Neumatica Ejercicios y Soluciones

Workbook TP 101

CD-ROM included

Festo Didactic

541088 en

PneumaticsBasic Level

541088_cover_workbook_tp101_en.indd 1 08.03.2005 14:25:34

2 © Festo Didactic GmbH & Co. KG • 541088

The Festo Didactic Learning System has been developed and produced solely for

vocational and further training in the field of automation and technology. The

training company and/or instructor needs to ensure that trainees observe the safety

precautions specified in this workbook.

Festo Didactic hereby disclaims any legal liability for damages or injury to trainees,

the training company and/or other third parties, which may occur during the

use/application of this equipment set other than in a training situation and unless

such damages are caused by intention or gross negligence on the part of Festo

Didactic.

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

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

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

The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design registration.

Intended use

© Festo Didactic GmbH & Co. KG • 541088 3

Preface______________________________________________________________ 5

Introduction__________________________________________________________ 7

Notes on safety and operation __________________________________________ 9

Technology package for pneumatics (TP100) ______________________________ 11

Training aims of Basic Level (TP101) _____________________________________ 13

Allocation of training aims and exercises _________________________________ 15

Equipment set - Basic Level (TP101) _____________________________________ 17

Allocation of equipment and exercises ___________________________________ 21

Methodical help for the trainer__________________________________________ 23

Methodical structure of the exercise _____________________________________ 25

Designation of equipment _____________________________________________ 26

Contents of the CD-ROM _______________________________________________ 27

Equipment set of Advanced Level (TP102) ________________________________ 29

Training aims of Advanced Level (TP102) _________________________________ 30

Part A – Exercises

Exercise 1: Pressing of cheese wheels____________________________________A-3

Exercise 2: Opening of an animal feed silo _______________________________A-11

Exercise 3: Testing of key blanks _______________________________________A-17

Exercise 4: Sorting of packages ________________________________________A-23

Exercise 5: Stopping crates of drinks____________________________________A-35

Exercise 6: Opening and closing of a pipe ________________________________A-41

Exercise 7: Shutting off using a quick shut-off function _____________________A-47

Exercise 8: Actuation of a shut-off device ________________________________A-53

Exercise 9: Brushing of cheese wheels __________________________________A-61

Exercise 10: Clamping of a workpiece ___________________________________A-67

Exercise 11: Actuation of a sliding door__________________________________A-75

Exercise 12: Supplying of workpieces ___________________________________A-81

Exercise 13: Crushing of drinks cans ____________________________________A-87

Exercise 14: Packaging of brochures ____________________________________A-93

Exercise 15: Mounting of locking clips___________________________________A-99

Exercise 16: Labelling of paint pots ___________________________________ A-105

Exercise 17: Cleaning of workpieces __________________________________ A-111

Exercise 18: Pressing in of lids _______________________________________ A-117

Contents

Contents


Part B – Fundamentals

Part C – Solutions

Exercise 1: Pressing of cheese wheels ___________________________________C-3

Exercise 2: Opening of an animal feed silo ________________________________C-9

Exercise 3: Testing of key blanks _______________________________________C-13

Exercise 4: Sorting of packages ________________________________________C-17

Exercise 5: Stopping crates of drinks____________________________________C-25

Exercise 6: Opening and closing of a pipe ________________________________C-29

Exercise 7: Shutting off using a quick shut-off function _____________________C-33

Exercise 8: Actuation of a shut-off device ________________________________C-37

Exercise 9: Brushing of cheese wheels __________________________________C-41

Exercise 10: Clamping of a workpiece ___________________________________C-47

Exercise 11: Actuation of a sliding door__________________________________C-51

Exercise 12: Supplying of workpieces ___________________________________C-55

Exercise 13: Crushing of drinks cans ____________________________________C-59

Exercise 14: Packaging of brochures ____________________________________C-63

Exercise 15: Mounting of locking clips___________________________________C-67

Exercise 16: Labelling of paint pots _____________________________________C-71

Exercise 17: Cleaning of workpieces ____________________________________C-75

Exercise 18: Pressing in of lids _________________________________________C-81

Part D – Appendix

Storage unit________________________________________________________ D-2

Assembly technology ________________________________________________ D-3

Plastic tubing_______________________________________________________ D-4

Data sheets


Festo Didactic’s Learning System for Automation and Technology is orientated

towards different training and vocational requirements and is therefore structured

into the following training packages:

• Basic packages to provide basic knowledge in all areas of technology

• Technology packages to address the major subjects of open and closed-loop

technology

• Function packages to explain the basic functions of automated systems

• Application packages to facilitate vocational and further training based on actual

industrial applications

The technology packages deal with the following technologies: Pneumatics,

electropneumatics, programmable logic controllers, automation using a personal

computer, hydraulics, electrohydraulics, proportional hydraulics and handling

technology.

Preface

Preface


The modular design of the learning system enables applications beyond the limits of

the individual packages. For example, to facilitate PLC actuation of pneumatic,

hydraulic and electrical drives.

All the training packages are of identical structure:

• Hardware

• Teachware

• Software

• Seminars

The hardware consists of didactically designed industrial components and systems.

The didactic, methodical design of the teachware is harmonised with the training

hardware and comprises:

• Textbooks (with exercises and examples)

• Workbooks (with practical exercises, additional information, solutions and data

sheets)

• Overhead transparencies and videos (to create an interesting and lively training

environment)

Tuition and training media are available in several languages and are suitable for

use in both the classroom and self-tuition.

Software is available in the form of computer training programs and programming

software for programmable logic controllers.

A comprehensive range of seminars dealing with the topics of the technology

packages completes the range of vocational and further training available.


This workbook is a component part of the Learning System for Automation and

Technology of Festo Didactic GmbH & Co. KG. This system provides a solid basis for

practice-oriented vocational and further training. The technology package TP100 is

comprised exclusively of pneumatic control systems.

Basic Level TP101 is suitable for basic training in pneumatic control technology and

provides knowledge regarding the physical fundamentals of pneumatics and the

function and use of pneumatic equipment. The equipment set enables you to

construct simple pneumatic control systems.

Advanced Level TP102 focuses on further training in pneumatic control technology.

The equipment set enables you to construct complex combinational circuits using

logic operations of input and output signals and control systems using sequencer

modules.

Prerequisite for the assembly of control systems is a fixed workstation using a Festo

Didactic profile plate, consisting of 14 parallel T-slots at 50 mm spacing. A mobile,

sound attenuated compressor (230 V, maximum 8 bar = 800 kPa) can be used for

pressure supply.

Working pressure must not exceed a maximum of p = 6 bar = 600 kPa.

Optimum operational reliability is achieved if the control system is operated

unlubricated at a working pressure of p = 5 bar = 500 kPa.

The Basic Level TP101 equipment set is used to construct all of the complete control

systems for the 18 exercise definitions. The theoretical fundamentals to help you

understand this collection of exercises can be found in the textbook

• Pneumatics, Basic Level

Also available are data sheets regarding the individual devices (cylinders, valves,

measuring devices, etc..).

Introduction

Introduction



The following advice should be observed in the interest of your own safety:

• Pressurised air lines that become detached can cause accidents. Switch off

supply immediately.

• Do not switch on compressed air until tubing is securely connected.

• Caution!

Cylinders may advance automatically as soon as the compressed air is switched

on.

• Do not operate roller lever valves manually during fault finding (use a tool).

• Observe general safety regulations (DIN 58126).

• Limit switches must be mounted laterally to the trip cam (not from the front).

• Do not exceed the permissible working pressure (see data sheets).

• Pneumatic circuit design: Connect devices using the silver metallic plastic tubing

of 4 mm outer diameter, plugging the tubing into the push-in fitting up to the

stop; no need for securing!

• Releasing of push-in fitting: The tubing can be released by pressing down the

releasing ring (disconnection under pressure is not possible!)

