. For electical connections use only electrical cable with safety plugs. Pneumatic circuit design: Components are to be connected by means of the silver-metallic plastic tubing with a 4 mm external diameter. Insert the tubing into the QS push-in fitting up to the stop; no further securing necessary! Releasing of the QS straight push-in fitting: The tubing can be released by simply pressing the clamping collet (blue ring). (Cannot be disconnected under pressure!) Switch off the pressure and power supply prior to disconnecting the circuit.
12
The profile plate for the assembly of components is equipped for mounting variants A to D: Variant A, Detent system Light, non load-bearing components (e.g. directional control valves). Simply clip the components into the groove of the profile plate. The components can be released by pressing the blue lever. Variant B, Rotational system Medium-weight, load-bearing components (e.g. actuators). These components are clamped onto the profile plate by means of T-head bolts. The components are clamped or released by means of the blue triple grip nut. Variant C, Screw-in system For heavy, load-bearing components, i.e. components which are rarely removed from the profile plate (such as start-up valves with filter regulator). The components are secured by means of cheese head screws and T-head nuts. Variant D, Plug-in system Light, non load-bearing components with locating pins (e.g. signalling device). These components are secured by means of plug-in adapters. Please observe the data sheets in Part D for information regarding the individual components.
13
Training contents of basic level and advanced level

Basic level (TP201) Physical fundamentals of electricity and pneumatics Function and application of electropneumatic components Designation and drawing of electropneumatic symbols Representation of motion sequences and switching statuses Drawing pneumatic and electrical circuit diagrams Assembly of control systems with relays Direct and indirect manual control systems Direct and indirect stroke-dependent control systems Logical AND/OR functions of the input signals Electrical latching circuits Using a magnetic proximity switch Using a pressure switch Fault finding in simple electropneumatic control systems
Advanced level (TP202) Function and use of electro-pneumatic components Stroke-dependent control systems with sensors Stroke-dependent control systems with preselect counter Control systems with marginal conditions (e.g. Single/continuous cycle, EMERGENCY-STOP) Position-scheduled control/process orientated sequence controls Timing controls/time orientated sequence controls Program control systems with latching and resetting sequence Fault finding in extensive electro-pneumatic control systems
14
List of training aims
Exercise 1 2 3 4 5 6
Training aim To teach the student the principle of the latching sequence. To teach the student the principle of the resetting sequence (with reliable switching reversal). To familiarise the student with the procedure for skipping program steps and with the use of a timer. To teach the student how to realise a stroke-dependent sequence control with resetting sequence. To teach the student how to realise multiple movements of a cylinder and monitor service life using a preselect counter. To familiarise the student with the use of a pneumatic/electric converter To teach the student how to construct a control system using single and double solenoid valves (resetting sequence with extension). To teach the student how to realise a control system with specified EMERGENCY-STOP conditions and how to realise a two-hand safety start-up control via a timer with switch-on delay. To teach the student how to incorporate step repetitions and manual step mode into a sequence. To teach the student how to incorporate EMERGENCY-STOP and marginal conditions in a latching sequence. To teach the student how to realise a control system with an alternative program by means of program switching. To teach the student to program repetition using an additional movement. To familiarise the student with step repetition using the preselect counter. To teach the student how to set up manual activation of the cylinder with protection against collision. To familiarise the student with automatic setting conditions. To teach the student how to construct a two-handed safety start-up with relay. To familiarise the student with restart before the end of the cycle. To teach the student how to develop a latching sequence with marginal conditions. To teach the student how to realise program branchings. To teach the student how to make multiple use of time relays. To familiarise the student with program section repetitions using the preselect counter. Consolidating the students knowledge. Program section repetition. To familiarise the student with parallel program division. To familiarise the student with the use of a timer with delayed switch-on as a delayed starting element. Familiarisation with an alternative solution to electropneumatics.
8 9 10 11 12 13
14 15 16
17 18 19 20
15
Equipment set for the basic level (TP201)

This equipment set is designed for basic training in electro-pneumatic control technology. It contains all the components required to achieve the specified training aims and may be extended as required with the addition of other equipment sets. To construct fully operational controls, it is also necessary to have a profile plate, a power supply unit and a compressed air supply.
Designation Relay, 3-off* Signal input plate, electrical * Indicator/distributor plate, electrical * Plastic tubing, 10 m, silver metallic Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right Pneumatic-electric converter 3/2-way solenoid valve, normally closed 5/2-way solenoid valve 5//2-way double solnoid valve Order No. 162241 162242 162244 151496 152887 152888 152894 152896 167060 183322 183345 177459 167073 167074 167076 Quantity 1 1 2 1 1 2 1 1 2 1 1 1 1 2 1
Equipment set for the basic level (TP201) (Order No.: 080243)
* These components can be attached to the profile plate by means of 4 adapters (Order No. 323571).
16
Symbols of the equipment set
Signal input plate, electrical
Indicator/distributor, electrical
Relay, 3-off
Single-acting cylinder
Double-acting cylinder
On/off valve with filter regulator
Manifold
17
Proximity sensor with cylinder mounting
Pneumatic-electric converter
Symbols of the equipment set
Limit switch, electrical, Actuation from left or right*
3/2-way solenoid valve, normally closed
5/2-way solenoid valve
5/2-way double solenoid valve
18
Equipment set for the advanced level (TP202)

This equipment set for the advanced level is designed for further training in electro-pneumatic control technology. The two equipment sets (TP201 and TP202) contain all the components required to achieve the specified training aims and may be extended as required with the addition of other equipment sets from the Learning System for Automation and Technology. Equipment set for the advanced level (TP202) (Order No: 184461)
Designation Relay, 3-off* Signal input plate, electrical* Time relay, 2-off* Preselect counter, electrical, incrementing* 5/2-way double solenoid valve Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor, optical EMERGENCY-STOP button Order No. 162241 162242 162243 162355 167076 178574 178575 178577 183347 Quantity 4 1 1 1 2 1 1 1 1
* These components can be attached to the profile plate by means of 4 adapters (Order No. 323571).
19
Signal input plate, electrical
Symbols of the equipment set advanced level
Relay, 3-off
Time relay, 2-off with switch-on delay with switch-off delay
Preselect counter, electrical, incrementing
EMERGENCY-STOP button
Proximity sensor, inductive
Proximity sensor, capacitive
Proximity sensor, optical
5/2-way double solenoid valve
20
Component and exercise allocation (table)

Exercise Designation Relay, 3-off* Signal input module, electrical * Time relay, 2-off Preselet counter, electrical, incrementing Distributor plate, electrical Single-acting cylinder Double-acting cylinder On-off valve with filter regulator Manifold EMERGENCY-STOP button Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor, optical Proximity sensor with cylinder mounting Limit switch, electrical, Actuation from the left Limit switch, electrical, Actuation from the right Pneumatic-electric converter 3/2-way solenoid valve, normally closed 5/2-way solenoid valve 5/2-way double solenoid valve 1 2 2 1 2 3 1 2 2 2 1 1 2 1 1 1 1 2 1 1 1 1 2 1 1 2 1 1 2 1 1 1 1 2 2 1 2 1 2 1 2 2 1 1 1 1 2 1 1 2 1 1 2 1 1 1 1 1 1 2 1 1 2 1 1 1 2 1 1 2 1 1 1 1 2 1 1 1 2 1 2 3 1 3 3 1 1 1 2 1 2 1 1 1 1 2 1 1 2 1 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 3 1 2 1 2 1 2 1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 2 2 2 3 1 2 1 2 2 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 1 4 4 1 5 5 2 6 5 2 7 2 1 1 1 2 1 2 1 1 1 2 1 2 1 1 2 1 2 1 1 2 1 2 1 1 2 1 2 1 1 1 1 1 8 2 2 9 5 2 10 11 12 13 14 15 16 17 18 19 20 3 1 4 1 5 2 5 2 5 1 1 6* 6* 6* 6* 6* 6* 2 1 1 1 1 1 2 1 2 1 1 2 1 1 1 1 2 1 2 1 1 2 1
3* 3* 3* 3* 1 1 1 1 1 1 1 1 2 1 1 1 2 1 1 1 1 1 1 1 1 2
2* 2* 2* 1 1 1
* Components which are not available in full quantity in equipment sets 201 and 202.
21
Methodical structure of the exercises

All 20 exercises in part A are of the same methodical design. The two exercise sheets are divided into: Subject Title Training aim Exercise Problem description Positional sketch Displacement-step diagram
sowie
The proposed solutions in part C cover a minimum of four pages and are divided into: Circuit diagram, pneumatic Circuit diagram, electrical Solution description Component list
22
Designation of components
The components in the circuit diagrams are designated in accordance with ISO 1219-2. All components within a circuit have the same main code. Letters are assigned dependent on the component. If there are several components within a circuit, these are numbered consecutively. Pressure lines are identified with the designation P and are numbered separately. Actuators: Valves: Signal detecter: Accessories: Electrical sensors: Pressure lines: 1A, 2A1, 2A2, ... 1V1, 1V2, 1V3, 2V1, 2V2, 3V, ... 1S1, 1S2, ... 0Z1, 0Z2, 1Z, ... 1B1, 1B2, ... P1, P2, ...
A-1
Part A Course
Basic exercises Exercise 1: Exercise 2: Exercise 3: Exercise 4: Exercise 5: Exercise 6: Exercise 7: Bench drill Feed unit for sheet metal strip Filling device Stamping device Drilling jig Clamping unit for grinding Forming press A-3 A-5 A-7 A-9 A-11 A-15 A-19
Consolidating exercises Exercise 8: Exercise 9: Exercise 10: Exercise 11: Exercise 12: Exercise 13: Exercise 14: Exercise 15: Exercise 16: Exercise 17: Exercise 18: Exercise 19: Exercise 20: Embossing device Handling device Drilling and reaming machine Loading station Internal grinding machine Assembly unit Moulding press Pick-and-place unit Galvanising process Loading station Rotary indexing station Checking station Handling device A-21 A-23 A-25 A-29 A-33 A-37 A-41 A-45 A-49 A-53 A-57 A-63 A-67
A-2
A-3
Aufgabe 1
Electropneumatics Bench drill
Subject Title
To teach the student the principle of a latching sequence. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.
Training aim Exercise
A-4
Aufgabe 1
Problem description
Workpieces are inserted into the clamping device by hand. Clamping cylinder 1A is to extend when the start button is pressed. When the workpiece is clamped, it is to be drilled via feed unit 2A and the drill retracted once again. At the same time, the swarf is to be blown away by an air jet 3Z. Then, the clamping cylinder 1A is to release the workpiece.
Fig. 1/1: Positional sketch
2A
3Z
1A
Fig. 1/2: Displacement-step diagram
1 1
5=1
1S2 1S1 2B2 2B1
1A
0
2A
0
A-5
Aufgabe 2
Electropneumatics Feed unit for sheet metal strip
Subject Title
To teach the student the principle of a resetting sequence (with reliable switching reversal). Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.
Training aim
Exercise
A-6
Aufgabe 2
Problem description
A sheet metal strip is to be fed from a drum towards the cutting tool. The feed unit may only start when the punch-tool is in the upper position (this signal must be simulated by a push button S3). Cylinder 1A holds the sheet metal strip and cylinder 2A retracts. Cylinder 1A releases the strip and cylinder 2A returns to the forward end position. The sheet metal strip feed unit must be provided with a main switch S1. When cylinder 2A has retracted and cylinder 1A has released the strip, a signal (optical indicator) is to be passed on to the press for the next part to be punched out.
Operating condition
1A
2A
1 1
6=1
1B2 1B1 2S2 2S1
1A
0
2A
0
A-7
Exercise 3
Electropneumatics Filling device
Subject Title
To familiarise the student with the procedure for skipping program steps. To familiarise the student with the use of a timer with switch-on delay. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.
Training aim
Exercise
A-8
Exercise 3
Problem description
Bottles are transported along a conveyor belt to a rotary table. Cylinder 1A is to retract only when a bottle has arrived on the conveyor belt (position 1) and the START signal (continuous/single cycle) has been given. The table is then to continue indexing (2A+), when the signal bottle on indexing table (position 2) has been sent. When a bottle has reached the filling station (position 3), cylinder 3A is to open the filling valve, remain it open for approx. 2 seconds and then reclose it. If no bottle is reported as present at the filling station (position 3), the installation must be indexed manually until a bottle is present for filling. Sensing of the bottles is to be simulated by push button.
Operating condition
1A
3A
2A
A-9
Aufgabe 4
Electropneumatics Stamping device
Subject Title
To teach the student how to realise a stroke-dependent sequence control with a resetting sequence. Drawing the displacement-step diagram and the pneumatic and electrical circuit diagram. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.
Training aim
Exercise
A-10
Aufgabe 4
Problem description
Cylinder 1A is to push parts out of the gravity feed magazine and clamp them. Only then can cylinder 2A stamp the part and retract once again. Next, clamping cylinder 1A is to unclamp. The part is to be ejected by cylinder 3A, which then returns to the retracted end position.
1 1
7=1
1S2 1S1 2B2 2B1 3B2 3B1
1A
0 1
2A
0 1
3A
0
A-11
Exercise 5
Electropneumatics Drilling jig
Subject Title
To teach the student how to realise multiple movements of a cylinder. To familiarise the student with the use of an incrementing preselect counter. Drawing the pneumatic and electrical circuit diagrams. Drawing the pneumatic and electrical circuits. Checking the circuit sequence.
Training aim
Exercise
A-12
Exercise 5
Problem description
Rectangular castings are to be drilled in 4 positions. Castings are inserted by hand and clamped by an eccentric cam. Feed unit 3A with hydraulic cushioning cylinder is aligned vertically (Zaxis). Positioning cylinders 1A and 2A move the table in X- and Ydirection so that drilling positions (1), (2), (3) and (4) can be approached consecutively. The first hole is drilled by means of feed unit 3A after the START button has been pressed. Next, double-acting cylinder 1A retracts and the second drilling process takes place. After double-acting cylinder 2A has retracted, feed unit 3A carries out the third double stroke. When cylinder 1A has once again reached its forward end position, the fourth hole is drilled. In the 12th step, cylinder 2A extends once again and the initial position is obtained.
Operating condition
To ensure that the service life of the drill is not exceeded, it is to be monitored via a counter. This is to emit a signal and interrupt the cycle once a predetermined number of drilling operations has taken place. Once the drill has been replaced and the counter has been reset by hand, the cycle is to continue again.
A-13
Exercise 5
1 4
2 3

