Globally active solution provider

for
Industrial Automation, Seminar
and Training in pneumatics .
 Festo - A Historical Perspective
Festo Headquarters in Esslingen
Berkheim
Introduction to Festo
1925
Festo founded in Esslingen,
Germany by Mr. Gottlieb
Stoll to manufacture Wood-
working machines
1952
Festool (independent from
April 2000) - Powertools
1957
Festo Pneumatic Automation
components and system
solutions (pneumatic and
electronics)
1965
Festo Didactic Learning
systems for automation
 Festo - An Independent Family Enterprise
 Festo Automation Group,
A Globally Active Organisation internationally
represented in over 176
countries.

 56 independent Festo
companies with over
250 branch offices

 Turnover of 1.5 Billion

Euro, 55% Export.

 Over 11.500 employees.

 R & D 7% of turnover
Cylinder production and Customer Service Centre p.a.
in St. Ingbert  Over 300,000 customers
in 176 countries.

Festo Production Facilities.  Vocational and further

training, 1.5% of
GPC INDIA personnel budget.
Introduction to Festo
Didactic  Didactic - A Greek
word. Means learning.
 Promotes the use of
automation in industry
by educating users on
the applications and
use of standard
available products.
 Festo Didactic has its
own product range.
 Festo Didactic present
in over 75 countries
Festo Didactic Headquarters in Esslingen- Denkendorf, worldwide. Annual
near Stuttgart turnover 30 Mio.Euro.
 100 employees.
 In India Festo Didactic
- The training division
Festo Didactic FMS. of Festo Controls Pvt.
Ltd.
Festo Didactic Products & Services
Festo Didactic products and services fall into the
following categories :
 Training
Seminars.

 Training Kits.

 Training Aids.

 Courseware.

 Software.

 Consultancy.
Training Seminars are offered on :

 Pneumatics.
 Electro-
Pneumatics.
 Advanced
Pneumatics.
 Customized need
based Training.
 Hydraulics.
Festo Sponsored Mechatronics Olympiad
Qualifications in Automation
Festo Didactic Products & Services
In India, Training
seminars are being
conducted at :
 Bangalore (HO).
 Mumbai.
 Delhi.
 Coimbatore.
 Ahmedabad.
 Pune.
 Chennai
Festo Didactic Products & Services
Training Kits are available for
 Pneumatics.
 Electro-Pneumatics.
 Hydraulics.
 Electro-Hydraulics.
 Programmable Logic
Controllers.
 Industrial Process
Control.
 Mechatronics &
Robotics.
 Customized kits.
 Types of training aids and
accessories available from Festo :
Overhead Projector
Slides.
Magnetic Circuit Symbols.
Cut-Sections.
Transparent Working
Models.
Videos.
Educational Software.
Low Noise Compressors.
Courseware
 Text books.

 Work books.

 Reference books.

 Recommended by
major universities in
India including
Bombay University.

 Detailed list available

on request.
 Major Courseware Topics
 Basic Pneumatics.
 Electro Pneumatics.
 Hydraulics.
 Electro Hydraulics.
 Proportional Hydraulics.
 Programmable Logic
Controllers.
 Sensors.
 Mechatronics.
 Fundamentals of Pneumatic
Control technology.
 Pneumatic Grippers.
 Cutting Costs with Pneumatics.
 Servo Pneumatic Positioning.
 Closed Loop Pneumatics.
 Robotics.
 Fieldbus Technology.
 Automated Production.
 The Amazing World of
Pneumatics.
 Handling Technology.
Technology
 SOFTWARE FOR EDUCATION

 The Fascination of Technology.

 An interactive journey through time and the
fascinating world of technology. From the
wedge to the conveyor belt and to how
technology will affect our future. Includes
animations, videos and commentaries.
 Fluid Studio - Pneumatics / Hydraulics.
 An interactive self study program to teach the
fundamentals of Pneumatics or Hydraulics.
 Includes various forms of exercises and
multiple choice questions.
 Cosimir Educational.
 Interactive learning program for robot
technology and professional 3D software
program or programming and simulation of
robots using numerous pre-designed robot
cells.
 Software for Design & Simulation :

 FluidSIM 3.6 for Pneumatics & Hydraulics.