• Switch off compressed air supply prior to dismantling the circuit.

• The mounting plates of the devices are equipped with mounting variants A,

B or C:

Variant A, latching system

For lightweight non loadable devices (e.g. directional control valves). Simply clip

the devices into the slot in the profile plate. Devices can be released by pressing

the blue lever.

Variant B, rotary system

Medium weight loadable devices (e.g. actuators). These devices are clamped

onto the profile plate by means of T-head bolts. Clamping and releasing is

effected via the blue knurled nut.

Variant C, screw system

For heavy loadable devices or equipment rarely removed from the profile plate

(e.g. Start-up valve with filter control valve). These devices are mounted by

means of socket head screws and T-head bolts.

• The data for the individual devices specified in the data sheets in Part D must be

observed.

Notes on safety and operation

Notes on safety and operation


A stop watch is required to evaluate the control systems assembled. This is used to:

• Adjust one-way flow control valves such that the cylinder stroke time achieves

specified values,

• Set time delay valves.


The technology package TP100 consists of numerous training media as well as

seminars. The object of this package is exclusively pneumatic control systems.

Individual components from the technology package TP100 may also form a

component part of other packages.

• Fixed workstation with Festo Didactic profile plate

• Compressor (230 V, 0.55 kW, maximum 8 bar = 800 kPa)

• Equipment sets of individual components (e.g. cylinders, directional control

valves, predetermining counters, stepper modules, logic elements, pneumatic

proximity sensors)

• Optional training aids (e.g. visual displays, 5/3-way valve, pulling/pushing load)

• Practical training models

• Complete laboratory setups

Training documentation

Textbooks Basic Level TP101

Fundamentals of pneumatic control technology

Maintenance of pneumatic devices and systems

Workbooks Basic Level TP101

Advanced Level TP102

Optional Teachware Sets of overhead transparencies

Magnetic symbols, drawing template

Simulation software FluidSIM®

Pneumatic

WBT Fluid Studio Pneumatic

Cutaway model set 1 + 2 with storage case

Technology package for pneumatics (TP100)

Important elements of

TP100

Technology package for pneumatics (TP100)


Seminars

P111 Fundamentals of pneumatics and electropneumatics

P121 Maintenance of and fault finding on pneumatic and electropneumatic systems

IW-PEP Maintenance and servicing in control technology – pneumatic and electropneumatic

control systems

P-AL Pneumatics for vocational training

Details of venues, dates and prices can be found in the current seminar planner.

Information regarding further training media is available in our catalogues and on

the Internet. The Learning System for Automation and Technology is continually

updated and expanded. The sets of overhead transparencies, films, CD-ROMs and

DVDs as well as technical books are available in several languages.


• To familiarise yourself with the design and mode of operation of a single-acting

cylinder.

• To familiarise yourself with the design and mode of operation of a 3/2-way valve.

• To be able to identify and draw types of directional control valve actuation.

• To be able to explain and design a direct actuation.

• To be able to analyse and evaluate circuits.

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

cylinder.


• To be able to explain and design an indirect actuation.

• To familiarise yourself with the mode of operation of a 5/2-way valve with

pneumatic actuation.

• To be able to differentiate between a signalling element and a control element.

• To be able to measure pressure in pneumatic control systems.

• To be able to differentiate between and utilise types of flow control according to

specifications.

• To be able to set cylinder advancing and retracting speeds.

• To familiarise yourself with one type of signal storage in pneumatic control

systems.

• To be able to explain and realise logic AND/OR/NOT operations.

• To be able to explain and configure latching circuits.

Training aims of Basic Level (TP101)

Training aims of Basic Level (TP101)


• To familiarise yourself with one possibility of cylinder end position sensing.

• To be able to combine logic operations.

• To familiarise yourself with the design and mode of operation of magnetic

proximity sensors.

• To be able to differentiate between and select and use 5/2-way valves according

to specifications.

• To be able to further develop existing circuits.

• To familiarise yourself with the design and mode of operation of a pressure

sequence valve.

• To be able to design pressure-dependent control systems.


regulating valve.

• To be able to analyse circuits and optimise these according to specifications.

• To familiarise yourself with the design and mode of operation of a time delay

valve.

• To be able to design circuits with oscillating movements.

• To be able to use time delay valves dependent on parameters.

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


Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Training aims

To familiarise yourself with the

design and mode of operation of a

single-acting cylinder.

• • •



3/2-way valve.

• • •

To be able to identify and draw

types of directional control valve

actuation.

• • •

To be able to explain and design an

example of direct actuation.

• • • •

To be able to analyse and evaluate

circuits.

• •



double-acting cylinder.

•



5/2-way valve.

• •

To be able to explain and design an

example of indirect actuation.

• •

To be able to differentiate between

a signalling element and a control

element.

•

To be able to measure pressure in

pneumatic control systems.

•


and utilise types of flow control

according to specifications.

• •

To be able to set cylinder advancing

and retracting speeds.

• •

Allocation of training aims and exercises

Allocation of training aims and exercises


Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Training aims

To familiarise yourself with one type

of signal storage in pneumatic

control systems.

•

To be able to explain and realise

logic AND/OR/NOT operations.

• • • •

To be able to explain and design

latching circuits.

•

To familiarise yourself with one

possibility of cylinder end position

sensing.

•

To be able to combine logic

operations.

• •


design and mode of operation of

magnetic proximity sensors.

•


and select and use 5/2-way valves

according to specifications.

•

To be able to further develop

existing circuits.

•



pressure sequence valve.

•

To beable to design pressure-

dependent control systems.

• • • •



pressure regulating valve.

•



time delay valve.

•

To be able to design circuits with

oscillating movements.

•

To be able to use time delay valves

dependent on parameters.

•

To be able to analyse and design

circuits using two cylinders.

•


This equipment set has been compiled for basic training in pneumatic control

technology. It contains all the components required to meet the specified training

aims and can be expanded in any way with other equipment sets. The profile plate

and a compressed air supply are required in addition.

Description Order No. Quantity

3/2-way pneumatic valve, pneumatically actuated, one side 539768 1

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

3/2-way valve with pushbutton actuator, normally open 152861 1

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

3/2-way valve with selector switch, normally closed 152863 1

5/2-way double pilot valve, pneumatically actuated, both sides 539769 3

5/2-way valve, pneumatically actuated, one side 538694 1

5/2-way valve with selector switch 152862 1

Double-acting cylinder 152888 1

Dual-pressure valve (AND) 539770 2

Manifold 152896 1

One-way flow control valve 539773 2

Plastic tubing, 10 m, PUN 4 x 0.75 151496 2

Pressure gauge 152865 2

Pressure regulator valve with gauge 539756 1

Pressure sequence valve 152884 1

Proximity switch, pneumatic, with cylinder attachment 539775 2

Push-in sleeve 153251 10

Push-in T-connector 153128 10

Quick-exhaust valve 539772 1

Shuttle valve (OR) 539771 1

Single-acting cylinder 152887 1

Start-up valve with filter control valve 540691 1

Time-delay valve, normally closed 540694 1

Equipment set – Basic Level (TP101)

Equipment set – Basic Level

(TP101

Order No.: 540710)