1 1 2 3 4 5 6 7 8 9 10 11 12 13=1
1B2 1B1 2B2 2B1 3S2 3S1
1A
0
2A
0
3A
0
A-14
Exercise 5
A-15
Exercise 6
Electropneumatics Clamping unit for grinding
Subject Title
To familiarise the student with the use of a pneumatic/electric converter. To teach the student how to construct a control system using single and double solenoid valves (Resetting sequence with extension). Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.
Training aim
Exercise
A-16
Exercise 6
Problem description
Semi-finished flanges of workpieces are to be placed manually in a clamping and grinding unit, pneumatically clamped and ground on the right and lefthand flanges. Once single-acting clamping cylinder 1A has reached its forward end position and the clamping pressure has built up in the piston chamber, feed unit 2A performs a double stroke. The righthand flange is ground. Double-acting cross-feed cylinder 3A extends prior to feed unit 2A carrying out the second double stroke and grinding the lefthand flange. Clamping cylinder 1A releases the workpiece when cylinder 3A has reached its retracted end position.
Operating condition
Clamping cylinder 1A, single-acting, controlled via a solenoid valve. Feed cylinders 2A and cross feed cylinder 3A are both double-acting and each controlled via a double solenoid valve. Monitoring of clamping pressure.
A-17
Exercise 6
1A
3A
2A
1 1
9=1
1S2 1S1 2B2 2B1 3B2 3B1
1A
0
2A
0
3A
0
A-18
Exercise 6
A-19
Aufgabe 7
Electropneumatics Forming press
Subject Title
To teach the student how to realise a control system with specified EMERGENCY-STOP conditions. To teach the student how to realise a two-hand safety control via a timer with switch-on delay. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.
Training aim
Exercise
A-20
Aufgabe 7
Problem description
A metal plate is inserted by hand into the forming press. A profile is to be stamped into the metal plate by means of a two-handed operation. When the operation is complete, the formed metal part is to be ejected by means of ejecting cylinder 2A. The START signal is obtained through a two-hand safety control with delayed switch-on timer. When the EMERGENCY-STOP button is pressed, the two cylinders must return immediately to their initial positions.
Operating condition
1A
1 1
5=1
1S2 1S1 2B2 2B1
1A
0
2A
0
A-21
Exercise 8
Electropneumatics Embossing device
Subject Title
To teach the student how to incorporate step repetitions and manual step mode into a sequence. Drawing the pneumatic and electrical circuits. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.
Training aim
Exercise
A-22
Exercise 8
Problem description
Workpieces to be embossed are inserted manually into a retainer and pushed under the embossing stamp by cylinder 1A. Cylinder 2A extends and embosses the workpiece. Then, cylinder 2A retracts again followed by cylinder 1A. It must be possible to carry out the individual movements step by step via a push button (manual step mode). In addition, steps 2A+/2A- must be repeatable to enable adjustment of the embossing cylinder. Cylinder 2A+ is to be moved in manual step mode, meaning that the 2A- movement must be effected via an additional push button. Step repetition and manual step mode should only be possible when no START signal is present.
Operating condition
1 1
5=1
1B2 1B1 2S2 2S1
1A
0
2A
0
A-23
Exercise 9
Electropneumatics Handling device
Subject Title
To teach the student how to incorporate EMERGENCY-STOP and marginal conditions in a latching sequence. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuits sequence.
Training aim
Exercise
A-24
Exercise 9
Problem description
Round parts are to be fed by a handling device from the outlet channel of processing station I to the inlet channel of processing station II. As an additional start condition, the outlet channel is to be interrogated for round parts. Separate push buttons for SINGLE/CONTINUOUS CYCLE. EMERGENCY-STOP: Linear drive 2A must be unpressurised. Gripper 1A must remain closed or open according to status. When EMERGENCY-STOP is no longer being actuated, pressing a push button is to bring the linear drive back into the initial position. A second push button is then to release the gripper (if this was closed in the EMERGENCY-STOP status). This push button must also simultaneously latch the start button (after the EMERGENCY-STOP), so that it is only possible to restart via the START button after this button has been pressed.
Operating condition
1 1
5=1
1S2 open
1A
0
Gripper
1S1 closed 2B2
2A
0
Linear drive
2B1
A-25
Exercise 10
Electropneumatics Drilling and reaming machine
Subject Title
To teach the student how to realise a control system with an alternative program by means of program switching step jump. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.
Training aim
Exercise
A-26
Exercise 10
Problem description
Program 1: - Drilling Parts, which only need to be drilled, are clamped by hand. The part is drilled when the START button is actuated. (Cylinder 1A). Program 2: - Drilling and reaming Parts, which also need to be reamed, are also clamped by hand. Then, upon actuation of a PROGRAM SELECTOR button and the START button, cylinder 1A starts the drilling process. When the drilling process is completed, positioning cylinder 2A extends and transfers the drilled part to the reaming station (cylinder 3A). When reaming of the part has taken place, positioning cylinder 2A retracts and the part can be removed. The PROGRAM SELECTOR button must be actuated before the START button in order to start up program 2. If these buttons remain unactuated, then program 1 is to automatically run.
A-27
Exercise 10
Fig. 10/2: Displacement-step diagram Program 1

1 1 2 3=1
Program 2
1 2 3 4 5 6 7=1
1S2
1S2 1S1 2B2 2B1 3B2 3B1
1A
0
1A
1S1 2B2
0
2A
0
2A
2B1 3B2
0
3A
0
3A
3B1
0
A-28
Exercise 10
A-29
Exercise 11
Electropneumatics Loading station
Subject Title
To teach the student to program repetition using an additional movement. To familiarise the student with the use of an incrementing preselect counter. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.
Training aim
Exercise
A-30
Exercise 11
Problem description
A plate on a conveyor belt is fitted with two steel parts. The parts advanced via a rail are centred by a spigot and held by an electromagnet whilst being transferred. The motion sequence towards position 1 is to be executed via cylinders 1A and 2A. Position 2 is to be reached by means of the same sequence as that employed for position 1, with the addition of cylinder 3A (see displacement-step diagram).
Operating condition
Sensing of steel parts is to be realised via a push button S2. When the conveyor belt has passed on the next plate for loading and transmitted a signal to the loading unit (simulated by push button S1), the machine is to proceed automatically. The functioning of the electromagnet is to be simulated by means of a lamp H1.
A-31
Exercise 11
Conveyor belt Plate
Position 2
Position 1

1 1 2 3 4 5 6 7 8 9 10 11 12 13=1
1S2 1S1 2B2 2B1 3B2 3B1
1A
0
2A
0
3A
0
Position 1
Position 2
A-32
Exercise 11
A-33
Exercise 12
Electropneumatics Internal grinding machine
Subject Title
To familiarise the student with step repetition using the preselect counter. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuit diagrams. Checking the circuit sequence.
Training aim
Exercise
A-34
Exercise 12
Problem description
Workpieces are fed along a conveyor belt. The forwardmost workpiece is pushed against the stop by the following one. When a workpiece is present, it is signalled by a sensor (switch) and the clamping stop is raised (cylinder 1A). Next, cylinder 2A is to clamp the part and signal when the clamping pressure has been reached so that the grinding process can commence. Cylinder 3A is to advance and the grinding wheel switched on simultaneously (simulation by means of visual indicator). Then cylinder 3A is to travel up and down ten times (half strokes) and then return to the initial start position. Next, cylinders 1A and 2A are are to retract simultaneously. Cylinder 2A now is to extend once again and push the part onto the conveyor belt which is to carry it away (only a minimal section of the stroke was required for the clamping operation). When cylinder 2A has returned once again and another workpiece has reached the stop, the cycle is to be repeated.
Operating condition
START and STOP at the end of each cycle are each controlled by one push button.
A-35
Exercise 12
3A
2A 1A

1 1 2 3 4 5 6 22 23 24 25 26=1
1B2 1B1 2S2 2S1 3B3 3B2 3B1
1A
0
2A
0
3A
0
A-36
Exercise 12
A-37
Exercise 13
Electropneumatics Assembly unit
Subject Title
To teach the student how to set up manual activation of a cylinder including precautions with protection against collision. To familiarise the student with automatic setting conditions. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.
Training aim
Exercise
A-38
Exercise 13
Problem description
Bushes which are placed ready for assembly in a gravity feed magazine are pressed into metal blocks which are also introduced in a similar manner. Cylinder 1A pushes a metal block from the magazine to a stop and clamps it. Then, cylinder 2A extends and presses the first bush into place. Next, cylinder 3A is activated, pressing the second bush into place. Then cylinders 1A and 3A retract simultaneously, followed by cylinder 2A retracting. The assembled metal block drops onto a conveyor belt.
Operating condition
The installation is to operate in a continuous cycle. It must be possible to select between manual and automatic operating mode. Manual operation is to be indicated by a lamp H1. Separate push buttons are to actuate each of the cylinders. This installation may only be run in manual mode; only one cylinder is to extend at a time.
A-39
Exercise 13
Fig. 13/1 Positional sketch
1 1
6=1
1S2 1S1 2B2 2B1 3B2 3B1
1A
0
2A
0
3A
0
A-40
Exercise 13
A-41
Exercise 14
Electropneumatics Moulding press
Subject Title
To teach the student how to construct a two-handed safetystart-up control with relay. To familiarise the student with restart before the end of the cycle. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.
Training aim
Exercise
A-42
Exercise 14
Problem description
Plastic plates are to be formed from duroplastic pellets. The pellets are inserted manually into the lower part of the mould. When the START button is pressed (two-handed safety control), the upper part of the mould is guided into the lower part of the mould. When the forward end position is reached, pressure must be sustained for approximately ten seconds to guarantee hardening of the formed part. Then, the plates are removed from the mould tool by the extractor unit and stacked next to the press.
Operating condition
The START signal must continue until cylinder 1A has assumed its forward end position. The press cylinder may extend immediately the extractor unit has been removed from the working area (half return stroke of cylinder 2A). The two-handed safety control using a relay. The function of the vacuum generator 4Z is to be represented by a lamp.
A-43
Exercise 14
1 1
7=1
1B2 1B1 2B3 2B2 2B1 3S2 3S1
1A
0
2A
0
3A
0
A-44
Exercise 14
A-45
Exercise 15
Electropneumatics Pick-and-place unit
Subject Title
To teach the student how to develop a latching sequence with marginal conditions. Drawing the pneumatic and electrical circuit diagrams.. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.
Training aim
Exercise
A-46
Exercise 15
Problem description
A triple-axis unit is used for insertion of parts from position 2 into positions 3 and 4 of a gear housing. The vacuum gripper 4Z is to be simulated by a lamp (gripper suction = lamp on, no gripper suction = lamp off). The start position is to be position 1, where the gripper is raised (Z-axis) and there is no suction. When the START button is pressed, position 2 is to be approached and a part picked up from the feed hopper and then deposited in position 3. Another part is then picked up from position 2 and deposited in position 4. The gripper then returns to initial position 1. Sensing of the magazine (simulated by a switch and indicated via a lamp): When the magazine is empty, the control system is to remain in position 1 or position 2 and must only proceed or restart when the magazine has been filled and the start button pressed. Sensing of the gear housing: This is to guarantee that a gear housing which is inserted into a device is removed after processing (switch and lamp off). The initial start positions of the double-acting cylinders are: 1A+, 2A+, 3A-.
Operating condition
A-47
Exercise 15
2A 1A
3A
down up Vaccuum generator on Vaccuum generator off Vaccuum generator on Vaccuum generator off
A-48
Exercise 15
A-49
Exercise 16
Electropneumatics Galvanising process
Subject Title
To teach the student how to realise program branchings. To teach the student how to make multiple use of time relays. To familiarise the student with program section repetitions using the preselect counter. To teach the student how to realise a pressure-dependent control system. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.
Training aim
Exercise
A-50
Exercise 16
Problem description
An overhead trolley beam transports the parts to be galvanised from a work surface across the three baths and back again. A doubleacting cylinder positions the basket on the work surface or else lowers it into the baths. It remains in the forward end position (bath 2) or swings the basket up and down in the bath (baths 1 and 3). Partial strokes are sensed by three limit switches. If the trolley has approached a horizontal position, a control lamp is illuminated (bath 1 lamp H1, bath 2 lamp H2, bath 3 lamp H3 and work surface lamp H4). In the initial position, the basket hangs above the work surface. When the up/down switch S2 is actuated, the cylinder extends and the basket is deposited on the work surface for loading. When the initial start position has once more been reached, the cylinder can be actuated via start button S. The movements of the trolley (from work surface to bath 1, from bath 1 to bath 2, from bath 2 to bath 3 and from bath 3 back to the work surface) are simulated by four identical time periods t1 = 2 seconds. Once the basket has been dipped into bath 1 (and bath 3), the piston extends four half strokes in the forward stroke area. The basket remains in bath 2 in the forward stroke area t2 = 3 seconds.
Operating condition
When the main power supply has been switched on, the control is to be activated via the SET button S1 and the time interval t1 started simultaneously. During this time period, the cylinder is to be brought into the initial position (as it would have moved into the forward end position by leakage losses when the installation was stopped). When the time t1 has expired, the positioning lamp H4 is illuminated. The installation can only be started once a pneumatic-electrical converter has signalled the supply of compressed air.
A-51
Exercise 16
Bath 1
Bath 2
Bath 3
Fig. 16/2: Displacement-step diagram START Bath 1