Useful for drawing and archiving circuit diagrams for
later use.
Accurately simulates circuits, with full animation.
Includes several educational videos and animations
of components to make understanding easy.
 COSIMIR Professional.
Used for simulation & control of multi-robotic
systems in 3D space, with anti collision detection and
Virtual Reality features.
 InTouch.
Process visualization software for visualizing,
controlling and monitoring industrial processes.
 Festo Didactic Consultancy Services

 Design & layout of complete training facility from concept to

implementation.
 Training kit design.
 Designing course content & handouts.
 Automation in Industry
Choice of Working Media :
 Pneumatics.
 Hydraulics.
 Electricity & Electronics.
 Combinations of the above.
 Combinations of technologies offer synergy.
 Has the capability of expanding the scope of
applications tremendously.

Pneumatics Versus Hydraulics

Typical Hydraulic Applications
Introduction to Pneumatics

PNEUMA : means “breath” in Greek

“Pneumatics is the name given to the branch of

physics which deals with the properties,
motions and behavior of air”
 Energy medium selection criteria

• Force exerted
• Distance through which the force can be
applied
 Automation in Industry
Media Selection Criteria :
 Speed of Operation.
Operation
 Reliability.
 Service Life.
Life
 Sensitivity to Environment.
Environment
 Ease of Maintenance.
Maintenance
 Available Expertise.
Expertise
 Training Requirements.
Requirements
 Availability
 Transportability
 Storability
 Explosion proof nature
 Cleanliness
 Overload safety
 Advantages of
Compressed Air
 Transport

• Air can be easily transported in

pipelines, even over large distances
 Storage
 A compressor need not be in
continuous operation.

 Compressed air can be stored in a reservoir

and removed as required.

 The reservoir can be transportable.

 Temperature

 Compressed air is relatively

insensitive to temperature
fluctuations.

 This ensures reliable operation,

even under extreme conditions.
 Explosion Proof

 There is minimal risk of

explosion or fire.

 No expensive protection against

explosion is required.
 Cleanliness
 Unlubricated exhaust air is clean.

 Any unlubricated air does not

cause contamination.

 Useful in food, wood and textile

industries.
 Components

 Operating components are of simple

construction and therefore relatively
inexpensive.
 Speed
 Compressed air is a very fast
working medium.

 High working speeds can be

obtained.
 Adjustable

 With compressed air components

speeds and forces are infinitely
variable.
 Overload safe
 Pneumatic tools and operating
components can be loaded to the
point of stopping and therefore
overload safe.
Disadvantages of
compressed air
 Preparation
 Compressed air requires good
preparation.

 Dirt and condensate should not

be present.
 Compressible

 It is not always possible to achieve

uniform and constant piston speeds
with compressed air.
 Force requirement
 Compressed air is economical only up
to a certain force requirement.

 At 6-7 bar, and dependent on the

travel and speed, the output
limit is between 20000 and
30000 Newtons.
 Noise level

 The exhaust air is loud.

 The problem is largely solved

with silencers.
 Costs
 Compressed air is a relatively
expensive means of conveying
power.

 The high energy costs are

partially compensated by
inexpensive components and
higher performance.
 Compressed Air as a
Working Medium
Advantages:

• Air is available everywhere

• Compressed air is easily conveyed in pipelines over large

distances

• Compressed air need not be returned

• Compressed air is insensitive to temperature fluctuations

• Compressed air is explosion proof

• Compressed air is clean

• Compressed air is fast

 Compressed Air as a
Working Medium
Disadvantages:
• Straight line movement can be produced directly.

• Compressed air is a relatively expensive means of

conveying energy

• Compressed air requires good conditioning

• It is only economical up to a certain force

expenditure.

• Air is compressible. Exhaust air is loud (reduced by

using silencers).