Description Symbol

3/2-way valve with pusbutton

actuator,

normally closed

2

31

3/2-way valve with pushbutton

actuator,

normally open

2

31

5/2-way valve with selector switch 24

35

1

3/2-way valve with selector switch 2

31

Pressure gauge

3/2-way roller lever valve,

normally closed

31

2

Pneumatic proximity switch

31

2

3/2-way pneumatic valve,

normally closed

2

31

12

5/2-way pneumatic valve 24

35 1

14

5/2-way pneumatic double pilot valve 24

35 1

14 12

Equipment set symbol



Description Symbol

Shuttle valve 2

1/31

Dual pressure valve 2

1/31

Time delay valve,

normally closed

2

31

Quick exhaust valve 2

1/31

One-way flow control valve 21

Pressure sequence valve 2

3112

Single-acting cylinder

Double-acting cylinder



Description Symbol

Start-up valve with filter control valve

2

31

Pressure regulating valve with

pressure gauge

2

31

Manifold

Connection elements


Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Equipment

Cylinder, single-acting 1 1 1 1

Cylinder, double-acting 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

One-way flow control valve 2 2 1 2 2 2 2 2 2 2 1 2 2

Quick exhaust valve 1 1

Pressure gauge 2 2 1 2 1

3/2-way valve, pushbutton actuator,

normally closed

1 1 2 2 1 2 2 1 1 1 1

3/2-way valve, pushbutton actuator,

normally open

1 1

3/2-way valve, selector switch,

normally closed

1 1 2 1

3/2-way roller lever valve,

normally closed

1 1 1

Pneumatic proximity switch 2 2 2 1 2 2 2 2

3/2-way pneumatic valve 1 1

3/2-way pneumatic double pilot

valve

1 1

5/2-way valve, selector switch 1 1 1

5/2-way pneumatic valve 1 1 1 1

5/2-way pneumatic double pilot

valve

1 1 1 1 1 1 1 1

Shuttle valve 1 1 1 1

Dual pressure valve 1 2 2 1 1 2 1 1

Pressure sequence valve 1 1 1

Pressure regulating valve with

pressure gauge

1 2 1 1

Time delay valve, normally closed 1 1

Manifold 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Start-up valve with filter control

valve

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Allocation of equipment and exercises

Allocation of equipment and exercises



• Training aims

The overall aim of this collection of exercises is the systematic design of circuit

diagrams and practical assembly of a control system on a profile plate. This

direct interaction of theory and practice ensures a quick progress with learning.

The precise training aims are documented in the table. Actual individual training

aims are allocated to each problem.

• Time required

The time required to work through a problem depends on the trainee’s prior

knowledge. Skilled workers in the engineering and electrical field require

approximately 2 weeks. Technicians or engineers require approximately 1 week.

• Components of the equipment set

The collection of exercises and equipment set are harmonised. For all

18 exercises you only require the components of the equipment set of Basic

Level TP101.

Each Basic Level exercise can be assembled on a profile plate.

Methodological help for the trainer

Methodological help for the trainer



All 18 exercises in Part A are of identical methodological structure.

The exercises are divided into:

• Title

• Training aims

• Problem definition

• Parameters

as well as

• Project task

• Positional sketch

• Worksheets

The proposed solutions in Part C are divided into:

• Circuit diagram

• Solution description

as well as

• Circuit assembly

• Equipment list

Methodological structure of the exercises


Components are designated in accordance with the DIN-ISO 1219-2 standard. All

components of a circuit have the same main code number. Letters are assigned

depending on component. Several components within a circuit are numbered

consecutively. The designation of pressure ports is P and these are separately

consecutively numbered.

Cylinder: 1A1, 2A1, 2A2, ...

Valves: 1V1, 1V2, 1V3, 2V1, 2V2, 3V1, ...

Sensors: 1B1, 1B2, ...

Signal input: 1S1, 1S2, ...

Accessories: 0Z1, 0Z2, 1Z1, ...

Designation of equipment


The CD-ROM supplied provides you with additional media. The contents of Part A –

Exercises and Part C – Solutions are stored in the form of pdf files.

The structure of the CD-ROM is as follows:

• Operating instructions

• Data sheets

• Demo

• Festo catalogue

• FluidSIM®

circuit diagrams

• Industrial applications

• Presentations

• Product information

• Videos

Operating instructions are available for the various pieces of equipment of the

technology package to assist you in the use and commissioning of the equipment.

The data sheets for the equipment of the technology package are available in the

form of pdf files.

A demo version of the software package FluidSIM®

Pneumatic is stored on the

CD-ROM. This version is suitable for the testing of the control systems developed.

Pages from the Festo AG & Co. KG catalogue are provided for selected pieces of

equipment. The representation and description of equipment in this form is intended

to illustrate how such equipment is represented in an industrial catalogue. You will

also find additional information here regarding the equipment.

FluidSIM®

circuit diagrams are stored in this directory for all of the 18 exercises in

the technology package.

Contents of the CD-ROM

Operating instructions

Data sheets

Demo

Festo catalogue

FluidSIM® circuit diagrams

Contents of the CD-ROM


Photos and pictures are provided of industrial applications, whereby you can

illustrate your own problem definitions. These illustrations can also be added to

project presentations.

Brief presentations are stored in this directory regarding the equipment of this

technology package. These presentations can for instance be used to create project

presentations.

This directory provides you with the product information and data sheets of Festo

AG & Co. KG regarding the equipment of the technology package and is intended to

explain what information and data are provided for an industrial component.

A number of videos of industrial applications complete the media for the technology

package. Short sequences are shown of practice-related applications.

Industrial applications

Presentations

Product information

Videos


This Advanced Level equipment set has been compiled for further training in

pneumatic control technology. The two equipment sets (TP101 and TP102) comprise

the components required for the specified training aims and can be expanded in any

way with other equipment sets of the Learning System for Automation and

Technology.

Description Order No. Quantity

3/2-way roller lever valve with idle return, normally closed 152867 1

3/2-way pneumatic valve, pneumatically actuated, one side 539768 4

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

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

Double-acting cylinder 152888 2

One-way flow control valve 539773 2

Plastic tubing, 10 m, PUN 4 x 0.75 151496 2

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

normally open

152864 1

Non-return valve, delockable 540715 2

Back pressure valve 152868 1

Push-in sleeve 153251 10

Stepper module 152886 1

Push-in T-connector 153128 20

Time delay valve, normally open 539759 1

Pneumatic preset counter 152877 1

Shuttle valve (OR) 539771 1

Shuttle valve, 3-off (OR) 152882 1

Dual pressure valve, 3-off (AND) 152883 1

Equipment set – Advanced Level (TP102)

Equipment set – Advanced

Level (TP102

Order No.: 540711)


• To detect end positions without limit switches

• To understand and design flip-flop circuits (flip-flop, double pilot valve)

• To convert a 3/2-way and/or 5/2-way valve

• To evaluate, use and adjust different sensors

• To explain the function of a back pressure end stop

• To describe the function of stepper (modules)

• To design basic stepper control systems (continuous cycle)

• To realise a stepper control system using the operating modes

AUTOMATIC/MANUAL, START and RESET

• To realise the OR function of feedback signals

• To adjust and harmonise delays

• To be able to interrupt time delays via an OR function

• To realise a stepper control with idle step (3 steps)

• To describe and design variable step repetition within a motion sequence using a

predetermining counter

• To develop an input circuit with self-latching loop and the functions

AUTOMATIC/MANUAL, START, STOP at CYCLE END and RESET

• To evaluate and realise the use of sensors for material sensing

• To actuate a final control element using two stepper modules via a shuttle valve

(double stroke of cylinder)

• To use a proximity sensor in the partial stroke range to realise the reversal of a

cylinder

• To develop an input circuit for a stepper control with protected pilot air and the

functions START, EMERGENCY-STOP and RESET

• To stop a cylinder within the partial stroke range (positioning) by means of

pressure applied at both ends (pre-pressurise)

• To adjust proximity sensors in the end positions and in the partial stroke range

• The combined use of quick exhaust valve and pressure regulating valve with

pressure gauge

• To design the inversion of a timer signal

• To realise a control system with command action in combination with a sequence

control in stepper design.