2 3 4 5 6 7 8 9
Bath 2
10 t2 11 12 13
Bath 3
14 15 16 17=1
1
1
1B3 1B2
1A
0
1B1
t1 t1 t1 t1
S1
A-52
Exercise 16
A-53
Exercise 17
Electropneumatics Loading station
Subject Title
Consolidating the students knowledge. Program section repetition. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.
Training aim
Exercise
A-54
Exercise 17
Problem description
A loading station is used for loading boxes. Empty boxes which are supplied via a conveyor belt must be placed onto the transfer unit by hand. Transfer unit 1A moves underneath the swivel device 4M, which then fills the box with containers row by row. The motion sequence can be seen in displacement-step diagram 1. Indicate on the diagram the step which has been reached by the installation shown in the positional sketch. The functioning of the suction cups is to be simulated by lamp. The motion sequences which recur (see displacement-step diagram 1, steps 3....21), should be brought together in a subroutine which is to be repeated itself a number of times (see displacement-step diagram 2).
Operating condition
4M
3A
1A 2A
The loading station shown here is not in the initial position.
A-55
Exercise 17
1B2
1B1
2B2
2B1
3S2
3S1
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25=1
Fig. 17/2: Displacement-step diagram 1
4B
1
4M
1A
2A
3A
4S
1A+ 3A+ 4M+ 4M- 3A- 2A+ 3A+ 4M+ 4M- 2A- 3A- 2A+ 3A+ 4M+ 4M- 2A- 3A- 2A+ 3A+ 4M+ 4M- 3A- 1A-
Abbreviated notation
A-56
Exercise 17
1B2
2B2
3S2
1B1
2B1
Fig. 17/3: Displacement-step diagram 2
3S1
4B
1
21
21
22
23
24
25=1
1A
3A
Abbreviated notation
1A+ 3A+
Main program
4M+ 4M- 2A- 3A- 2A+ 3A+

3 x Subroutine
4M
2A
4S
4M+ 4M- 3A- 1AMain program
A-57
Exercise 18
Electropneumatics Rotary indexing station
Subject Title
To familiarise the student with parallel program division. Drawing the pneumatic and electrical circuit diagram. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.
A-58
Exercise 18
Problem description
Workpieces are drilled vertically and horizontally on an eight-station rotary indexing table. Six feed units are used for the various machining operations. Two each for drilling, counterboring and countersinking. Two transferring units load and unload the machine respectively. Lifting cylinders 1A and 3A descend onto the workpieces. These are picked up by suction (functioning of the vacuum generator is to be indicated by a lamp) and then lifted. The stroke of cylinder 5A then causes the table to index on by one position. At the same time, transfer cylinders 2A and 4A approach the positions for placing on the indexing table and depositing via the conveyor belt 2. Then, cylinder 5A latches the rotary indexing table and the two lifting cylinders 1A and 3A deposit the parts. At the same time as the lifting cylinder retracts, processing via feed units 6A to 11A begins. When these have reached their forward end positions, the feed units and the transfer cylinders return to their initial positions.
Operating condition
Choice between manual and automatic operating modes. Separate push buttons for START and STOP (continuous cycle). The start signal must be maintained until the machine has been supplied with lubricant via a centralised lubrication system (the pump motor is to be simulated by a lamp). Then, the start signal is to be stored and indicated by a lamp. Workpiece sensing on conveyor belt 1 is simulated by a switch. The air blast for swarf removal is to be simulated using a solenoid valve.
A-59
Exercise 18
EMERGENCY-STOP The electrical power to the control must be switched off. The feed units are to retract. The transfer units and the cylinder of the indexing table are to complete their movements. When the vacuum generators are active, they must continue to remain active until, after the RESET and a renewed START, the controller gives the command to deposit. RESET If, after indexing on, processing can no longer take place because the EMERGENCY-STOP has been actuated, processing must be carried out in RESET mode via a time control. All cylinders must be brought into their initial position. In the case of the transport units, cylinders 1A and 3A must retract before cylinder 2A and 4A. Note regarding solution For the purpose of simulation, this exercise can be solved using four cylinders: The transer units are to be represented by double-acting cylinders. Cylinders 1A and 2A are sufficient for this as the movements of the two units are synchronised. Cylinder 5A for indexing of the table is also represented by a doubleacting cylinder. All feed units are to be represented by a single-acting cylinder. Only the limit switches of the four cylinders are to be drawn in the electrical circuit diagram.
A-60
Exercise 18
Discharge Conveyor 2
9A
Counter 2
1A
8A
Counter 1 Rotary indexing table
Conveyor 1
7A
Drilling 1
A-61
Exercise 18
7=1
Transfer 1
1S2 (1B2) 1S1 (1B1) 2S2 (2B2) 2S1 (2B1)

1 2 3 4 5 6 7=1
1A
0 1
2A
0
Transfer 2
3S2 3S1 4S2 4S1

1 2 3 4 5 6 7=1
3A
0 1
4A
0
1 Rotary indexing table 5A 0 1 2 3 4 5 6 7=1
5S2 5S1
Drilling 1
6S2 (6B) 6S1 (6S) 7S2 7S1 8S2 8S1 9S2 9S1 10S2 10S1 11S2 11S1
6A
0
Drilling 2
7A
0 1
Counterboring 1
8A
0 1
Counterboring 2
9A
0 1
Deburring 1
10A
0 1
Deburring 2
11A
0
A-62
Exercise 18
A-63
Exercise 19
Electropneumatics Checking station
Subject Title
To familiarise the student with the use of a timer with delayed switchon as a delayed starting element. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.
Training aim
Exercise
A-64
Exercise 19
Problem description
Transfer cylinder 1A is to push a container onto the scales. Then, cylinder 2A is to release the scales and cylinder 1A is to return to its initial position. After a waiting time of approx. 3 seconds, cylinder 2A is to block the scales again. If the container is within the weight tolerance (switch S4 is activated), cylinder 3A is to push it onto the conveyor belt to move it on and then to retract once again. However, if the tolerance limit is not maintained (switch S4 not activated), cylinder 4A is to transfer the container to the outlet chute and then to retract again. Then, the container is to be transferred on by the conveyor belt (simulated by a lamp H1).
Operating conditions
The installation is to operate in continuous mode and started by a push button S1 and stopped at the end of the cycle by a second push button S6. The good parts are to be counted. As the sensor for the containers is not attached directly to transfer cylinder 1A, for technical reasons, the run-time of the conveyor belt must be controlled as follows: The conveyor belt continues running until a sensor (push button S4) outside the transfer area, signals the presence of a container and uses this to control a timer. When the time has expired, the conveyor belt can stop and cylinder 1A then commences the cycle once again.
A-65
Exercise 19
1A
4A
3A
1 1
6=1
1B2 1B1 2B2 2B1 3B1 3S1 4S2 4S1
1A
0
2A
0
3A
0
4A
0
A-66
Exercise 19
A-67
Exercise 20
Electropneumatics Handling device
Subject Title
Familiarisation with an alternative solution to Electropneumatics. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.
A-68
Exercise 20
Problem description
Cylindrical parts are to be distributed evenly from outlet channel 1 onto the two inlet channels 2 and 3 (see displacement-step diagram) The unit is to be operated in continuous cycle only. START and STOP AT END OF CYCLE are each to be effected by one push button. Sensing of parts at channel 1 is to be simulated by a switch. If this switch is not activated, the unit is to stop at the end of the cycle. After the swivel movement to inlet channels 2 and 3 has been carried out, the gripper is not to open until a short delay time has expired. After actuation of the EMERGENCY-STOP switch, cylinders 1A, 2A and 3A are to retract and cylinder 4M switched to an unpressurised condition. When the EMERGENCY-STOP has been unlatched, the reset button is to return cylinder 4M to the initial position. It must be possible to limit the number of cycles using a preselect counter.
Operating condition
A-69
Exercise 20

1 1 2 3 4 5 6 7 8 9 10 11 12 13=1
1S2 1S1 2B2 2B1 3B2 3B1 4B 4S
1A
0
2A
0
3A
0
4A
0
A-70
Exercise 20
B-1
Part B - Fundamentals
The theoretical fundamentals for the training package Electropneumatics are summarised in the textbook
Learning System for Automation and Technology
Introduction to Electropneumatics.
Basic Level TP201
B-2
C-1
Part C Solutions
Solution 1: Solution 2: Solution 3: Solution 4: Solution 5: Solution 6: Solution 7: Solution 8: Solution 9: Solution 10: Solution 11: Solution 12: Solution 13: Solution 14: Solution 15: Solution 16: Solution 17: Solution 18: Solution 19: Solution 20: Bench drill Feed unit for sheet metal strip Filling device Stamping device Drilling jig Clamping unit for grinding Forming press Embossing device Handling device Drilling and reaming machine Loading station Internal grinding machine Assembly unit Moulding press Pick-and-place unit Galvanising process Loading station Rotary indexing station Checking station Handling device C-3 C-9 C-17 C-21 C-27 C-35 C-41 C-45 C-49 C-55 C-59 C-63 C-69 C-75 C-81 C-87 C-95 C-103 C-111 C-117
C-2
C-3
Solution 1
Bench drill
Fig. 1/3: Circuit diagram, pneumatic
**
* For the purposes of this exercise, feed unit 2A is replaced by a double-acting cylinder. ** Detailed representation of the on/off valve with filter regulator.
C-4
Solution 1
Fig. 1/4 Circuit diagram, electrical
24 V- 1
1 33 33 13 13
2 K2
4 14
3 K3 BN
14 34
4 K1 BN BK BU
34
5 K2
10
11 K3
12
33 34
13
13
S 2B2 2B1
K1
1S2
14 1
14
1S1 BK BU
41
23
23
23
41
K4
24 A1 24 A1
K1
K2
K3
24 A1
K3
42
42 A1
K1
A2 A2
K2
K3
K4
A2
1Y 1A+
2Y 2A+
1
3Y
A2
3Z
11 7 9

4 5 11
2 3 10
Ausblasen
C-5
Solution 1
Since in this case the memory function is via a relay, single solenoid valves are generally activated using a latching sequence. It should be remembered that the coil circuit should be interrupted by a second contact for the return motion, for example, in order to achieve spring return of the valve to the initial position. (The final step represents an exception to this since it is possible to dispense with a normally closed contact as all valves are returned to their initial positions through interruption of all the circuits). This is why a latching sequence is used since in the case of power failure all cylinders will return to an accurately defined initial position. This is important for accident prevention, although it is important to watch out for overlapping of movements which may occur on reaching the initial position.
Solution description
24 V- 1
13
2
13
10
33
Fig. 1/5: Step 1, Cylinder 1A+
S
14 1
K1
14
K1
34
1S1
4
41
K4
42 A1
K1
A2
1Y 1A+
When START button S is actuated and normally open contact 1S1 is activated via cylinder 1A, the circuit to relay K1 is closed via the normally closed contact of K4, which then goes into self-holding (latching) via the parallel contact of K1. A further normally open contact of K1 switches the circuit to solenoid coil 1Y. This in turn switches the solenoid valve and cylinder 1A travels into the forward end position.
C-6
Solution 1
Fig. 1/6: Step 2, Cylinder 2A+
24 V- 1
13
2
13
3
1
4
13
10
33
11
33
S
14 1
K1
14
1S2
4
K2
14
K1
34
K2
34
1S1
4
41
23
41
K4
42 A1
K1
24 A1
K3
42
K1
A2
K2
A2
1Y 1A+
2Y 2A+
When cylinder 1A has reached its forward end position, it actuates limit switch 1S2. Then, the circuit for relay K2 is closed via S2 and the setting condition K1, this then goes into self-latching via a parallel normally open contact. A second normally open contact of K2 switches the current to solenoid coil 2Y via normally closed contact K3; this switches the valve and cylinder 2A extends. The principle of the latching sequence is to interrogate the preceding step and its acknowledgement (limit switch) and then to set a new memory for the next step. Finally, the complete sequence (the self-latching circuits) is reset by the last step (or cycle) no self-latching is required for the last step.
C-7
Solution 1
Quantity 2 1 1 2 1 1 2 1 1 1 2 1 1
Designation Relay, 3-off Signal input plate, electrical Indicator/distributor plate, electrical Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 3/2-way solenoid valve, normally closed 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V
Components list
C-8
Solution 1
C-9
Solution 2
Feed unit for sheet metal strip
1B1 1A
1B2 2A
2S1
2S2
1Y1
5 1 3
1Y2
2Y1
5 1 3
2Y2
0Z2
0Z1
1 3
Simplified representation of on/off valve with filter regulator
Solution 2
C-10
Fig. 2/4: Circuit diagram, electrical (1)
24 V- 1 6
13 23 1 13
2 7 K3 2S1
24 4 13 14
3 8 K5
14
4 9 K3
10
23
13
13
23
S1 K1
14 13 14 22
K1 1B1 BN BK BU
13
K5
24
S2 K4
14 1
14
2S2
4 11 14
K2
K8
14 41 41 21
K4
42 A1 A1 42 A1
K6
A1
K8
22 A1 A1
K1
A2 A2
K2
K3
A2
K4
A2
K5
A2
K6
A2