• The oil mist mixed with air for lubricating purposes

exhaust or escapes to the atmosphere
Structure of pneumatic control
Elements in a Pneumatic System
Hierarchy of Elements

Flow Control Valve Flow Control Valve

Quick Exhaust Valve Quick Exhaust Valve

Pneumatic Direction Control Valve Pneumatic

Actuation [Power Valve] Actuation

Direction Control Valves Direction Control Valves

Pressure Sequence Valves Service Unit Pressure Sequence Valves
Pneumatic Timers Pressure Regulator Pneumatic Timers
Dual Pressure [AND] Valves Dual Pressure [AND] Valves
Shuttle [OR] Valves Shuttle [OR] Valves
Limit Switches Main Air Supply Limit Switches
Push Buttons Push Buttons

Low Pressure, High Pressure, Low Pressure,

Low Flow High Flow Low Flow
Rate Zone Rate Zone Rate Zone
< 4 Bar > 4 Bar < 4 Bar
Drawing Functional Block Diagrams

LS1 LS2  Block diagrams are more

easily understood by a
layman. No knowledge of
symbols is necessary.
QE FC  They are faster and easier
to draw.
 Corrections are also easier
5/2 Way to make.
 A block diagram can be
LS1 Timer easily converted into a
circuit diagram.
 Individual blocks in a
PB LS2 diagram may represent a
single item, or multiple
items, performing a certain
function.
Correct Method of Drawing Circuits
 Actuators
An actuator is an output device for the
conversion of supply energy into useful work.
They can be described Into two groups.
Linear Motion
• Single Acting Cylinders
• Double Acting Cylinders
Rotary Motion
• Air Motor
• Rotary Actuator
 Actuators Operation

An Actuator Can be Controlled by the

Following Methods:
• Pneumatic
• Hydraulic
• Electrical
 Linear motion

• Single Acting Cylinders

• Double Acting Cylinders

 Rotary motion

• Rotary actuators - single and double

acting
• Pneumatic motor - continuous motion
 Single acting cylinders
.
 Single acting cylinders
.
 Single acting cylinders
.
 Single acting cylinders
.
Single acting cylinders
Single acting cylinders

Reed Switches
Single acting cylinders
Single acting cylinders
Single acting cylinders
Single acting cylinders
Single acting cylinders
Single acting cylinders
Single acting cylinders
Single acting cylinders
Single acting cylinders

Force = Pressure x Area (piston)

Single acting cylinders

Force = Pressure x Area (piston)

Single acting cylinders

Force = Pressure x Area (piston)

Single acting cylinders

Force = Pressure x Area (piston)

Single acting cylinders

Force = Pressure x Area (piston)

Single acting cylinders

Force = Pressure x Area (piston)

Double rod double acting
cylinders
Multi-position cylinders
Multi-position cylinders
 Multiposition cylinders
.

1 2 3
 Multiposition cylinders
.

1 2 3
 Multiposition cylinders
.

1 2 3
 The Rodless Cylinder
• Conventional Double Acting Cylinders require
space to house the cylinder.
• Plus space to carry out the work.

• More effective use of the available space can be

made by using Rodless Cylinders.
 Rodless Cylinder -
Mechanically Coupled

Clamp for seal and Piston and carriage

protection strip assembly

Body of Cylinder

End caps with

Internal seal
cushioning and
adjustment
Protection strip
 Rodless Cylinder -
Mechanically Coupled
.
 Rodless Cylinder -
Mechanically Coupled
.
Rodless cylinder -
mechanically
coupled
 Rodless Cylinder -
Mechanically Coupled
 Rodless Cylinder -
Mechanically Coupled
 Rodless Cylinder -
Mechanically Coupled
 Rodless Cylinder -
Mechanically Coupled
.
Wipers Bearings Magnets Cushioning End Caps
Pistons with cushioning
adjustment