Training aims of Advanced Level (TP102)

© Festo Didactic GmbH & Co. KG • 541088 A-1

Part A – Exercises

Exercise 1: Pressing of cheese wheels____________________________________A-3

Exercise 2: Opening of an animal feed silo _______________________________A-11

Exercise 3: Testing of key blanks _______________________________________A-17

Exercise 4: Sorting of packages ________________________________________A-23

Exercise 5: Stopping crates of drinks____________________________________A-35

Exercise 6: Opening and closing of a pipe _______________________________A-41

Exercise 7: Shutting off using a quick shut-off function _____________________A-47

Exercise 8: Actuation of a shut-off device ________________________________A-53

Exercise 9: Brushing of cheese wheels __________________________________A-61

Exercise 10: Clamping of a workpiece ___________________________________A-67

Exercise 11: Actuation of a sliding door__________________________________A-75

Exercise 12: Feeding of workpieces _____________________________________A-81

Exercise 13: Crushing of drinks cans ____________________________________A-87

Exercise 14: Packaging of brochures ____________________________________A-93

Exercise 15: Fitting of locking clips _____________________________________A-99

Exercise 16: Labelling of paint pots ___________________________________ A-105

Exercise 17: Cleaning of workpieces __________________________________ A-111

Exercise 18: Pressing in of lids _______________________________________ A-117

Contents

Contents

A-2 © Festo Didactic GmbH & Co. KG • 541088



cylinder.



• To be able to explain and design an example of direct actuation.

During cheese production, pneumatic cylinders are to be used to press cheese

wheels into moulds. Design the control system whereby this process can be carried

out.

• A single-acting cylinder is to be used .

• The pneumatic control of the cylinder is to be realised by mean of a manually

operated valve.

1. Describe the mode of operation of a single-acting cylinder.

2. Describe the mode of operation of a 3/2-way valve.

3. Complete the pneumatic circuit diagram for the pressing device.

4. Carry out the assembly.

5. Check the assembled circuit.

6. Describe the mode of operation of the circuit.

7. Compile an equipment list.

Exercise 1: Pressing of cheese wheels

Training aims

Problem definition

Parameters

Project task



Cheese production

1. Cheese wheels are to be manually inserted into the device.

2. Actuation of the pushbutton is to cause the cylinder to advance and press the

cover onto the device.

3. The pushbutton is to be pressed until the pressing operation is completed.

4. If the pushbutton is released, the cylinder is to retract again and release the

device.

5. The wheel can then be removed.

Note

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

system.

Safety advice

Please limit the pressure at the service unit to a maximum of 3.5 bar (350 kPa) for

this exercise.

Positional sketch




Name: Date:

Design and mode of operation of a single-acting cylinder Sheet 1 of 2

– Compare the symbols shown with the schematic representation of the single-

acting cylinder. Check whether these match.

1A1

Symbol of a single-acting cylinder

1 2 3 4 5

678

Schematic representation of a single-acting cylinder

– Assign the designations to the individual components.

No. Description

Cylinder barrel

End cap

Bearing cap

Piston rod

Piston

Reset spring

Supply port

Exhaust port

Table of component designations




Name: Date:

Design and mode of operation of a single-acting cylinder Sheet 2 of 2

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

Fth = A • p

Fth = Theoretical piston force (N)

A = Effective piston surface (m2)

p = Working pressure (Pa)

The effective piston force is of significance in practice. Frictional resistance is to be

taken into account when you calculate this. Friction forces of approx. 10% of the

theoretical piston force can be assumed for standard operating conditions (pressure

range of 4 to 8 bar (400 to 800 kPa),.

The following applies for single-acting cylinders:

Feff = A • p – (FF + FR)

Feff = Effective piston force (N)

FF = Friction force (approx. 10% of Fth

) (N)

FR = Return spring force (N)

– Calculate the effective piston force in the advance stroke for the cylinder when

used at an operating pressure of 6 bar (600 kPa)!

Note

You will find information regarding the technical data in Chapter D and on the

CD-ROM provided.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




Name: Date:

Mode of operation of a 3/2-way valve. Sheet 1 of 1

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

normally closed.

2

31

Symbol of a 3/2-way valve

1

2

3

Schematic representation of a 3/2-way valve

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

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




Name: Date:

Completing the pneumatic circuit diagram Sheet 1 of 1

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

designations.

Pneumatic circuit diagram

Note

The Start-up valve with filter control valve and the manifold are not shown. These

components are required for the circuit assembly.




Name: Date:

Compiling the equipment list Sheet 1 of 1

Apart from the circuit diagram, comprehensive project documentation also requires

an equipment list.

– Compile the equipment list by entering the required equipment in the table

below.

Quantity Description

Equipment list





cylinder.


• To be able to identify and draw directional control valves.


The slide of an animal feed silo is to be opened by pressing a pushbutton. The slide

is closed again when the pushbutton is released.

• A single-acting cylinder is to be used.

• The pneumatic control of the cylinder is to be realised by means of a pushbutton

actuator.

1. Answer the questions regarding the 3/2-way valve.

2. Create the pneumatic circuit diagram for the slide control.




6. Compile the equipment list

Exercise 2: Opening of an animal feed silo

Training aims

Problem definition

Parameters

Project task



Animal feed silo

1. Operation of the pushbutton actuator is to cause the cylinder to retract until the

retracted end position is reached.

2. The pushbutton actuator is to be operated for as long as the slide is to remain

open.

3. If the pushbutton actuator is released again, the cylinder is to advance thus

causing the slide to close the silo opening.

Note

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

system.

Safety advice


this exercise.

Positional sketch




Name: Date:

Mode of operation of a 3/2-way valve Sheet 1 of 1

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

normally open.

2

31


3

2

1


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

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




Name: Date:


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

designations.

Note

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

2

31

1A1

1S1


Note

The On-Off valve with filter regulating valve and the manifold are not shown. These





Name: Date:

Amending the equipment list Sheet 1 of 1

– Amend the equipment list.


1 Compressed air supply

Tubing material

1 Single-acting cylinder

1 3/2-way valve, manually operated, normally closed

Equipment list


Amended equipment list





cylinder.




• To be able to to analyse and evaluate circuits.

Key blanks are to be tested at a manual workstation. The insertion of the key blanks

requires a certain amount of time. It must therefore be possible for the clamping

cylinders to be retained in both end positions.

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

of this problem.

1. Complete the pneumatic circuit diagram for the clamping device




5. Amend the equipment list

Exercise 3: Testing of key blanks

Training aims

Problem definition

Parameters

Project task



Test station for key blanks

1. Key blanks are to be inserted manually into the test device.

2. Actuation of the selector switch is to cause the cylinder to advance and secure

the key blanks.

3. The cylinder is to remain in this position even after the selector switch is

released.

4. Resetting of the selector switch is to cause the cylinder to return into the

retracted end position and to remain there until the selector switch is actuated

again.

Safety note


this exercise.

• What errors can occur during the assembly and tubing up of the circuit?

• What is the effect of such errors. Describe these.

Positional sketch

Additional exercises




Name: Date:


– Complete the circuit diagrams below.

– Select the optimal circuit and complete this by adding the required type of

actuation. Explain the reasons for your choice.

a) b)

Pneumatic circuit diagrams

Note

The On/Off valve with the filter regulating valve and the manifold are not shown.

These components are required for the circuit assembly.




Name: Date:


– Amend the equipment list.


1 Cylinder, single-acting

1 3/2-way valve with pushbutton, normally open

1 Manifold

1 Start-up valve with filter control valve


Equipment list


Amended equipment list




Name: Date:

Completing additional exercises Sheet 1 of 1

– What errors can occur during the assembly and tubing up of the circuit?

– What is the effect of such errors? Describe these.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




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

cylinder.



Packages are sorted manually from a conveyor into large containers at a sorting

station. When the containers are filled, these are transferred and a new container is

made available. During this time material flow is to be stopped whilst the conveyor

continues to run. The stopping action is realised by means of a mechanical blocking

device (slide). This blocking device is to be operated from the sorting position.