2 3 12 5 17
6 7
8 18
9 10
5 12 16 19
24 V- 11
11 23 23 23 33 31
12 K7 K7
24 24 24 24 34 34
13 SET 13 K6 K2 K4 K6 K8
14 21
14
15
16
17
18
19
20

14 13 14
1B2
BN
BK BU K6
41
K2
42 A1 A1
K7 H1
A2
K8 1Y1 1A13 15 8 1 20 A2
2Y1 2A-
1Y2 1A+
2Y2 2A+
C-11
Solution 2
C-12
Solution 2
When the SET button is pressed, relay K7 goes into self-latching and switches relay K8, which represents the start condition. If appropriate, the SET button should be latched in such a way that it can only be active at the time when the main current supply is applied, in order to safeguard the circuit sequence. Once the feed has been initiated with S1 and S2, K1 goes into selflatching and K2 switches, self-latching at K7 is cancelled via a normally closed contact of K2. A further possibility is to replace the SET key by a relay (see exercise 13).
Fig. 2/6: Step 1, Cylinder 1A-
24 V- 1
13
2
13
3
23
17
23
S1
14 13
K1
14
K1
22
K2
24
S2
14 1
2S2
4 11
K8
14 41
K4
42 A1 A1
K1
A2
K2
A2
1Y1 1A-
When START button S1 is actuated, the circuit for relay K1 is closed via the signal from pressing S2, the limit switch S22, the setting signal for relay K8 and the normally closed contact K4. The relay goes into selflatching via the parallel normally open K1. At the same time, a further normally open contact of K1 switches the circuit for the relay K2. A normally open contact of K2 switches the circuit in the power section to solenoid coil 1Y1. The valve switches and cylinder 1A travels into the retracted end position and there actuates limit switch 1B1.
C-13
Solution 2
Fig. 2/7: Step 2, Cylinder 2A24 V- 1

13
2
13
3
23
5 K3
6
13
7
23
17
23
18
23
S1
14 13
K1
14
K1
22
K3
14 24
K2
24
K4
24
1B1 BN BK BU K2
S2
14 1
13 14
2S2
4 11
K8
14 41 41
K4
42 A1 A1
K6
42 A1 A1
K1
A2
K2
A2
K3
A2
K4
A2
1Y1 1A-
2Y1 2A-
Now sensor 1B1 emits a signal which closes the circuit for relay K3 via the normally open contact K2 and the normally closed contact K6. This goes into self-latching via the parallel normally open contact K3. At the same time, relay K4 is switched via a further normally open contact K3. Only now, when self-latching of K3 has been established, is the setting condition K1 or K2 reset by normally closed contact K4 and in the power section, the normally open contact K4 switches the circuit to solenoid coil 2Y1, which in turn switches the valve, cylinder 2A retracts and activates 2S1 in the end position. Owing to its additional switching time, relay K4 serves as a delay between the build-up of self-latching of K3 and the reset of setting condition K2. This guarantees that K3 is in self-latching before the setting signal is set. Then, the next step is activated (K5, K6) by 2S1 via K4. The principle of the latching sequence is based on the interrogation of the preceding step and its acknowledgement (limit switch). The next step is activated on the basis of these conditions; when this happens, the preceding step is reset. The reset sequence is particularly suitable for the control of double solenoid valves, since here the memory behaviour is assumed by the bistable solenoid valve.
C-14
Solution 2
This can be very important in the case of power failure, in respect of accident prevention. To be able to start up again after power failure or switch off the main power supply (circuit dead), relays K7 and K8 must be switched. This happens here via the SET key. The principle of reversal of the latched sequence which is shown here is completely reliable owing to the use of an additional relay per step and can be used for every type of relay. Where there is a late opening or early closing relay, it may be possible to get by without an additional one. (Normally, only contactors have this type of switching behaviour). In such a case, the circuit up to step 2 would look as follows. Compare this simplified circuit diagram with the electrical circuit diagram.
Fig. 2/8 Circuit diagram, simplified
24 V13 13 13 23 23
S1
14 13
K1
14
K2 1B1 BN BK BU K1
23 24 14
K1
24
K2
24
S2
14 1
2S2
4 11
K8
14 41 41
K2
42 A1
K4
42 A1
K1
A2
K3
A2
1Y1 1A-
2Y1 2A-
C-15
Solution 2
Quantity 3 1 2 2 1 1 2 1 1 2 1 1
Designation Relay, 3-off Signal input plate, electrical Indicator/distributor plate, electrical Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 5/2-way double solenoid valve Cable set with safety plug Electrical power supply unit, 24 V
Components list
C-16
Solution 2
C-17
Solution 3
Filling device
1S1 1A
1S2 2A
2B1
2B2
3A
3B1
3B2
1Y
5 1 3
2Y
5 1 3
3Y
1 3
0Z2
0Z1
1 3
Solution 3
C-18
24 V1 BN K1 BK S1 13 S2
13 14 13 14 4 14 14 4 13 1 13 13 1
2 2B2 BN BK BU 1S1 K2 1S2 K3
10 K4
11
13 14
3B1
BU
14
S3 13 S4
14 35 14
S1 = Single cycle S2 = Continuous cycle K6

36 41 23 23
23
K7
42 A1 24 A1
K1
K2
24 A1
K3
24 A1
st S3 = 1 interrogation S4 = 2nd interrogation
K1
A2
K2
A2
K3
A2
K4
A2

4 5 18
18 6 7
8 10 19
19 11 13 17
24 V2B1 BN K5 BK
13 14 13
12 2B2 BN S6 BK BU
14 34 34 34 13 33 33 33
13 K1 K3 K5
TP202 Festo Didactic 14 15 16 17 18 19 20 BU S5

14
rd S5 = 3 interrogation S6 = Idle cycle without filling
23
23
33 41
41
K4 K2
34 A1 42 24 A1 24 A1
K5
K4
K4
42
K5
A2 A2 A2
K6
K7
1Y
2Y
3Y
1A14 16 20 2 2
2A+
3A+
C-19
Solution 3
C-20
Solution 3
When S1 or S2 and S3 are activated, the control system is started up. Cylinder 1A retracts and the bottles move along. If S4 is actuated, the cylinder extends again. Then, the indexing table (cylinder 2A) inches round one position. Once a bottle has reached the filling station, it is filled until the time delay closes the container (cylinder 3A), and the control system is brought back into the initial start position. If no bottle is reported as being present at the filling station, the control can be returned to the initial start position via S6. Then the indexing table can be supplied with bottles until a signal is received from S7.
Quantity 3 1 1 1 1 2 1 1 1 1 2 1 1 1 2 1 1 Designation Relay, 3-off Signal input plate, electrical Time relay, 2-off Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, capacitive Proximity sensor, optical Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 3/2-way solenoid valve, normally closed 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V
Components list
C-21
Solution 4
Stamping device
2B1 2A 1A 1S1 1S2
2B2
3A
3B1
3B2
2Y1
5 4 2 1 3
2Y2
4 2
1Y1
5 1 3
1Y2
3Y1
5 1 3
3Y2
0Z2
0Z1
1 3
Solution 4
C-22
24 V- 1 6
13 23
2 7 2B2 BN BK BU K3
14 24
3 8 9
13 23 13
4 K1 K2
24 1 14
5 K3
10
13
3B1 K1
14 11
K5
14
K12 1S2
14 13 4
13
S
14
K4
14
41
41
11
K4
42 A1 A1 42 A1
K6
A1
K8
12 A1
K1
A2 A2
K2
K3
A2
K4
A2
K5
A2

3 4 20 5 23
6 7
9 24
10 11
24 V- 11
23
12 2B1 BN K7 K7 1S1
24 4 21 14 24 14 13 11 21 11 21 1
13 K9 K9
14
15
16
17
18
K5
24
BK BU K6
14 24
K8
11
21
K10
A1 12 A1 A1
K12
24 A1 A1
K6
A2 A2
K7
K8
A2
K9
A2
K10
A2
5 13 25
14 15
6 7
9 24
9 24
C-23
Solution 4
Solution 4
C-24
24 V- 19
11 23 23 31 31
20 SET 13 K11
14 24 24 24 24 34 14 21 23
21 K2 K4 K6 K8 K10
34
22
23
24
25
26
27 K12
28
31 34
K11
3B2
21 22
K10
41 42 A1 A1
K2
K11
A2 A2
K12 1A+
20 22 16 2 20
1Y1
2Y1 2A+
2Y2 2A-
1Y2 1A-
3Y1 3A+
3Y2 3A-
C-25
Solution 4
This solution corresponds to a reset sequence of 6 steps with single cycle operation. Only when the last step has been set via the SET button, can another single cycle be started. The signal generators are directly switched to limit the number of relays.
Quantity 4 1 1 1 2 1 1 1 1 2 1 1 3 1 1 Designation Relay, 3-off Signal input plate, electrical Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, capacitive Proximity sensor, optical Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 5/2-way double solenoid valve Cable set with safety plug Electrical power supply unit, 24 V
Components list
C-26
Solution 4
C-27
Solution 5
Drilling jig
1B2 1A
1B1 2A
2B1
2B2
3A
3S1
3S2
1Y
5 1 3
2Y
5 1 3
3Y
5 1 3
0Z2
0Z1
1 3
* For the purposes of this exercise, feed unit 3A is replaced by a single-acting cylinder. A 3/2-way solenoid valve may also be used as a final control element.
3A
3S1
3S2
Fig. 5/4: Part of circuit diagram, pneumatic
3Y
Solution 5
C-28
24 V- 1 2B2 K1 3S2 3S1

14 4 14 13 4 14 13 1 11 13 1 11
2 K2 K4
14 11
3 K3
8 K5
9
13 14
S
14
K16
12
11
23
23
K14
12 A1 A1
K1
24 A1 A1
K3
24 A1
K1
A2
K2
A2
K3
A2
K4
A2
K5
A2

3 5 35
5 13 20 27
35 6 8
8 15 22 29
9 11 33
24 V- 10 1B1 K6
14 24 14 24 14 13 21 13 21 13
11 K2 BK BU
14
12 K7 K4 K8 2B1 BN K9
11
TP202 Festo Didactic 13 14 15 16 17 18 19

21
K16
22
23
23
23
23
K5 K7
24 A1 24 A1 24 A1
K6
K8
24 A1
K6
A2 A2 A2
K7
K8
K9
A2
12 13 36
36 14 15
16 18 34
19 20 37
C-29
Solution 5
Solution 5
C-30
24 V- 20
11 31 11
21 1B2 BN K12 BK BU K16

32 42 14 44 14 11 41 11 41
22 K4 K11
34 31 14
23 K2 K13 K4
44 41
24
25
26
27
28
29
30
31 14
K2
K10
34
K16
21
21
21
21
21
K9
24 A1 24 A1
K10
K11
K12
24 A1
K13
24 A1 A1
24 A1
K10
A2
K11
K12
A2
K13
A2
K14
A2
K15
A2
A2

33 23 25
37 21 22
26 27 38
38 28 29
31
24 V- 31
11 33 33 31 31 33 33
32 K5 K8
34 41 41 31 31 34 34 34 34 34
33 K1 K6 K9 K12
34
35
36
37
38
K15
14
TP202 Festo Didactic K3