Cylinder Barrel

Bearings Magnets Seals

Yoke assembly Magnets, Bearings, Wipers

Piston assembly Magnets, Bearings, Seals, Cushioning Pistons
 Rodless Cylinder -
Mechanically Coupled
.
 Rodless Cylinder -
Mechanically Coupled
.
 Rodless Cylinder -
Mechanically Coupled
 Rodless Cylinder -
Mechanically Coupled
 Rack and pinion rotary
actuator
Pistons with ‘Rack’
arrangement

End cap with

pneumatic
connections

End Cap with

Shock absorber
type cushioning
Body of Actuator
Driven Adjustable
Shaft with
gear
Rack and pinion rotary
actuator
Rack and pinion rotary
actuator
Rack and pinion rotary
actuator
Rack and pinion rotary
actuator
Rack and pinion rotary
actuator
Rack and pinion rotary
actuator
Rack and pinion rotary
actuator
Rack and pinion rotary
actuator
Rack and pinion rotary
actuator
Rack and pinion rotary
actuator
Rack and pinion rotary
actuator
Vane Type Rotary Actuator
Vane Type Rotary Actuator
 Vane Type Rotary Actuator
.
 Vane Type Rotary Actuator
.
 Vane Type Rotary Actuator
.
 Vane Type Rotary Actuator
.
 Linear and Rotary
Actuator Combination
 Linear and Rotary
Actuator Combination
Air Motor
Air Motor
Air Motor
High Precision Guidance
Unit
High Precision Guidance
Unit
Cylinder seals
Cylinder seals
 Cylinder mountings
.

Centre s swivel flange Rear s swivel flange Foot mounting

Front flange Rear mounting Swivel flange

Front swivel flange Rear flange

PNEUMATIC SYMBOLS
 Pneumatic Symbol
The development of pneumatic systems
is assisted by a uniform approach to the
representation of the elements and the
circuits. The symbols used for the
individual elements must display the
following characteristics:
 Number of switching positions
 Number of connections
 Actuation and return actuation methods
 Function
 Simplified representation of the flow path
 Pneumatic Symbol
A symbol does not represent the
following characteristics:
• Size or dimensions of the component
• Particular manufacturer, methods of
construction or costs
• Operation of the ports
• Any physical details of the elements
• Any unions or connections other than
junctions
 The standard used is ISO 1219
Symbol development
Ports and Positions
 Energy supply
• Compressor with fixed capacity

• Air receiver and ‘T’ junction

 Air Service Equipment
• Air filter

• Air lubricator

• Pressure regulator
 Air Service Equipment
Air service unit
• filter
• Regulator
• Gauge
• Lubricator

Simplified air Service unit

Directional Control Valves
 Directional Control Valves

• Methods of actuation
• Mechanical
• General manual operation

• Push button

• Lever operated

• Detent lever operated

 Directional Control Valves

• Methods of actuation
• Mechanical
• Foot pedal

• Roller operated

• Idle return, roller

Directional Control Valves

• Methods of actuation
• Mechanical
• Spring return

• Spring centered
 Directional Control Valves

• Methods of actuation
• Pneumatic
• Direct pneumatic actuation

• Indirect pneumatic
• actuation (piloted)
 Non - Return Valves
• Check valve

• Spring loaded check valve

• Shuttle valve: ‘or’ function

 Non-return valves

• Two pressure valve:

‘AND’ function

• Quick exhaust valve

 Flow control valves
• Flow control valve adjustable

• One-way flow control valve

 Pressure valves

• Adjustable pressure regulating valve,

• non-relieving type

• Adjustable pressure regulating valve,

relieving type (overloads are vented)
 Pressure valves
• Sequence valve combination
 Linear Actuators

 Single acting cylinder

 Double acting cylinder

 Double acting cylinder with

double ended piston rod

 Rodless cylinder
 Linear actuators
• Double-acting cylinder with non-
adjustable cushioning in one direction