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

1. Describe the mode of operation of a double-acting cylinder.

2. Describe the mode of operation of a 5/2-way valve.

3. Draw a pneumatic circuit diagram for the package blocking device.





Exercise 4: Sorting of packages

Training aims

Problem definition

Parameters

Project task



Package conveyor

1. Actuation of the selector switch is to cause the cylinder to advance and push the

slide into the material flow.

2. The cylinder is to remain in this position even after the selector switch is released

and the material flow is to remain interrupted.


retracted end position and release the material flow again.

4. The cylinder is to remain in this position until the selector switch is actuated

again.

Safety note


this exercise.

Positional sketch




• What is the effect of such errors? Describe these.

• What are your observations with regard to the advance and return movement of

the cylinder? Explain these.

• Why is a double-acting cylinder more cost effective than a single-acting cylinder?

• Determine the requirements placed on the directional control valve.

• Give the reasons why a selector switch has been chosen to realise the actuating

function.







Name: Date:

Design and mode of operation of a double-acting cylinder Sheet 1 of 4

– Compare the symbol shown with the schematic representation of the double-

acting cylinder. Check whether these match.

1A1

Symbol of a double-acting cylinder




Name: Date:


2 3 4 5

6

1

9 8 7

Schematic representation of a double cylinder

– Assign the designations to the individual components.

No. Designation

Cylinder barrel

End cap

Bearing cap

Piston rod

Piston

Supply port of piston chamber

Supply port of piston rod chamber

Adjusting screw of end position cushioning





Name: Date:


The piston force generated by a working element is dependent on the air pressure,

cylinder diameter and frictional resistance of the sealing elements. The theoretical

piston force is calculated according to the following formula:

Fth = A • p

Fth = Theoretical piston force (N)


p = Working pressure (Pa)

The effective piston force is of significance in practice. Frictional resistance is to be

taken in account when you calculate this. Under normal operating conditions,

friction forces of approx. 10% of the theoretical piston force can be assumed.

The following applies for double-acting cylinders:

Advance stroke Feff = (A • p) – FF

Return stroke Feff = (A' • p) – FF

Feff = Effective piston force (N)


= )4

D(

2π•

A' = Effective annular surface (m2)

= 4)d(D 22 π

−

p = Working pressure (Pa) FF = Friction force (approx. 10% of Fth

) (N)

D = Cylinder diameter (m) d = Piston rod diameter (m)




Name: Date:


– Calculate the effective piston force of the advance stroke and return stroke for

the cylinder in question using at a working pressure of 6 bar (600 kPa).

Note

You will find information regarding the technical data in Chapter D and on the

CD-ROM provided.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




Name: Date:

Mode of operation of a 5/2-way valve Sheet 1 of 1

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


2 3514 4 1


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

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




Name: Date:

Designing the pneumatic circuit diagram Sheet 1 of 1

– Complete the circuit diagram below and also enter the required type of actuation.

Explain the reasons for your choice.


Note

The Start-up valve with filter control valve is not shown. These components are

required for the circuit assembly.




Name: Date:



an equipment list.


below.


Equipment list




Name: Date:

Completing aditional exercises Sheet 1 of 1



– Describe the mode of operation of a double-acting cylinder.

– What are your observations with regard to the advance and return movement of

the cylinder? Explain these.

– Why is a double-acting cylinder more cost effective than a single-acting cylinder?

– Determine the requirements placed on the directional control valve.

– Explain your reasons why the selector switch is the form of actuation selected for

the directional control valve.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________


• To be able to explain and design an example of indirect actuation.

• To familiarise yourself with the mode of operation of a 5/2-way valve with

pneumatic actuation.

• To be able to differentiate between a signal element and a control element.

Crates of drinks are to be provided with new labels. This process is to be checked via

a test set-up. The crates of drinks are supplied on a conveyor and must be

individually transported past a labelling device. The crates are to be stopped by

means of a mechanical stop (slide). The slide is to operated from the system control

console.

• Stopping of the material flow is to be effected from a second control console,

where compressed air is available and a pneumatic solution is therefore to be

used.

1. Determine the circuit requirements with regard to the actuating components and

control element.

2. Complete the pneumatic circuit diagram for the stopping of material flow.




6. Compile an equipment list

Exercise 5: Stopping crates of drinks

Training aims

Problem definition

Parameters

Project task



Labelling crates of drinks

1. Actuation of a selector switch is to cause the cylinder to advance and push the

slide into the material flow; the crates are thus stopped.


retracted end position and once again release the flow of material.

3. It is to remain in this position until the selector switch is actuated again.

Safety note


this exercise.

• What errors can occur during the design and tubing up of the circuit?


• Explain the terms „pilot control“ and „remote control“.

Positional sketch





Name: Date:


– Complete the circuit diagram below.

24

35

1


Note






Name: Date:



an equipment list.


below.


Equipment list



Exercise 5: Stopping of crates of drinks

Name: Date:




– Explain the terms „pilot control“ and „remote control“.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




• To be able to measure pressure in pneumatic control systems.

• To be able to differentiate between and utilise types of flow control in

accordance with specifications.

The slide in a pipe is to be opened and closed. Actuation is to be triggered by means

of a valve with selector switch. A double-acting cylinder is to be used as the drive.

• The slide is to open/close only gradually since the load on the pipe would

otherwise be to great (the formation of surges is to be avoided).

1. Design the pneumatic circuit diagram.





6. Observe the pressure ratios upstream and downstream of the flow control valve

and document these.

Exercise 6: Opening and closing of a pipe

Training aims

Problem definition

Parameters

Project task



Waste water treatment

1. If the selector switch is actuated, the cylinder is to advance and open up flow.

2. If the selector switch is reset, the cylinder is to return into the initial position and

the slide is to close.

Safety note


this exercise.



• At what pressure do you notice juddering operation?

• Describe what causes juddering operation.

Positional sketch





Name: Date:

Function of a one-way flow control valve Sheet 1 of 1

1

2

Symbol of a one-way flow control valve

1 2

Schematic representation of a one-way flow control valve

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

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




Name: Date:


– Complete the circuit diagram below. Enter the symbols of the one-way flow

control valves.

1A1

1S1 2

1 1

2 2

4

35

1

1V1 1V2


Note






Name: Date:



an equipment list.

– Create the equipment list by entering the required equipment in the table below.


Equipment list




Name: Date:




– At what pressure do you notice juddering operation?

– Describe what causes juddering operation.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________



• To be able to differentiate between and utilise types of flow control in


A filling plant fills pots of paint with wall and ceiling paint. The pipes through which

the paint flows are to close quickly. The opening of the pipe is to be effected

gradually.

• A double-acting cylinder is to be used

1. Create the pneumatic circuit diagram for the shut-off device.




5. Compile the equipment list.

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

Training aims

Problem definition

Parameters

Project task



Filling paint pots

1. Actuation of a selector switch is to cause a shut-off valve to open gradually.

2. Resetting of the selector switch is to cause the shut-off valve to close quickly.

Safety note


this exercise.

• What errors can occur during the tubing up?

• What is the effect of such tubing errors? Describe these.

Positional sketch




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

Name: Date:


– Complete the circuit diagram below and add the symbols of the one-way flow

control valves.

1A1

1S1 2

1 1

2 2

4

35

1

1V1 1V2

1Z2

1Z1


Note






Name: Date:



an equipment list.


below.


Equipment list




Name: Date:


– What errors can occur during tubing?

– What are the effects of such tubing errors. Describe these.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




• To familiarise yourself with one type of signal storage in pneumatic control

systems.


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

slide is to be effected gradually.

• A double-acting cylinder is to be used.

1. Describe the mode of operation of a quick exhaust valve.

2. Describe the mode of operation of a 5/2-way double pilot valve.

3. Design the pneumatic circuit diagram for the shut-off device.





Exercise 8: Actuation of a shut-off device

Training aims

Problem definition

Parameters

Project task



Granulate filling system

1. Actuation of a pushbutton is to cause a shut-off device (ball valve) to open

gradually.