42 42 32
K7
K10
K13
32
31
K11
A1 32
K16 1Y 1A8 15 22 29
H 2Y 2A3Y
A2
3A+
C-31
Solution 5
C-32
Solution 5
The preselect counter receives pulses from 3S2. When the preselect figure or the end of the drill life has been reached, the sequencer is stopped. It will not continue running until the drill has been changed (counter reset). Signal generators 3S1 and 3S2 must be switched indirectly to ensure reliable sensing. Otherwise, self-latching would supply a continuous signal (see example) when a latching sequence is being used.
Example
Kn+1 can be set without acknowledgement 3S1 being activated since current can flow via the self-latching of K3 and Kn.
Fig. 5/9:
24 V3S1 K3 Kn+1
K2 K3
Kn Kn+1
C-33
Solution 5
The signal generators indirectly switched (as in the solution to the exercise).
Fig. 5/10: Alternative circuit (1) K1 K3 K1 Kn+1
24 V3S1
K2 K1 K3
Kn Kn+1
As the connection is interrupted here by K4 via K3, Kn+1 may only be set if Kn and 3S1 are activated.
Fig. 5/11: Alternative circuit (2) K3 3S2 K4 Kn+1
24 V3S1
K4
K2 K3
K3 K4
Kn Kn+1
C-34
Solution 5
Components list
Quantity 5 2 1 2 1 2 1 1 1 1 2 1 1 1 2 1 1
Designation Relay, 3-off Signal input plate, electrical Preselect counter, electrical, incrementing Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 3/2-way solenoid valve, normally closed 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V
C-35
Solution 6
Clamping unit for grinding
1A
1S1
1S2
2A
2B1
2B2
3A
3B1
3B2
1B
P1
4 2
2Y1
5 2 1 3
2Y2
4 2
1Y
1 3
3Y1
5 1 3
3Y2
0Z2
0Z1
1 3
* For the purposes of this exercise, feed unit 2A is replaced by a double-acting cylinder.
Solution 6
C-36
24 V- 1
23 13 23
2 2B2 BN K4
24 14 24 13 23
3 2B1 BN K1 K4 BK BU
24 1 14
4 K2 BK BU K2
10
11 K6
12
13 14
13
13
K1
14
14
1S2
4
1B BN K3 BK BU K5
42 41 14
13
13
1S1
P1
K5
14
P2
K7 K9
11 11
11
K14 K13
A1 A1
K7
12 A1 A1
K9
12 A1
12 A1
K1
A2 A2
K2
K3
K4
A2
K5
A2
K6
A2
A2

4 5 7 29
2 3 28
8 9
4 11 31
12 13
24 V- 13 18
11 21 11
14 19 K10
24 14 24 14
15 20 K10 K12 21 22
11 21
16 K8 K8
14
17
23
3B2
K6
24

21 21 21
K7 K9
24 24 24
K11
11 11
21
K11 K13
12 A1 A1 12 A1 A1
K14
A1 24 A1
K7
A2 A2 A2 A2
K8
K9
K10
K11
A2
K12
A2
7 15 4 33
16 17
11 18 4 30
19 20
15 21 32
27 22 23
C-37
Solution 6
Solution 6
C-38
24 V- 23 29
23 31 23 31 31
24 31 K5
34 24 34 34
25 32 K11 K7 K13 33 34
31 23 33
26 S
34 24 34 24
27 K1 K3 K9
28
30
21
3B1
41 44
K12
K14
24
21
K13
24
11
31
K15
32 A1
K12
A1
12 A1
K13
A2
K14 1A+
25
K15
1Y
2Y1 2A+
2Y2 2A-
3Y1 3A+
3Y2 3A-
A2
A2
18 25 4 34
1 26 21
C-39
Solution 6
In this exercise, two problems can be solved with minimal modifications to the reset sequence: Memorising of the start signal (K1) for the movement 1A+, Resetting of the final step (K14) via START button S. The pressure switch does not switch over until the clamping pressure has been reached; consequently the sequencer stops until the required pressure has built up. In this exercise, sensor 2B1 and 2B2 can be interrogated directly several of times without faulty actuation of the control taking place (compare with exercise 5).
Quantity 5 2 1 1 2 1 1 1 1 2 1 1 1 1 2 1 1 Designation Relay, 3-off Signal input plate, electrical Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right Pneumatic-electric converter 3/2-way solenoid valve, normally closed 5/2-way double solenoid valve Cable set with safety plug Electrical power supply unit, 24 V
Components list
C-40
Solution 6
C-41
Solution 7
Forming press
1A
1S1
1S2 2A
2B1
2B2
1Y
5 1 3
2Y
5 1 3
0Z2
0Z1
1 3
Solution 7
C-42
24 V- 1
21 13
2 K1
ES
22
1
11
14
3 2B1 BN BK BU
14 13 23 24 23 24 41
K5
12 13
K4
S1
14 13
S2
14 35
K3 K2
36 A1 42 A1 A1
A1 = 0,5s A2
K1
A2 A2
K2 K3
K4
A2

2 4 14 3
24 V-
8 1
1 21 1 11
9 2B2 BN K2 BK BU
14 34 13 31
TP202 Festo Didactic 10 K6

4 14
11 K6
12
13
14
15
1S2 1S1
24 4
K5
41 31
21
41
K7
42 A1 34 A1
K5
K6
24 A1
K5
42
K5 K6
A2 A2
K7
A2
1Y 1A+
2Y 2A+
8
3 9 14 10 11 13 15
C-43
Solution 7
C-44
Solution 7
If the EMERGENCY-STOP switch ES is not activated, current path (1) is supplied with current. In order to switch relay K2, the two push buttons S1 and S2 must be actuated simultaneously (START signal). If one of the push buttons is pressed before the other, the time relay with switchon delay is energised which then switches after 0.5 secs. (For safety reasons, the switch-on delay must not exceed 0.5 seconds). The result of this is that the normally closed contact K3 in current path 3 opens and, thus the connection to K2. If two buttons are actuated simultaneously so that the time relay does not switch through, relay K2 is switched and cylinder 1A extends. When the EMERGENCY-STOP switch is actuated, the current to path 1 is interrupted and the solenoid coils are no longer supplied with current. The result of this is that the reset springs reverse the solenoid valves and the cylinders return to the initial position.
Components list
Quantity 2 1 1 1 2 1 1 1 2 1 1 2 1 1
Designation Relay, 3-off Signal input plate, electrical Time relay, 2-off Indicator/distributor plate, electrical Double-acting cylinder On/off valve with filter regulator Manifold EMERGENCY-STOP button Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V
C-45
Solution 8
Embossing device
1A
1B1
1B2
2A
2S1
2S2
1Y
5 1 3
2Y
5 1 3
0Z2
0Z1
1 3
Solution 8
C-46
24 V- 1
13 11
2 S2
14
3 K3
14
10
11 K4
12
11
13
11
S1 1B1 1B2
K1
14
14
14
31
11
41
21
K1
34 14
K2
K1
44
K2
24
S1 = START-button S2 = Manual step mode

21
11
K6
21 21
K3
24 11
12
K1
A1 22 A1 22 A1
K7
K7
12 A1
A1
K1
A2 A2
K1'
K2
K3
A2
K4
A2
A2

18 13 16 7 11 14 17
4 2 6 10
8 10 19
12 13 20
24 V- 13
1 1 13 31 31 11
14 K5 2S1
14 4 14 34 34
15 S3 K3 K4
16
17
18
19
20
2S2
4

11 31 21 41
K1'
14 34 24 44
S3 = Step repetition K2 K1' K2

21 21 31
31
K1
24 A1 24 A1
K5
K1'
32 A1
K5
32
K5
A2 A2
K6
K7
A2
1Y 1A+
2Y
2A+
10
20 15 16
1 6
C-47
Solution 8
C-48
Solution 8
Solution description Manual step mode Step repetition
By pressing the START button, the program is started in accordance with the displacement-step diagram. By pressing push button S2, it is possible to carry out one movement per actuation in accordance with the program or control sequence. When, after pressing S2, cylinder 1A has advanced via K3 and cylinder 2A via K4, self-latching at K4 can be reset via K7 by means of push button S3. As a result of this, K4 is de-energised and cylinder 2A retracts. Cylinder 2A is now able to advance again via S2.
Quantity 2 2 1 2 1 1 1 1 1 1 2 1 1 Designation Relay, 3-off Signal input plate, electrical Indicator/distributor plate, electrical Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V
Components list
C-49
Solution 9
Drilling and reaming machine
2B1 1S1 1A 1S2
2B2
*
2A
1Y
5 1 3
2Y1
2Y2
0Z2
0Z1
1 3
* For the purposes of this exercise, linear drive 2A is replaced by a double-acting cylinder.
2A 2B1 2B2
Fig. 9/4: Part of circuit diagram, pneumatic
2Y1
1 3
2Y2
5 1 3
Solution 9
C-50
24 V21 11
7 ES K4
22 1 14
NA 3
13 13 23 23
1 K2 1S2
24 2 14 14 24
2 K1 1B K2
10
11
12
11
13
13
S1
K1
S2
K6
14
14
14
2B1
21
11
BN BK BU
13
K5
24
K5
S1 = Single cycle S2 = Continuous cycle S3 = STOP

31 32 A1 A1 A1 A1
14
K3
14 21
11
K9
S3
K9
24 A1
1B = Sensing of parts ES = EMERGENCY-STOP K3

A2 A2
12 A1
K1
K2
K4
A2
K5
A2
K6
A2
A2

4 6 11 25
2 5
19 8 26
1 3 18
12 13 21
24 V21 11 31 11
19 K10
22 14 32 14
20 K6 K11
21
22
K4 13
1 11 11 31
14 K7 K8 BN
12 34
15 K5
16
17
18
TP202 Festo Didactic 1S1

4 14
2B2
BK BU
S4 = RESET linear drive

11
K12
21 21 21 31 12 13
K6 K8
24 A1 24 A1 24 A1
K7
S4
32 A1
K13
14 A1
K7
A2 A2
K8
K9
A2
K10
A2
K11
A2
30 14 15 29
17 18 23
29 20 30
22 28
C-51
Solution 9
Solution 9
C-52
24 V- 23
31 31 21 23 23 21
24 K12 K3
24 32 24 24 24
25 K4 29
31
26 S5 K11
27
28
K8
34
30
41
K7
34 21
K7
42 31
K10
22
K10
32
S5 = RESET gripper
41
K5
42 23
K13
24 A1 A1
K12
A2
K13
A2
1Y
2Y1
2Y2
1A+
21 24 21 23
2A+
3A-
C-53
Solution 9
Line 1 is supplied with current via relay K4 (provided the EMERGENCYSTOP button has not been pressed). The cycle is started via S1 or S2. A latching sequence is then constructed for this motion sequence through current paths 9 to 18. When the EMERGENCY-STOP switch (ES) has been actuated, the gripper is to remain in its current position, whether open or closed. The signal close gripper is acquired via relay K6. This signal must be stored after actuation of EMERGENCY-STOP to keep the gripper in a closed position (see current paths 21 and 22). However, this memory must be erased if, at the time of the EMERGENCY-STOP actuation, the control had opened the gripper. In this case, the open signal K8 MUST BE STORED (SEE CURRENT PATHS 23 AND 24). Relay K13 is required to ensure that the reset button for gripper S5 is only active when the EMERGENCY-STOP key has already been switched off and the controller has been stopped. This is only released when no start signal or EMERGENCY-STOP signal is present and push button S5 has been actuated. Coil Y2 is actuated by signal K7 and the linear drive proceeds. Selflatching of relay K10 is required to switch the linear drive to unpressurised on actuation of the EMERGENCY-STOP and to memorise this status. This is then reset by RESET button S4 and the unit is returned once again to the initial start position. A new start signal is not memorised until the gripper has actuated limit switch 1S2 (K5). The cycle only starts if parts are present in the outlet channel (sensor 1B) and the initial position of the linear drive (sensor 2B1) is being signalled. Owing to multiple sensing, limit switch 1S2 must be switched indirectly via relay K5.
C-54
Solution 9
Components list
Quantity 5 2 1 2 1 1 1 1 2 1 1 1 2 1 1
Designation Relay, 3-off Signal input plate, electrical Indicator/distributor plate, electrical Double-acting cylinder On/off valve with filter regulator Manifold EMERGENCY-STOP button Proximity sensor, capacitive Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 3/2-way solenoid valve, normally closed 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V
C-55
Solution 10
Drilling and reaming machine
1A
1S1
1S2 2A
2B1
2B2
3A
3B1
3B2
1Y
5 1 3
2Y
5 1 3
3Y
5 1 3
0Z2
0Z1
1 3
* In order to assemble this control system on the profile plate, feed unit 1A is replaced by a double-acting cylinder and feed unit 3A by a single-acting cylinder.
C-56
Solution 10
24 V- 1 6
1 33 1 23
2 7 K1
4 34 21
3 8 K3
24
4 9
13
5 K2 1S1
14 4
10
11
13
13
2B1 BN 1S2 BK BU K3 K4
14 13 24 13
K1
14 41 14
K5
14
K2
42
S
14 23
K1
11 24 21 23 31
S = START-button
PS = PROGRAM SELECTION button

11
K4
12 A1 22
K8
A1
K8
12 A1
K2
24 A1
K4
34 A1
K1
A2 A2
K2
K3
A2
K4
A2
K5
A2

2 5 8 1 5 7 19
4 9
4 8 19 9
10 12 20
24 V- 11 19
33 31 31
12 20 K5
34 34 34
13 21 K6
11
14 3B2 K7 K2
14 11
15 3B1
16
17
18
2B2 K6
14