• Double-acting cylinder with single

adjustable cushioning

• Double-acting cylinder with adjustable

cushioning at both ends
 Rotary actuators

• Air motor, rotation in one direction, fixed

capacity

• Air motor, rotation in one direction,

variable capacity

• Air motor, rotation in both directions,

variable capacity

• Rotary actuator, limited travel, rotation in

both directions
 Auxiliary Symbols
Exhaust port

• Exhaust port with threaded

connection

• Silencer

• Line connection
 Auxiliary symbols

• Crossing lines (not connected)

• Pressure gauge

• Visual indicator
 Port labelling
.
Letters Numbers
A 2
Z Y P Supply 1 12 14

P R 1 3
A, B, C Outlet 2, 4,

A B R, S, T Exhaust 3, 5, 4 2
Z Y 14

R S 5 3
P X, Y, Z Pilot 1
Exhaust from pilot stage

Port Labelling
84 82
Pilot operated non-return valve

21

1
Switches and contacts
Switches and contacts
Normally open switch
Normally closed switch
Changeover switch
Switches
Momentary and sustained
switches
Sustained normally open
switch
Changeover switch
Normally open contact
Normally closed contact
Changeover contact
Typical push button
switches
Relays
 Relays
A Relay has Certain Characteristics
• Low Maintenance
• Able to Switch a Number of Independent Circuit Paths
• Easily Adaptable to Various Operating Voltages
• High Operating Speed, ie. Short Switching Times
• Can be Used as a Logic or Interlocking Device
Relay Contact Configuration
Relays, timers and solenoids
Relays and solenoid coils
Electrical Output Devices
 Basic logic functions

There are four commonly used logic

functions in Electro-Pneumatics.
Electro-Pneumatics

• YES Function
• NOT Function
• OR Function
• AND Function
Basic electrical circuits
YES Function
+24V

+24V

Push Button

Lamp

0V

0V
 Basic electrical circuits
NOT Function
+24V

+24V

Push Button

Lamp

0V

0V
 Basic electrical circuits
OR Function
+24V

+24V

S1 S2

Lamp

0V

0V
Basic electrical circuits
AND Function
+24V

+24V

S1

S2

Lamp

0V

0V
 Classification of Sensors

Sensors are classified as either :

Contact type
Non-contact type (proximity sensors)

Proximity sensors being the more commonly used sensor.

 Limit Switches
Limit switches are considered to be contact
sensors, as it needs to be actuated to give a
signal output
 Reed Switches
Most Widely Known
and Used as Cylinder
a)
Switches

1
Magnet

b)

1 Magnet
Glass Tube filled with Reed contacts LED
nitrogen indicator
24v
Reed Switches
Sensor Switching Distance

Object

Sensor

Sn

Sn = Switching Distance
Sensor Hysteresis

Sensor Object

h
Sn

Sn = Switching Distance h = Hysteresis

 Classification of Sensors

Sensors are further categorized as either :

Binary
Analogue.
Binary sensors convert a physical quantity
into a binary signal which means it has
two switching states. The most common
being an electrical signal ON or OFF.
Types of Sensors
Sensors
 Inductive Sensors

Cable
plug-in
LED

Active surface
Inductive Proximity Sensors

High Frequency magnetic field

(300 to 800 kHz) Active Surface

Resonant circuit coil

LED indicator

Connection cable
Inductive Proximity Sensors
Target

Sensor

Oscillation
Amplitude

Sensor
output ON
signal OFF
 Target

Sensor

Oscillation
Amplitude

Sensor
output ON
signal OFF
 Target

Sensor

Oscillation
Amplitude

Sensor
output ON
signal OFF
Inductive Proximity Sensors

• The bigger the coil, the greater the active

switching gap.
• Inductive sensors can only detect metals.
• Different switching distances for different metals
 Selection Criteria
• They can be selected according to the material which
they are to detect.

• Metals of any kind can be detected easily and

economically with inductive sensors if short switching
distances only are required (eg. 0.4 …. 10 mm)
Uses of Inductive Proximity Sensors

Inductive sensors detect metals and operate

quickly, reliably and tirelessly. They are used to:
• Count
• Identify
• Detect
• Switch
• Control
• Check
• Distinguish
• Sort
• Position
Inductive Sensors
Capacitive Sensors
 Capacitive Proximity
Sensors

Sensor is looking for a change

Electrostatic field in capacitance in the active field

Active surface

Active electrode

Earth electrode

LED indicator

Adjusting screw
Connection cable
 Capacitive Proximity
Sensors

• Almost similar to the inductive sensor.