2. Actuation of a second pushbutton is to cause the shut-off device to close quickly.

Safety note


this exercise..



Positional sketch





Name: Date:

Function of a quick exhaust valve Sheet 1 of 1

2

1/31

Symbol of a quick exhaust valve

1

2

3

Schematic representation of a quick exhaust valve

– Describe how a quick exhaust valve functions.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




Name: Date:

Mode of operation of a 5/2-way double pilot Sheet 1 of 1

2 3514 124 1

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

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

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




Name: Date:



1

2

24

35

1

2


Note






Name: Date:



an equipment list.


below.


Equipment list




Name: Date:


– What errors can occur during the assembly and tubing up of a circuit?


_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




• To be able to explain and configure an indirect actuation.


• To be able to explain and configure.

Cheese wheels are to be brushed during production. Loading of the brushing device

is to be controlled manually. The cheese wheels are to be supplied via a conveyor.

Material flow is to be stopped by means of a slide if the device is filled .

• Material flow is to be controlled via two valves and the use of pushbuttons, i.e.

one pushbutton actuator to block and one to release material flow.

• Since the signal of the pushbutton actuators is only briefly applied, a circuit that

stores the signal status needs to be designed.

1. Describe the function of a shuttle valve.

2. Describe the construction of a self-latching loop.

3. Complete the pneumatic circuit diagram.





Exercise 9: Brushing of cheese wheels

Training aims

Problem definition

Parameters

Project task



Cheese production

1. Actuation of the pushbutton is to cause the cylinder to advance and push the

slide into the material flow.

2. The cylinder retains this position even after the pushbutton is released and

material flow is to remain interrupted.

3. Actuation of the second pushbutton is to cause the cylinder to return into the

retracted end position and release material flow again.

4. It is to remain there until the first pushbutton is actuated again.

• What errors can occur during tubing up?

• What are the effects of such tubing errors? Describe these.

• Describe the mode of operation of the self-latching loop on the basis of the

circuit.

Positional sketch





Name: Date:

Function of a shuttle valve Sheet 1 of 1

2

1/31

Symbol of a shuttle valve

2

1 1/3

Schematic representation of a shuttle valve

– Describe the function of a shuttle valve.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




Name: Date:


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

24

35

1

14

2

31

1S1

1A1

1 1

2 2





Name: Date:



an equipment list.



Equipment list




Name: Date:


– What errors can occur during tubing up?

– What are the effects of such tubing errors? Describe these.

– Describe the mode of operation of the self-latching loop on the basis of the

circuit.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________



• To familiarise yourself with one possibility of cylinder end position sensing.

An automatic rotary indexing machine is used in production for the feeding of

workpieces. Workpieces to be processed are to be clamped in the individual

workpiece retainers. A clamping device is to be designed and checked by means of a

test setup.

• The clamping operation must not be started until the cylinder is in the retracted

end position.

• Actuation of a second pushbutton is to cause the cylinder to return into the

retracted end position and release the workpiece.

• A pressure gauge is to be installed at each of the working ports between the one-

way flow control valve and cylinder to display the pressure.

1. Describe the function of a dual pressure valve.

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






Exercise 10: Clamping of a workpiece

Training aims

Problem definition

Parameters

Project task



Automatic rotary indexing machine

1. A double-acting cylinder is to advance only if a pushbutton is actuated AND if the

cylinder is in the retracted end position at the same time, since it is otherwise not

possible to insert a workpiece for processing.

2. The clamping cylinder is to retain the forward end position until the workpiece is

processed. The duration of the processing time can vary.

3. Pressing of a second pushbutton is to cause the workpiece to be released.

Safety note


this exercise.



• What is the effect of adjusting the 3/2-way roller lever valve?

Positional sketch





Name: Date:

Function of a dual pressure valve Sheet 1 of 1

2

1/31

Symbol of a dual pressure valve

2

1 1/3

Schematic representation of a dual pressure valve

– Describe the function of a dual pressure valve.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




Name: Date:

Function of a 3/2-way roller lever valve Sheet 1 of 1

2

31

Symbols of a 3/2-way roller lever valve

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

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




Name: Date:



1A1

24

35

1

14

1B1

1 1

2 2

2

31

1B1

12





Name: Date:


Apart from a circuit diagram, comprehensive project documentation also requires an

equipment list.


below.


Equipment list




Name: Date:


– What errors can occur during the assembly and tubing up of the circuit diagram?


– What is the effect of adjusting the 3/2-way roller lever valve?

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________






• To familiarise yourself with the design and mode of operation of magnetic

proximity sensors.

• To be able to differentiate between and select and utilise 5/2-way valves in


A sliding door is to be opened and closed from both sides by means of a pushbutton.

Only one pushbutton is to be located on each of the door in order to eliminate

incorrect operation in cases of emergency.

• Both functions must only be started if the door is in the forward end position.

• For reasons of safety, pressure must be limited to 3 bar (300 kPa) (risk of being

trapped).

1. Design a pneumatic circuit diagram for the control system of the sliding door.





Exercise 11: Actuation of a sliding door

Training aims

Problem definition

Parameters

Project task



Sliding door

1. Provided that the sliding door is in a defined end position, it can be moved into

the opposite end position by means of pressing a button. The sliding door can

thus be opened or closed.

2. It is not possible to start the opening or closing function for as long as the door is

not in an end position.

Safety note

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

exercise.



• What happens if compressed air supply fails during the advancing and retracting

movement?

• How can the circuit be re-started; what needs to be done for this?

Positional sketch





Name: Date:

Function of a pneumatic proximity sensor Sheet 1 of 1

31

2

Symbol of a pneumatic proximity sensor

S

N S

N

2

31

Schematic representation of the pneumatic proximity sensor

– Describe the function of the pneumatic proximity sensor.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




Name: Date:



1A1

24

35

14 12

3 31 1

2 2

3 31 1

1S11B1 1S2 1B2

1B1 1B2

2 2

1 1

2 2





Name: Date:



an equipment list.



Equipment list




Name: Date:


– What errors can occur during the assembly or tubing up of the circuit?


– What happens if the compressed air supply fails during the advancing and

retracting movement?

– How can the circuit be re-started and what needs to be done to this effect?

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________


• To familiarise yourself with the logic NOT operation.


• To be able to further develop existing circuits.

Workpieces are to be fed from a magazine towards a machining process. The

ejecting of a workpieces must be prevented if the removal position is not clear.

• The checking function as to whether a workpiece is present in the removal

position is to be effected by means of a roller lever valve.

• The cylinder is to be throttled during advancing and retracting.






Exercise 12: Feeding of workpieces

Training aims

Problem definition

Parameters

Project task



Automatic rotary indexing machine

1. The ejecting function is to be started by means of a pushbutton if the cylinder is

in the retracted end position. The ejecting cylinder is to push a workpiece from

the magazine only if a sensor in the removal area signals that the removal

position is NOT occupied.

2. If the removal position is clear, the cylinder is to move into the forward end

position with exhaust air restricted, eject the workpiece and immediately return

into the retracted end position.



• How would you need to change the circuit if the ejecting process were to start

only once a workpiece is present in the magazine AND the removal position is

clear?

Positional sketch





Name: Date:



1A1

24

35

1

14 12

1 1

2 2


Note

Use a 3/2-way valve with pushbutton actuator or selector switch in the circuit

instead of a 3/2-way roller lever valve in order to simulate whether the removal

position is clear or occupied.




Name: Date:



an equipment list.


below.


Equipment list




Name: Date:

Carying out additional exercises Sheet 1 of 1



– How would you need to change the circuit, if the ejecting process were to start

only once a workpiece is in the magazine AND the removal position is clear ?

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________





sequence valve.