21 21 41 31
BN
BK
BU
21
K5 K4
24 A1 42 24 A1
K6
K7
K7
32
24 A1
K6
A2 A2
K7
K8
1Y
2Y
3Y
A2
1A+
21 16 18 1 5
2A+
3A+
13 15 21
Solution 10
C-57
C-58
Solution 10
Relay K1 is switched via the PROGRAM SELECTOR BUTTON PS. This is only possible prior to actuation of the START button. If program 2 (drilling and reaming) is selected, the latched sequence runs through as usual. However, if program 1 (drilling) is required, it is simply necessary to press the start button. If 1S2 and contact K2 switch the relay K4, the sequencer is reset by K4 and cylinder 1A retracts.
Components list
Quantity 3 1 1 1 2 1 1 1 1 2 1 1 1 2 1 1
Designation Relay, 3-off Signal input plate, electrical Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 3/2-way solenoid valve, normally closed 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V
C-59
Solution 11
Loading station
1A
1S1
1S2
2A
2B1
2B2 3A
3B1
3B2
1Y
5 1 3
2Y
5 1 3
3Y
5 1 3
0Z2
0Z1
1 3
* For the purposes of this exercise, cylinder 1A is replaced by a single-acting cylinder.
C-60
Solution 11
24 V11 1 14 4 11 1 11 21 21
1 7 K3 1S1
14 24 24 4
2 8 K4 K5 K6 9 10 11 12 13 K2
14
3 1S2
11 12
S1 2B1
K1
11
11 11
K9 K4
14 21 12 12
K5
2B2
S1 = START button S2 = Sensing of steel parts K1

24 1
41
S2
4 41 21 21 31 31
K10
42
K7 K2
42 24 A1 A1
K3
24 A1 A1
K4
34 A1
K5
34 A1
A1
K1
A2
K2
K3
A2
K4
A2
K4'
A2
K5
A2
K6
A2
A2

5 6 21 22 15 7 22 8
2 4 15
6 9 12 24
25
8 12 13 23
21 13 22 14
14
31 13 31 41 41 41 11
15 K1 3B1
BN BK BK BU BU BN
16 K2 K2
34 44 44 44 14
17 K5 K4 K8
18
19
20
21
22
23
24
25
K1
34 14
TP202 Festo Didactic 3B2

41 11
K5
42
K4'
14
Electromagnet
31 41
21
31
K6 K6
32 A1 A1 R1 A1 32 42
K3
K6
24
A1
K7 H1
A2 A2 R2 A2
K8
K9
K10
1Y
2Y
3Y
A2
4 25 1 16
Electromagnet
1A+
2A+
3A+
Solution 11
C-61
C-62
Solution 11
The cycles of the control are counted to enable cylinder 3A to extend. Where there is a preselected figure 2, cylinder 3A is extended together with cylinder 2A on the second cycle of the control system in order to bring the part past position 2. If cylinder 3A has extended, start condition K1 is reset via 3B2 (K10) and the counter is reset to zero.
Components list
Quantity 4 1 1 2 1 2 1 1 1 1 2 1 1 1 2 1 1
Designation Relay, 3-off Signal input plate, electrical Preselect counter, electrical, incrementing Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 3/2-way solenoid valve, normally closed 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V
C-63
Solution 12
Internal grinding machine
3A
1A
1B1
1B2
2A
2S1
2S2
3B1
3B3
3B2
2B
P1
1Y
5 1 3
2Y
5 1 3
3Y
5 1 3
0Z2
0Z1
1 3
* For the purposes of this exercise, cylinder 1A is replaced by a single-acting cylinder and feed unit 3A by a double-acting cylinder. The inductive proximity sensor 3B2 is switched to mid-position by the trip cam.
C-64
Solution 12
24 V- 1
23 13
2 K1 K4
p 14 p1 2
3 K3 K5 BK BU
14 1 4 14 24 13 14
4 1B2 2B BN 3B3
13 13
5 BN
10
11
12
13
13
13
S1 K2
K1
2S1
14
14
BK BU
S1 = START-button S2 = Part of the stop S3 = STOP-button

11 23 23
S2
31
S3 K14
14 A1 24 A1
K3
K4
24 A1 A1 A1
32 A1
A1
K1
A2 A2
K2
K3
K4
K5
A2
K5'
A2
K6
A2
A2
A2

5 7 32
2 4
4 29
8 10 33
11 14 22 35
37
20 14 16
C-65
Solution 12
C-66
Solution 12
24 V- 28
21 1 33 33 41 41
29 K13 2S2
24 34 41 31 42 44 31 4 34
30 K3 K4 K13 K5 K5'
31
32
33
34
35
36
37
11 14
1B1
23
K2 K12
42 32
K7
K10
34
24
21
31
41
11
K12 K12
A1 32
K11
42
K12'
12
24 A1
K13
A2
K14
1Y
2Y
3Y
H1
A2
1A+
4
2A+
3A+
Grinding wheel
17 30 31 35
C-67
Solution 12
When the installation is started up and the initial position of cylinder 2A (2S1) and a workpiece (S2) are signalled, cylinder 1A extends. Then cylinder 2A extends and clamps the part. When the clamping pressure has been reached, cylinder 3A is extended via K5. Sensor B5 is activated in the forward end position. This in turn activates relay K6. Then feed cylinder 3A retracts again. In addition, K6 passes on a counting pulse to the preselect counter. Sensor 3B2 is activated when the cylinder has retracted by a half. This then reverses the valve via further contacts (K6, K7, K9) and cylinder 3A extends again. This sequence is carried out until the preselected figure has been reached. If 3B2 is activated on the return stroke, the valve may not switch since counter contact K9 interrupts the circuit. The sequence is switched on via a second counter contact.
Quantity 5 2 1 2 1 2 1 1 1 1 1 2 1 1 1 1 2 1 1 Designation Relay, 3-off Signal input plate, electrical Preselect counter, electrical, incrementing Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor, optical Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right Pneumatic-electric converter 3/2-way solenoid valve, normally closed 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V
Components list
C-68
Solution 12
C-69
Solution 13
Assembly unit
2A 1A
2B1
2B2
1S1
1S2 3A
3B1
3B2
2Y1
4 2 5 1 3
2Y2
4 2
1Y1
5 1 3
1Y2
3Y1
5 1 3
3Y2
0Z2
0Z1
1 3
* For the purposes of this exercise, cylinder 1A is replaced by a single-acting cylinder.
C-70
Solution 13
24 V- 1
23 11
13
S2 K1
24
14
1 3
11 21 1 11 21
12
2 K2 K2 1S2
24 4 11 14 24 14
5 K4 K4 2B2
10
11 K6
12
11 14
2B1 K3
13 14
S1 = OFF/ON S2 = MAN/AUT
S1
14 13
21
K5
24
K11
14 11 11 11
K5
12 A1 A1
K7
12 A1 A1
K9
12 A1
A1
K1 K2
A2
K3
A2
K4
A2
K5
A2
K6
A2
A2

5 6
4 32 36 40
19 7 29
8 9
4 11 33
12 13
24 V-
TP202 Festo Didactic 13

21
14 3B2 BN K8 K8 K10 K12

14 42 24 11 21
15 3B1 BN K10 BK BU
21 1 13 41 23
16
17
18
19
20
21
22
K6
24
BK BU
14 24
K7 1S1
24 4 21
K9
24 41 21
K11 K3
42 A1 A1 A1
22 A1
A1
K7 K8
A2 A2 A2
K9
K10
A2
K11
A2
7 15 37
16 17 28
11 19 31 39
20 22 23
15 4 35
Solution 13
C-71
C-72
Solution 13
24 V21
32
Fig. 13/6: Circuit diagram, electrical (3) K1 25 26 27 28 30

22
23
13 13 31 41 31 13
24 S3
14 14 31 32 13 14 41 42 14 42 13 42 41 34
29 K3 K13
14
31
31 41
33
K10
K12
K9
34
K13
42
34
S4
32 31
S5
32
A1 A1 A1 A1
K12 K13 K15

A2 A2
K14
H1
A2
1Y1
1Y2
A2
1A+ MAN
40 38
1A-

32 30 36 34
21 24
24 V31 41
36
40
K1 34
32 42
K1 38
TP202 Festo Didactic 33 37

41 31 13 41 41
35 39 K15
34 14 42 13 23
31
K5 K14
24 42 34 14
K14
K11
K7
K9
K15
42
2Y1
2Y2
3Y1
3Y2
2A+
2A-
3A+
3AFig. 13/7: Circuit diagram, electrical (4)
Solution 13
C-73
C-74
Solution 13
When the MAN/AUT switch S2 or relay K1 is not actuated, voltage is applied at line 1 (MANUAL mode). The cylinder can be extended individually via push buttons S3, S4 and S5. Cylinder 1A extends and remains in the extended position for as long as push button S3 is actuated or an additional push button is pressed. Movement is prevented if two or three push buttons are pressed simultaneously. To ensure that there is no interference with AUTOMATIC mode, the lines to the normally closed contacts of relays K13, K14 and K15 are each interrupted by a normally closed contact of K1. As soon as line 2 (AUTOMATIC mode) is supplied with current, selflatching is set via the normally closed contact K12 in current path 12. At the same time, when K10 goes into self-latching, relay K12 is switched via a normally open contact K10. This also goes into self-latching and the normally closed contact K12 in current path 21 opens. Thus, the last step which is normally required as a start condition can be activated without the use of a SET button.
Components list
Quantity 5 2 2 1 2 1 1 1 1 2 1 1 3 1 1
Designation Relay, 3-off Signal input plate, electrical Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 5/2-way double solenoid valve Cable set with safety plug Electrical power supply unit, 24 V
C-75
Solution 14
Moulding press

2B1 2B2 2A 2B3
1A
1B1
1B2
3A
3S1
3S2
1Y
5 1 3
2Y
5 1 3
3Y
5 1 3
0Z2
0Z1
1 3
* For the purposes of this exercise, the double-acting cylinder is replaced by a singleacting cylinder.
C-76
Solution 14
24 V- 1
23
2 1B2 K4
13 24 23 14 13 14 24 13 13 23 17
3 K5 K4 K6
18
10 K7
11
13 14
13
S1
14
S1, S2 = START-button K3
14 14 24 11
S2
K14
14 41
K5
13 42 41 11 23
41
K3
14 A1 42 A1 A1
K1 K2
K11
12 A1 A1
K5
24 A1
42 A1
K1
A2 A2
K2
K3
K4
A2
K5
A2
K6
A2
K7
A2
A2

4 1 7 30
24 7 9
8 10 31
10
31 11 13
24 V- 12
11 1 11 1 21 11
13 K8 2B3 3S1
14 4 24 14 4 14
14 K9 3S2 BK BU K10 K11 2B1 BN
15
16
17
18
19
20
21

23 21 21 21
1B1
K7
24 A1 24 A1 24 A1 24 A1
K8
K9
K10
A1
K8 K9
A2 A2 A2
K10
K11
A2
K12
A2
24 13 15 32
15 16 27 33
33 17 18 25
7 19
27 26
Solution 14
C-77
C-78
Solution 14
24 V11 21 31 11 21 23 33 41 11
22 K14
14 31 31 41 24 34 14 24 24 34 14
23 K12 K9 K15 K15 K3 K5 K8

44
24
25
26
27
28
29
30
31
32 K9
33
41 44
BN
K13
2B2 K10
32 34
BK K7
42
BU
K8
41
21
41
K4
42 A1 22 A1
K12
K10
42
A1
K13
A2 A2
K14
K15
H1
1Y
2Y
3Y
A2
1A+
28 29
2A+
3A+
Vacuum generator

4 25
24
C-79
Solution 14
The two-hand safety control is realised in current paths 1 to 4. Relay K2 serves here as a delaying element. The maximum time duration allowable between the actuation of S1 and S2 is dependent on the switching time of this relay. If the two push buttons S1 and S2 are activated simultaneously, cylinder 1A extends. These buttons must remain depressed until the cylinder has reached its forward end position. The start condition is decided by the connections in current paths 24 26. It has been established that the signal from signal generator B5 only becomes effective when the extractor unit leaves the working area, i.e. on the return stroke of cylinder 2A. Relay K15 starts the operation of the vaccum generator which must be specially stored as the sequence is set before the retraced end position of cylinder 2A is reached.
Quantity 5 1 1 2 1 2 1 1 1 1 1 2 1 1 1 2 1 1 Designation Relay, 3-off Signal input plate, electrical Time relay, 2-off Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor, optical Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 3/2-way solenoid valve, normally closed 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V
Components list
C-80
Solution 14
C-81
Solution 15
Pick-and-place unit

2B1 2A 2B2
1A
1S1
1S2
3A
3B1
3B2
1Y
5 1 3
2Y
5 1 3
3Y
5 1 3
0Z2
0Z1
1 3
* For the purposes of carrying out this exercise on the profile plate, cylinder 3A is replaced by a single-acting cylinder.
C-82
Solution 15
24 V- 1
13 1 13
2 2B1 BN 3B2 K3
14 13 14
3 K2
4
10 K4
11
21 24
13
S1 1S2
14
K1 BK BU
14 13
S2
S1 = START-button S2 = Gear housing S3 = Magazine

23 41 11
14 11
13
S3 K3 K4
42 23 12 24
K5
12
14
K1
24 21 23 23
11
K15
22 A1
K15
K2
24 A1
K3
24 A1
12 A1
K1
A2
H1 K2
K3
A2
K4
A2
A2
Magazine

5 7 40
2 4 22
8 10 36
7 11 41 13
24 V- 12
1 21 21 21 21
13 K6 K9
24 24 4 24 24
14 K7 K8
15
16
17
18
19
20
21
22
23
24
3B1
21
K5
1S1