• Able to detect most materials.
• Switching distance adjustable.
 Selection Criteria
Capacitive proximity sensors are suitable for
the detection of a wide range of materials, but
again only for relatively small distances,
similar to inductive proximity sensors.
Target
 Capacitive Proximity
Sensors

Detection of matt, black objects.

Optical Proximity Sensors
There are three different
types of optical
proximity sensors:

• Through beam optical

sensor
• Retro-reflective optical
sensor
• Diffuse optical sensor
 Solenoid valves

The directional control valves used in electro

pneumatics are similar to those used in pure
pneumatics. The only difference is that they are
actuated by solenoids.
Solenoids
2/2-way single solenoid
valve
3/2-way single solenoid
valve
Pilot signal flow

ELECTRICAL SIGNAL
APPLIED TO
SOLENOID

SOLENOID ACTUATES
PILOT VALVE

PILOT ACTUATES
MAIN VALVE
Pilot control
3/2-way single solenoid valve with
pilot control
3/2-way single solenoid valve with pilot
control

1 3
3/2-way single solenoid valve with pilot
control

Y1
1 3
5/2-way single solenoid valve with pilot control
5/2-way single solenoid valve with pilot control

5 4 1 2 3
(A) (S) (P) (B) (R)
5/2-way single solenoid valve with pilot control

5 4 1 2 3
(A) (S) (P) (B) (R)
5/2-way single solenoid valve with pilot control

5 4 1 2 3
(A) (S) (P) (B) (R)
5/2-way single solenoid valve with pilot control

5 4 1 2 3
(A) (S) (P) (B) (R)
5/2-way single solenoid valve with pilot control

5 4 1 2 3
(A) (S) (P) (B) (R)
5/2-way single solenoid valve with pilot control

5 4 1 2 3
(A) (S) (P) (B) (R)
5/2-way single solenoid valve with pilot control

5 4 1 2 3
(A) (S) (P) (B) (R)
5/2-way single solenoid valve with pilot control

5 4 1 2 3
(A) (S) (P) (B) (R)
5/2-way single solenoid valve with pilot control

5 4 1 2 3
(A) (S) (P) (B) (R)
5/2-way double solenoid valve with pilot
control
5/3-way double solenoid valve
with pilot control
5/3-way double solenoid valve
with pilot control
5/3-way double solenoid valve
with pilot control
5/3-way double solenoid valve
with pilot control

4 2
4 2

5 3
5 3
1
1

4 2

5 3
Pneumatic-Electic Converter
(PE Switch)
Pressure Switches

Two-Wire
Technology
Component Handling

Mounting Arrangements
for Limit Switches
Component Handling

Press blue lever to mount

Or remove components
Components requiring two
slots for mounting can fall
if not mounted correctly.
e.g. Pneumatic Counter
& Electrical Pressure
Switch
 Component Handling

Blocking of two
Press blue ring and
gently pull the connectors
tube Blocking a single
to disconnect connector
Component Handling
Lift knob to set
pressure.

Set pressure to 3 Bar.

If there is no pressure,
first check if the
compressor is ON.

Output valve
Component Handling
Electrical Pressure Switches and
Pressure Sequence Valves
are not to be adjusted.
They are preset to work at about 4 bar.
Component Handling

No components should
be fixed in front of a
cylinder.

All components are

marked with their
respective symbols.
Electro-Pneumatic Components
Push Button Box Relay Box
Electro-Pneumatic Components
Timer Box Distributor Box
Electro-Pneumatic Components
Positive and Negative
supply lines
internally connected

Looped Power Supply

connections input connections
Electro-Pneumatic Components
Pressure Switch
port markings. Use
only the port marked P1.
Do not make any
connections to port P2.