In a recycling plant drinks cans are to be crushed into a block for space-saving

storage. The pressing operation is to be triggered by means of a pushbutton. The

return stroke can be triggered by a pushbutton. The pressing operation is to start

only if sufficient pressure is available.

• The retracted end position is the initial position of the pressing cylinder.

• The pressing operation is to start only if the system pressure is above 6 bar

(600 kPa).

• The return stroke can be triggered manually since, depending on material load,

the pressing cylinder does not reach the forward end position.

1. Complete the pneumatic circuit diagram for the crushing of cans.





Exercise 13: Crushing of drinks cans

Training aims

Problem definition

Parameters

Project task



Tin can press

1. A pressure sequence valve is to switch upon reaching the preset pressure and to

release compressed air for the circuit. The circuit must not function below a

pressure of 4.5 bar (450 kPa).

2. It should not be possible to commence the pressing operation via a start button

unless the pressing cylinder is in the upper end position. The pressing cylinder is

to move up to the forward end position or a stop predefined by the material.

3. The return stroke is to be triggered by means of a limit switch or pushbutton.

Note

The required protective grid is not shown.



Positional sketch





Name: Date:

Function of a pressure sequence valve Sheet 1 of 1

2

3112

Symbol of a pressure sequence valve

23 1 12

Schematic representation of a pressure sequence valve

– Describe the function of a pressure sequence valve.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




Name: Date:



1V4

1V5 24

351

1V6

14 12

2

1/31

3 31 1

1V3 2

1/31

2

2

2

3

3

31

1

1

1S1

1V2

1V1

1B1 1S2 1B2

1V7

2 2

2

3112

1 1

2 2

1A1

1B1 1B2





Name: Date:



an equipment list.


below.


Equipment list




Name: Date:




_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

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regulating valve.

• To be able to design pressure-dependent control circuits.

10 brochures at a time are to be manually wrapped in plastic film. In order for the

film to be neatly bonded, the brochures will need to be clamped. To be able to

securely clamp the brochures a minimum pressure of 6 bar (600 kPa) must be

available. However at the clamping cylinder a maximum pressure of 8 bar (800 kPa)

is to be applied.

The advance and return stroke are to be triggered by means of a pushbutton. The

end positions of the clamping cylinder are to be sensed via pneumatic proximity

sensors.

• The process can only be started if the clamping cylinder is in the retracted end

position.

• It must only be possible to start the circuit if the operating pressure is above 6

bar (600 kPa.

• The return stroke is to be triggered intentionally since the duration of the

packaging process varies.

1. Complete the pneumatic circuit diagram for the packaging unit.





Exercise 14: Packaging of brochures

Training aims

Problem definition

Parameters

Project task



Brochure production

1. A pressure sequence valve is to switch when the preset pressure is reached and

release the compressed air into the circuit.

2. The clamping operation is to start when the clamping cylinder is in the retracted

end position and a pushbutton is pressed. The cylinder is to advance and remain

in this position.

3. The process is to be completed via a second pushbutton and the cylinder to

return into the retracted end position.



• What is the function of the one-way flow control valve which is connected in

parallel to the pressure regulating valve?

Positional sketch





Name: Date:

Function of a pressure regulating valve Sheet 1 of 1

2

31

Symbol of a pressure regulating valve

p1 p2

Schematic representation of a pressure regulating valve

– Describe the function of a pressure regulating valve.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




Name: Date:



1V4 24

35

1

14 12

2

31

1A1

1B1

2

31

1V2

1V1

2

3112

1

1

2

2





Name: Date:



an equipment list.


below.


Equipment list




Name: Date:




– What is the function of the one-way flow control valve, which is connected in

parallel to the pressure regulating valve?

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________



• To be able to analyse circuits and optimise these in accordance with

specifications.

Locking clips are to be fitted onto connector housings by means of an automatic

assembly system. Previously, pressure was set at the assembly system via a

pressure regulating valve, which repeatedly led to malfunctioning of the assembly

process.

The assembly process is to be tested using a test setup. Each assembly function is

to be triggered manually. The circuit is to be changed such that it only operates if the

pressure does not exceed a certain level.

• The pressure at the working port of the assembly cylinder must be a minimum of

3.5 bar (350 kPa), in order for the locking clips to be securely fitted.

• It must not be possible to start the process if the pressure is greater than 3.8 bar

(380 kPa).

• The return stroke of the assembly cylinder is to start automatically once the

forward end position is reached.

1. Complete the pneumatic circuit diagram for the automatic assembly system.



4. Describe the mode of operation of the circuit .

5. Compile the equipment list.

Exercise 15: Mounting of locking clips

Training aims

Problem definition

Parameters

Project task



Automatic assembly system of connector housings

1. The process is to be started via a pushbutton, when the assembly cylinder is in

the retracted end position.

2. The cylinder is to move into the forward end position using minimal force.

3. There it is to actuate a limit switch.

4. Then it is to return into the retracted end position.

Positional sketch



Exercise 15: Fitting of locking clips

Name: Date:

Complete the pneumatic circuit diagram Sheet 1 of 1


1A1

1V6 2

1 1

2 2

4

35

1

1V7

14 12

1B1 1B2

1V8





Name: Date:

Analysing the pneumatic circuit diagram Sheet 1 of 2

– Analyse the circuit diagram below.

1V4 24

351

14 12

2

31

1V6

1V7

1A1

1V3 2

1/31

31

2 2

3 31 1

1B1 1S1 1S2

1B1

2

2

31

1V2

1V1

2

3112

1

1V5 1

2

2





Name: Date:

Analysing the pneumatic circuit diagram Sheet 2 of 2

– Check whether the circuit of sheet 1 is also suitable for this problem definition?

– Where does the difference between these two circuits lie?

_____________________________________________________________________

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_____________________________________________________________________




Name: Date:



an equipment list.


below.


Equipment list



• To familiarise yourself with the design and mode of operation of a time delay

valve.

Pots of paint are to be labelled in a bonding fixture. The bonding process is to be

triggered via a pushbutton on the device.

A press-on time of 10 s is required in order for the adhesive to take effect. The

system is ready to start if the piston of the press-on cylinder is in the retracted end

position.

• The working pressure must be adjustable since the labels are to be bonded onto

the paint pots using minimal pressure.

• The cylinder is to retract as quickly as possible.

• The working pressure must be adjustable between 3 and 7 bar (300 and 700

kPa).

• The pressure is to be readable from a pressure gauge in front of the cylinder.

1. Complete the pneumatic circuit diagram





Exercise 16: Labelling of paint pots

Training aims

Problem definition

Parameters

Project task



Labelling device

1. The process is to be started using a pushbutton if the cylinder is in the retracted

end position.

2. The cylinder is to move into the forward end position using minimal force and to

remain in this position for a variable time period.

3. It is then to return into the retracted end position.

4. The pressure during advancing is to be displayed on a pressure gauge.



Positional sketch





Name: Date:

Function of a time delay valve Sheet 1 of 1

2

31

12

Symbol of a time delay valve

12

3

1

2

Schematic representation of a time delay valve

– Describe the function of a time delay valve.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




Name: Date:



2

1/31

24

351

14 12

2

1/31

3 31 1

2

31

1B1 1B21S12 2

2

31

1A1

1B1 1B2

2

1





Name: Date:



an equipment list.



Equipment list




• To be able to design circuits with oscillating movements.

• To be able to use time delay valves dependent on parameters.

A wire-mesh container with workpieces is to be moved in a cleaning bath. The

process is to be started via a pushbutton. The number of movements in the cleaning

bath is to be adjustable via a time delay valve.

• A roller lever valve is to be used to detect the retracted end position.

• 6 movements are to be carried out in the cleaning bath.