11 11 11 11
24
11
K6
12 12 12 12 33
K7 K8 K1
34 31 31 31 31
K9
K10
12
31
K4
34 34 A1 A1 A1 A1 34
K5
K6
K7
K8
34 A1 A1
34
A1
K5
A2 A2 A2 A2
K6
K7
K7'
K8
K9
A2
K9'
A2
A2
10 14 15 38 42
13 16 17 42
15 18 36 20
17 21 38 22
20 23 25 37
43
Solution 15
C-83
C-84
Solution 15
24 V- 25
21 13 13 11 11 31
26 K11 S2
14 32 24 14 14 14
27 K12 K13 K14
28
29
30
31
32
33
34
35
23 24
K10
41
41
2B2 BN BK BU
K11
42
K12
42
31
31
23
23
21
21
K9
34 A1 A1
K10
K11
24 A1
K12
24 A1
K13
24 A1
K14
24 A1
34
A1
K10
A2 A2
K11
K11'
K12
A2
K13
A2
K14
A2
K15
A2
H2
A2
Gear housing

25 28 31 39 40
22 26 43 27
27 31 32 44
44 32 33
39 33 34
1 4
24 V- 36
33 41 41 33 33 41 11 33
37 K9 K5
44 44 14 34 44 34 34
38 K11 K2 K6 K9' K12
39
40
41
42
43
44

34 41 31 41 31 41 41 11 41 31
K7
42 32 42 32 42 42 12
K13
K8
K14
K11'
K4
K7'
K10
42
K13
32
H3 1Y 2Y
3Y
Vacuum generator 1A-
2A-
3A+
Solution 15
C-85
C-86
Solution 15
If one of the magazines is empty, then the installation remains stationary at position 1 or 2 by resetting the START signal, and waits there until the magazine has been filled and a new START signal is issued (see current paths 1, 4, 22). In order to fulfil the gear sensing, it is necessary to establish whether a gear housing is available (starting precondition). When the assembly has been completed, the gear housing must be removed. Without this, it will no longer be possible to start the installation (see current path 1, 4, 34).
Components list
Quantity 6 2 2 1 2 1 1 1 1 2 1 1 1 3 1 1
Designation Relay, 3-off Signal input plate, electrical Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 3/2-way solenoid valve, normally closed 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V
C-87
Solution 16
Galvanising process
1B1 1A
1B3
1B2
1Y
5
0B
P1
0Z2
0Z1
1 3
C-88
Solution 16
24 V- 1.0 0B K1 K2
24 23 24 14 14 13 14 13 23 21 13 11 13 23
1.1 K15 K2 K18 K4

14 11
1.2 K4
24
10
BN
1B1 K1
24 14
BK K3 K13
14 11
S = START-button K15
14 11
BU
K21
14 13
S
14 41 41 11
K2 K5
42 42 A1 A1
K7
12 A1 A1 A1
A1
K21
A2
K1
K2
A2
H1
K3
A2
K4
A2
K5
A2
A2
22 3 4 26
5 6 42
Bad 1
9 10
4 11 27
TP202 Festo Didactic 1A+
1A-
24 V- 11
31 35 11 21 41 11 13 23
12 K6 K8
36 21 14 24 44 21 14
13 K6 K19
24
14 K8 K15 K10
15
16
17
18
19
20
K15
34 13 14
K5 K9
24 24 14

11 11 21
K9
12 A1 A1 A1 12 A1
K11
K13
22 A1
K6
A2 A2 A2
H2 Bath 2
8 15 36 16 17
K7
K8
K9
A2
K10
A2
H3 Bath 3
12 14 44
11 18 28
19 21 43
1A+
1A-
1A+ Fig. 16/5: Circuit diagram, electrical (2)
Solution 16
C-89
C-90
Solution 16
24 V- 21
11 17 13 21 33 23 31 31
22 1B3 BN BK BU S1 K12
14 34 24 34 34 18 24
23 K1 K5 K9 K12 K14
24
25
26
27
28
29
30
31
32
21 14
21
K10
K18
K12
24
24 21
K11
S1 = SET-button
A1 A1 A1
24
41
K1
A1
42
A1
A1
K11
A2
K12
K13
K14
A2
K15
A2
K16
A2
A2
A2
15 22
23 25 29 45
18 2 37
34 30 45
2 4 11 18
33 37
TP202 Festo Didactic t1
1A-
24 V- 33
31 21 11
34 K16
32 34 34 3 31 21 28 44 27 24 14 4 34
35 K20 K2 K10 K6 K12 1B2 1

33 31 33 41
36
37
38
39
40
41
42
43
44
45
11
11
K16 K7
K17
14
14
TP202 Festo Didactic K14 K13

32 22
K20
S2 = Up/Down
35 11 31
13
K14 K22
12 A1 A1 A1 32 14
K18
S2
36
A1
R1
A1
K17
A2 A2 A2
K18
K19
K20
K22
1Y
H4
A2
R2
A2
Work surface
oscillate
t1 > tReturn stroke
35
40 8 22
15
42 38
37
t2
1A+
Solution 16
C-91
C-92
Solution 16
Initial position: Cylinder 1A is retracted and is located above the work surface and lamp H4 is illuminated. Cylinder 1A can be extended via the up/down switch (current path 41). Once the initial start position has been regained, the cycle is started with the start button. Then lamp H4 is switched off and the time t1 expires. This switches lamp H1 (bath 1 reached) and allows cylinder 1A to extend via relay K2. Counting pulses are passed on to the counter via 1B3 (current paths 31-34). Additionally, 1B3 reverses the valve so that cylinder 1A retracts as far as 1B2. As a result, cylinder 1A is switched back to Extend (current paths 37-40). This oscillating movement of cylinder 1A is repeated until the counter switches and interrupts the signal of sensor 1B2. When the cylinder has retracted, time delay t1 is activated once again by relay K5, which switches relay K6 when it has completed its cycle. Lamp H2 is illuminated and cylinder 1A extends. Next, the delay period t2 of the basket in bath 2 is switched via K7. Then, relay K8 switches, cylinder 1A retracts once again and the time t1 is repeated. When the time relay has switched, the cylinder enters bath 3 and the motion sequence carried out for bath 1 is repeated. Time period t1 is then activated a final time and signals the initial start position via lamp H4. The time t1 must be longer than the time which the cylinder requires for its return stroke.
C-93
Solution 16
Quantity 6 1 1 1 1 1 1 1 1 1 2 1 1 1 1
Designation Relay, 3-off Signal input plate, electrical Time relay, 2-off Preselect counter, electrical, incrementing Indicator/distributor plate, electrical Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor with cylinder mounting Pneumatic-electric converter 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V
Components list
C-94
Solution 16
C-95
Solution 17
Loading station

1B 1 1A1
1B2
1A2
2B1
2B2
2A
1V1
1Y1
1V2
1Y2
2V
2Y1
2Y2
5 1 3 5 1 3 5 1 3
3A
3S1
3S2 4M
4S
3V
3Y1
4V
3Y2
4Y
4B
0Z2
* For the purposes of this exercise, the rotary actuator (4M) is replaced by a singleacting cylinder, and the rodless cylinder (1A) by a double-acting cylinder.
0Z1
1 3 2
C-96
Solution 17
24 V- 1
11 13 11 11 11 13 11
2 K1 K4
11 14 12 14 14
3 1B2 K11
14 14 14 14 14
4 K2 K9 K3 K19 K5
10
11
11 14
1B1
13 14
K18
S = START-button
41 21 21 21
21
K7
42 A1 24 A1 24 A1
K1
K2
K3
24 A1
K4
24 A1
K1
A2 A2
K2
K3
A2
K4
A2
K5
A2
3 5 35 36
35 5 6 39
7 8 20
20 9 10 44
44 11 12 34
TP202 Festo Didactic 1A+ 3A+
4M+
4M-
24 V- 12
13 11 23 11 1 1 1
13 3S1 3S2 4B
4 14 24 14
14 4S K12 K11 K13

4
15
16
17
18
19
20
21
22
23
13 14 4
13
K10
K6
K8

23
14
14
K9
24 31
K4
32 21
K18
23 22 31 21
21
K5 K3
24 A1 A1 A1 A1 A1 34 A1
K6
K12
24 A1
24 A1
K6 K11
A2 A2
K7 K12
A2 A2 A2
K8
K9
K10
K13
A2 A2
A2
39 13 14 42
14 28
6 20
12 24
10 22
21 22 33 43
33 23 43 24
3A-
1A-
4M+
4MFig. 17/6: Circuit diagram, electrical (2)
Solution 17
C-97
C-98
Solution 17
24 V- 24
11 11 11 21 31 11 23
25 2B1
14 14 24 14 14 24
26 K15 K8 K16 2B2 K17 K17 K12

34
27
28
29
30
31
32
33 K5
34
31 34
23
K10
K14
24
21
21
21
21
31
K13
24 A1 24 A1
K14
K15
K16
24 A1 A1
K13
32 A1 R1
24 A1
K14
A2 A2
K15
K16
K17
A2
K18
A2
K19
A2 R2
A2
25 27 37
39 27 28 41
37 29 31 38
41 31 32 40
20 8
TP202 Festo Didactic 3A2A+
2A-
3A+
24 V- 35
31 41 41 31 41 33 41 41
36 K16 K17
44 31 34 44 41 44 41 34 44 41
37 K2 K15 K6 K12 K4
44
38
39
40
41
42
43
44
31 34
41
K1
K1
K14

32 42 42 42
34
44
K17
K13
K5
31
31
41
K2
32 42
K16
K6
32
1Y1
1Y2
2Y1
2Y2
3Y1
3Y2
4Y
H1
Suction cups
1A+
1A+
2A-
2A+
3A+
3A-
4M+
Solution 17
C-99
C-100
Solution 17
Solution description Main program
The loading station is located in step 21 of the subroutine. When the START button has been pressed, K1 causes cylinder 1A to extend. Then cylinder 3A is extended via K2 and cylinder 3A is switched to the unpressurised condition. Next, the jump from K3 to K12 into the subroutine takes place. When the subroutine has run through, the return jump through K18 and K19 to K4 in the main program takes place. Cylinder 4M advances and is retracted by K5. The, cylinder 3A is retracted by K6 and cylinder 1A by K7.
Subroutine
Movements 4M+, 4M-, 2A- (with every 2A- movement, cylinder 1A which has been switched unpressurised, is pushed back by a partial stroke), 3A-, 2A+, 3A+ are executed in the subroutine and repeated three times via a counter. When the counter has reached the preselected figure, the return jump to the main program is carried out. In the case of this motion sequence, costs make it necessary to realise this by means of a repetition of a program section (subroutine). Increased expenditure on planning is justified here by a considerable saving on relays and very much simpler circuitry, so that in this case, the solution shown is more economical than a solution with the full sequence which requires less planning.
Comment
C-101
Solution 17
Quantity 6 1 1 2 1 3 1 1 1 1 1 2 1 1 1 2 2 1 1
Designation Relay, 3-off Signal input plate, electrical Preselect counter, electrical, incrementing Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor, optical Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 3/2-way solenoid valve, normally closed 5/2-way solenoid valve 5/2-way double solenoid valve Cable set with safety plug Electrical power supply unit, 24 V
Components list
C-102
Solution 17
C-103
Solution 18
Rotary indexing station

2 3 2 1 4 5 4 5 5 1 3 5 1 3 1 3
6A
(6S) 6S1
(6B) 6S2
11S1 11S2
5S2
5S1
5Y2
5A
5Y1
11A
10S1 10S2
4S2
4S1
4Y2
11Y
4A
4Y1
10A
3S2
3Y2
3S1
9S1
9S2
3A
3Y1
9A
2S2
2Y2
2S1
8S1
8S2
9Y
(2B1) (2B2)
2A
2Y1
8A
(1B1) (1B2)
1S2
1S1
1Y2
7S1
7S2
1A
1Y1
7A
For the purposes of this exercise, cylinders 3A and 4A are not constructed. Feed units 6A to 11A are represented in the construction by a single-acting cylinder. The on/off valve with filter regulator and manifold are not represented.
7Y
8Y
10Y
12Y
6Y
Solution 18
C-104
24 V-
13
31
S2 4 2B1 K2 K2
14 1 24 13 14 13 23
14
32
3 1B2 K4 K17
14 13 11
10
11
12 K5
13
13
14
23
13
23
17
S1
K1
K5
14 24
14
24
18
6S
4 13
K3
14
S3
14 11
K16
14 41
S1 = ON S3 = Sensing of parts S2 = AUTO/MANUELL S4 = OFF K6

42 27
35
31
S4 K1
28 A1 A1
11
K1
36
32
K9
A1 12 A1 A1
A1
H1
A2
K1
H2
K2
K3
A2 28 11 44 57
K4
A2 11 24 34
K5
A2 13 14
K6
A2 6 17 46
A2
Pump
36 7 8 34
START
1 3 6
24 V-
15
16
11 21
17 2B2 BN K10 BK BU 5S2

4 21 4 21 1 1 23 14 24 24 14 24 11 21 23 11 21
18 6B K8 K10 K4 K12 K12

14 24
19
20
21
22
23
24
25
26
27
28
1B1
13
TP202 Festo Didactic 5S1 K7

24 21
K7
K8
14
13
K6
14
K9
24 24
K11
K13
24
11
11
21
41
K11
A1 A1 12 A1 22 A1
K13
K16
A1
K3
42 A1
A1
12 A1
K7
A2 A2 A2
K8
K9
K10
K11
K12
A2
K13
A2
K14
A2
A2
A2
17 28 51
18 19 52
11 21 36 49
22 23
17 24 45 53
34 25 26
21 28 47 55
29 31 33
C-105
Solution 18
Solution 18
C-106
34
21 13
35 S5
22 14
36 K21
40
41
42
11 14
24 V-
38
13 23 24
39
31 32
29 37
14 33 31 11 21 21 31
30 K14 K9
24 34 14
31 K2 K18
34 33 34
32 K17
33
S6
11 24
11
21
K14
K15
K14
K15
14
12
24
K4
34
S5 = EMERGENCY-Stop S6 = RESET
31 41
K12
A1 32 A1 42 A1
K2
A1 A1 A1
A1
K15
A2 A2
K16
K17
K18
A2
K19
A2
K20
A2
K21
A2
A2

24 6 50 44 12 35 43
30 32
37 56
48 51 54
56
50 42
43
24 V48
11 21 31
51 K19
24 33 31 41 41 21 33
54 K19
34
56
TP202 Festo Didactic 47

14 41 31
44 50 K16 K8
34 17 34 44 44 24
45 52 K11 K13 K18 K3

34
46 53 55 57
31
K19 49 K9 K7
34 21
31 34 44
23
31
23
K17
K3
K11
K6
K13
34
24
34
24
41
K17
22
K21
K20
18
42
Air blast
Vacuum generator 2Y1 2Y2 5Y1 5Y2 6Y 12Y 2A+ 2A5A+ 5A6A+
H3
1Y1
1Y2
1A+
1A-
C-107
Solution 18
C-108
Solution 18
Current paths 1 to 3 fulfill the following functions: START and STOP via push buttons, display of the start signal and simulation of the central lubrication system. Power to the installation is switched off with the EMERGENCY-STOP in order to add a memory and secure the movement 2A-. Otherwise, cylinder 2A would retract as a result of the automatic setting condition if cylinder 1A is already located in its initial start position. The status of the vacuum generator is stored by current paths 33 and 34. After EMERGENCY-STOP, the unit is reset and a restart can be made. If the fact that the vacuum generator is active has now been stored, steps 1 and 2 (1A+, 1A-) are now skipped because a workpiece has already been collected. In manual mode, the initial start position of the machining station can be achieved via the RESET button, cylinder 2A only being able to retract when cylinder 1A is in its initial position. In addition, processing is started via the RESET key if memory K18 reports that no processing has yet been carried out. Memory K21 (EMERGENCY-STOP actuated) is reset. In order to limit the cost incurred through additional equipment, relay K21 can be replaced by the counter (preselected figure 1).
C-109
Solution 18
40
21
41
13 14
S5
22
Fig. 18/8: Circuit diagram, electrical (3) Addition with counter
38
13
39
23 24 31 32
S6
14
A1
A1
A1
R1 R2
K19
A2
K20
A2
K21
A2
S5 = EMERGENCY-STOP S6 = RESET
C-110
Solution 18
Components list
Quantity 6 2 1 2 1 3 1 1 1 1 1 1 2 2 1 2 3 1 1
Designation Relay, 3-off Signal input plate, electrical Time relay, 2-off Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold EMERGENCY-STOP button Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor, optical Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 5/2-way solenoid valve 5/2-way double solenoid valve Cable set with safety plug Electrical power supply unit, 24 V
C-111
Solution 19
Checking station

2A 1B1 1A 1B2 2B1 2B2 3A 3S 3B 4A
4S1
4S2
2Y
4 2 5 1 3 4 2
4Y
5 1 3
3Y 1Y1
5 1 3
1Y2
0Z2
0Z1
1 3
* For the purposes of this exercise, cylinder 4A is to be replaced by a single-acting cylinder.
Solution 19
C-112
24 V- 1
1 1 23 11
2 1B2 BN K5
14 11 11
3 1B1 BN BK BU K1 K6
14 14 4 24 23
4 K4 BK BU
10
11
12
13
13
S1 3S
4
K1 4S1
14 13
14
K2
24 23
K2
S1 = START-button K3
24 17 21
14 13
K3
14
31
S2
A1 A1 18 A1
K19
A1
K4
24 A1 A1
32 A1
S2 = STOP-button K2
A2 A2 A2
K1
K3
K4
K5
A2
K6
A2
K7
A2
A2

1 5 1 5 6 9 37 39
2 5
37 10 16 38
15
24 V- 13 2B1 K7 K12
14 14 14 13 18 14 13 17 11
14 2B2 S3
13 11
15 K9 K10
TP202 Festo Didactic 16 17 18 19 20 21 22 K8

14 21 21
S3 = Tolerance check K6
A1 A1
K10
24 A1 A1 A1 24 A1
= 3s K10 K10'
A2 A2
K8
A2 A2
K9
K11
A2
K12
A2
15
16
17 21 23 33
39
23
41 22 40
C-113
Solution 19
Solution 19
C-114
24 V- 23
11 11
24 3B 4S2
14 14 14 24 13 11 21 11
25 K14 K14 K15

14
26
27
28
29
30
31 K17
32
11 14
K11
14
K13
31
21
K10
34 A1 A1 A1 A1
K13
24 A1 A1
K13
A2 A2
K14
K15
A2
K16
A2
K17
A2
K17'
A2

24 29 40 41 28 29
31
40 32 33 36
41
24 V- 33
21 11 21 31 31 41 41 31 41
34 K18 K18
14 22 34 34 44 44 34 21 44 31
35 K17 K6 K4 K13 K13 K4
36
37
38
39
40
41
K17
24 13
TP202 Festo Didactic K12 K12

24 32 14 41 31 11 41 11
S4
= Interrogate container K6
44 A1 A1 32
K10 K10'
K17
12 42
K17'
12
K18 1Y1 1Y2

A2 A2
K19
H1
2Y
3Y
4Y
1A+
1A-
2A-
3A+
4A+
Conveyor belt
35 34
C-115
Solution 19
C-116
Solution 19
In this solution, end position sensing is indirectly interconnected. The START and STOP conditions for continuous cycle using one push button each, are both realised by means of relay K1. Selection between tolerance conditions Good/Reject is made with the switch S4 (K12), with the result that either cylinder 3A or 4A extends. Parts are counted by 3B (position C+) indirectly via K14. The conveyor belt is started by the final step (K17) and does not stop until the timer which resets the sequence has run through. The time delay is not started until the control is in the final step and a container (S4) has been signalled as being present. The time element with switch-on delay is activated immediately after power supply has been switched on, meaning that interruption of this causes delayed start-up behaviour. That is, the time element switches to its normal position when the time has expired. However, for this purpose it is necessary to store the interruption signal (see K18).
Components list
Quantity 6 1 1 1 2 1 3 1 1 1 1 1 2 2 1 1 2 1 1 1
Designation Relay, 3-off Signal input plate, electrical Time relay, 2-off Preselect counter, electrical, incrementing Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor, optical Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 3/2-way solenoid valve, normally closed 5/2-way solenoid valve 5/2-way double solenoid valve Cable set with safety plug Electrical power supply unit, 24 V
C-117
Solution 20
Handling device
1A
1S1
1S2 2A
2B1
2B2
1Y
5 1 3
2Y
5 1 3
*
3A 3B1 3B2
4M
4S
4B
3Y
4Y1
4Y2
0Z2
4Y3
4Y4
0Z1
1 3
* For the purposes of this exercise, cylinder 1A is replaced by a single-acting cylinder. Rotary actuator 4M is replaced by a double-acting cylinder.
Solution 20
C-118
24 V- 1
10
21
11
S6
K1
22
14 13
31
S2 7 5
23 17 13 13 13
14
32
8 9 3B1 K6
14 23 14 13
4 K4
11 24 41 18 14 14
6 S5 K10 K5 K15
11
12
13
14
21
15
13
16
1
17
13
13
S1 = START-button S2 = MAN/AUT S3 = Sensing of parts K7

24 14
S1
1S2
4
K8
14
14 11
13
K18 K15 K2
14 42
K2 K2
24
14 13
14
S3
14 31 11 11 23 23
S4 K16
12 A1 R1 A1 A1
32 11
K13
12 A1
K6
24 A1
K7
24 A1
S4 = STOP S5 = RESET S6 = EMERGENCY-STOP K4

A2 R2 A2 7 50
K3
A1
12 A1
K1
K2
H1
K3
K5
A2 22 10 30
K6
A2 13 14 42
K7
A2 15 16 41
K8
A2 42 17 19
A2
A2
START

2
46 2 48 45
3 12
2A+
1A+
2A-
24 V-
18
41 21 27 21 11 21 31 11 1
19 1B2 BN BK BU K5 K16
42 24 28 24 14 24 34 23 14 4
20 K10 K11 1S1 K12 K18 K9 K14
21
22
23
24
25
26
27
28
29
30
31
32
33
1B1

11 24 21
BN
11
K9
BK
14
BU
K17
14 22
K17
23
11
21
31
21
31
K8 K11
12 A1 A1 A1 A1 A1 A1 24 34 24
K9
K11
K12
K12
32 A1 A1
24
A1
K9
A2 A2 A2 A2 A2
K9'
K10 K11 K12 K12'
K13
K14
A2 A2
K15
A2
A2
20 24 30 44
45
9 24
22 25 41 26
30 27 44 29
45 47 49
12
31 43
5 14
3A+ 4M+
1A-
3A- 4M-
C-119
Solution 20
Solution 20
C-120
24 V-
46
48
40
31 41
50
23 42 21
34
32 33 33 21 41 21
35 K7
34 34 24 44 24 11
36 K6 K14 K9 K1 K12'
37
38
39
41
42
43
44
45
K1 47
K1
49
31
K4
24
3B2
4B
4S
K12'
24 34
K9'
14 11
K12'
12
41
41
41
K11
42 42
K8 2Y 3Y
K12
42
A1
A1
A1
K16 H2 H3
K17
K18
1Y
4Y1
4Y2
4Y3
4Y4
A2
A2
A2
MAN
AUTO
9 23
30 22
2 29
TP202 Festo Didactic 1A+ 2A+
3A+
4M+
4M+
4M-
4M-
C-121
Solution 20
The continuous cycle is introduced via the START button. The handling device then runs until a STOP is actuated at the end of the cycle or until the counter has reached the preselected figure or no parts are reported as being present. At this point, lamp H1 indicates whether the start signal is still stored. Memories K5 and K14 cause cylinder 3A to move every second cycle. Lamp H2 indicates that the installation is operating in AUTOMATIC mode. H3 lights up when MANUAL mode is operating (RESET).
Quantity 6 2 1 1 2 1 3 1 1 1 1 1 1 2 2 1 2 2 1 1 Designation Relay, 3-off Signal input plate, electrical Time relay, 2-off Preselect counter, electrical, incrementing Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold EMERGENCY-STOP button Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor, optical Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 5/2-way solenoid valve 5/2-way double solenoid valve Cable set with safety plug Electrical power supply unit, 24 V
Components list
C-122
Solution 20

Electroneumatica Avanzada

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Learning System for Automation and Technology

TP202 Festo Didactic

TP202 Festo Didactic

TP202 Festo Didactic

TP202 Festo Didactic

TP202 Festo Didactic

TP202 Festo Didactic

TP202 Festo Didactic

TP202 Festo Didactic

Notes on safety and operation

TP202 Festo Didactic

TP202 Festo Didactic

Training contents of basic level and advanced level

TP202 Festo Didactic

List of training aims

TP202 Festo Didactic

Equipment set for the basic level (TP201)

TP202 Festo Didactic

Symbols of the equipment set

Signal input plate, electrical

On/off valve with filter regulator

TP202 Festo Didactic

Proximity sensor with cylinder mounting

Symbols of the equipment set

Limit switch, electrical, Actuation from left or right*

3/2-way solenoid valve, normally closed

5/2-way solenoid valve

5/2-way double solenoid valve

TP202 Festo Didactic

Equipment set for the advanced level (TP202)

TP202 Festo Didactic

Signal input plate, electrical

Symbols of the equipment set advanced level

Time relay, 2-off with switch-on delay with switch-off delay

Preselect counter, electrical, incrementing

Proximity sensor, inductive

Proximity sensor, capacitive

Proximity sensor, optical

5/2-way double solenoid valve

TP202 Festo Didactic

Component and exercise allocation (table)

TP202 Festo Didactic

Methodical structure of the exercises

TP202 Festo Didactic

TP202 Festo Didactic

TP202 Festo Didactic

TP202 Festo Didactic

Electropneumatics Bench drill

Training aim Exercise

TP202 Festo Didactic

Fig. 1/1: Positional sketch

Fig. 1/2: Displacement-step diagram

1S2 1S1 2B2 2B1

TP202 Festo Didactic

Electropneumatics Feed unit for sheet metal strip

TP202 Festo Didactic

Fig. 2/1: Positional sketch

Fig. 2/2: Displacement-step diagram

1B2 1B1 2S2 2S1

TP202 Festo Didactic

Electropneumatics Filling device

TP202 Festo Didactic