1. Convert a 5/2-way double pilot valve into a 3/2-way double pilot valve.

2. Complete the pneumatic circuit diagram for the automatic washing plant.





Exercise 17: Cleaning of workpieces

Training aims

Problem definition

Parameters

Project task



Automatic washing plant

1. The process is to be started via a pushbutton if the lifting cylinder is in the

retracted end position.

2. The lifting device cylinder is to advance up to the forward end position and then

move up to the mid position and move back again to the forward end position.

This movement is to continue until the time delay valve interrupts the process.

3. The cylinder is then return into the retracted end position.

• Which components do you need to install in the circuit to ensure that the wire-

mesh container does not drop into the cleaning bath if the compressed air supply

is switched off?

• What is the effect of the one-way flow control valve on the operating behaviour of

the cylinder?

Positional sketch





Name: Date:

Converting a 5/2-way double pilot valve Sheet 1 of 1

24

35 1

14 12

Symbol of a 5/2-way double pilot valve

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

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




Name: Date:



1V3 2

1/31

2

31

1S1

1V2

1V1

2

31

10 12

2

31

31

1B1 2

31

1B3 2

31

1B2 2

1V4 24

351

14 12

1B11B31A1

1B2





Name: Date:



an equipment list.



Equipment list



Aufgabe 17: Cleaning of workpieces

Name: Date:


– Which component needs to be installed in the circuit to ensure that the wire-

mesh container does not drop into the cleaning bath if the compressed air supply

is switched off?

– What is the effect of the one-way flow control valves on the operating behaviour

of the cylinder?

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________


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

Lids are to be pressed into a fixture in a machining station. First, the lids are placed

onto the fixture. They are then to be pressed into the fixture by means of a press-in

cylinder.

Clamping of the lids is to be effected via a pushbutton. Once clamped, the pressing

process is to start. When the press-in cylinder reaches the forward end position,

both cylinders are to retract again.

Note

Any protective devices required are not taken into consideration.

• A single-acting cylinder is to be used for the clamping of workpieces.

• A roller lever valve is to be used to detect whether the clamping cylinder has

reached is forward end position.

• A double-acting cylinder is to be used as a press-in cylinder.

• The feed speed of the clamping and press-in cylinders is to be adjustbable.

1. Analyse the pneumatic circuit diagram for the press-in device.





Exercise 18: Pressing in of lids

Training aims

Problem definition

Parameters

Project task



Press-in device

1. Plastic lids are to be placed into a fixture.

2. The pressing in process is to be started via a pushbutton.

3. A limit switch is to be used to detect whether the clamping cylinder has reached

its position.

4. The pressing-in cylinder is to advance only once the clamping cylinder has

reached its forward end position.

5. Both cylinders are to retract when the plastic lid is pressed in.



• What happens if the proximity sensor 1B2 on the cylinder is moved?

Positional sketch




Exercise 18: Pressing-in of lids

Name: Date:



1V3

1A1

1V2 2

31

12 10

2

1

2A1

2V2

2B1 2B2

1

2

2V1 24

35

1

14 12

1B2





Name: Date:



an equipment list.



Equipment list




Name: Date:




– What happens if the pneumatic proximity switch 1B2 is moved?

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________



© Festo Didactic GmbH & Co. KG • 541088 B-1

The theoretical fundamentals for the Pneumatics training package are summarised

in the textbook:

Pneumatics, Basic Level

This standard textbook deals with the fundamentals of pneumatic control

technology as well as the function and use of pneumatic components. Numerous

illustrations facilitate and ensure comprehension and pneumatic circuits are

explained with the help of examples. Model solutions and detailed explanations

consolidate the knowledge acquired regarding circuit design and functions.

P. Croser, F. Ebel, 2002 edition,

274 pages, bound

Order No.: 093131

Part B – Fundamentals

B-2 © Festo Didactic GmbH & Co. KG • 541088

© Festo Didactic GmbH & Co. KG • 541088 C-1

Part C – Solution

Exercise 1: Pressing of cheese wheels____________________________________C-3

Exercise 2: Opening of an animal feed silo ________________________________C-9

Exercise 3: Testing of key blanks _______________________________________C-13

Exercise 4: Sorting of packages ________________________________________C-17

Exercise 5: Stopping of crates of drinks _________________________________C-25

Exercise 6: Opening and closing of a pipe ________________________________C-29

Exercise 7: Shutting off using a quick shut-off function _____________________C-33

Exercise 8: Actuation of a shut-off device ________________________________C-37

Exercise 9: Brushing of cheese wheels __________________________________C-41

Exercise 10: Clamping of a workpiece ___________________________________C-47

Exercise 11: Actuation of a sliding door__________________________________C-51

Exercise 12: Feeding of workpieces _____________________________________C-55

Exercise 13: Crushing of drinks cans ____________________________________C-59

Exercise 14: Packaging of brochures ____________________________________C-63

Exercise 15: Fitting of locking clips _____________________________________C-67

Exercise 16: Labelling of paint pots _____________________________________C-71

Exercise 17: Cleaning of workpieces ____________________________________C-75

Exercise 18: Pressing in of lids _________________________________________C-81

Contents

Contents

C-2 © Festo Didactic GmbH & Co. KG • 541088



Name: Date:


2

31

0Z1

2

31

1A1

1S1

0Z2



Solutions

Exercise 1: Pressing of cheese wheels Solutions



Name: Date:

Process description Sheet 1 of 1

Initial position

In the normal position, the direction of flow in the valve is closed. The piston rod of

cylinder 1A1 is retracted.

Steps 1-2

If the pushbutton of the 3/2-way valve 1S1 is pressed, compressed air flows into the

piston chamber and the cylinder 1A1 advances.

Steps 2-3

If the pushbutton is released, the valve exhausts and the cylinder returns into its

initial position as a result of the reset spring action.

Safety note


this experiment.




Name: Date:



an equipment list .


below.



1 3/2-way valve with pushbutton, normally closed

1 Manifold



Equipment list




Name: Date:


Assembly error

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

Tubing errors

• Tubing is not properly clipped in. � Tubing ends can whip to and fro at more

than 100 km/h. Risk of injury.

• Tubing is not properly pushed in. � Compressed air escapes.

Mode of operation of a single-acting cylinder.

Compressed air flows into the cylinder piston chamber (pressurised at one end),

where pressure builds up and generates a force across the piston surface. If this

force increases beyond the static friction, the piston moves forward. Only if the

piston has advanced fully, can pressure build up to the full operating pressure.

If this pressure drops, a built-in reset spring presses the piston back into the initial

position. The spring force is not sufficiently great to enable it to move heavy loads

on the piston rod. Single-acting cylinders therefore only perform work in one

direction.

Calculation of piston force

The following applies for single-acting cylinders:

Feff = A • p – (FR + FF)

Feff = 0.9 • A • p – FF

Feff = 0.9 • (π • 0.012) • 600.000 – 13.5

Feff = 169.66 – 13.5 = 156.15 N

Data in data sheet: 150 N




Name: Date:


Component parts of a single-acting cylinders

1 2 3 4 5

678

Schematic representation of a single-acting cylinder

– Allocated designations to the individual components.

No. Designation

1 End cap

2 Supply port

3 Cylinder barrel

4 Exhaust port

5 Piston rod

6 Bearing cap

7 Reset spring

8 Piston





Name: Date:


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

The 3/2-way valve has 3 working ports and 2 switching positions. It is shown in the

normal position.

In this example, the valve is shown in the normally closed position, which means

that compressed air cannot flow through the valve. If the pushbutton is actuated,

the valve opens the air flow and piston of a connected cylinder advances.

Monitoring advancing and retracting movement

The single-acting cylinder advances quickly and retracts slowly.

Reason

Compressed air can quickly increase the working pressure against the reset spring

and push out the piston. The reset spring first has to work against the air cushion in

the piston chamber.



Name: Date:


2

31

0Z1

2

31

1A1

1S1

0Z2



Solutions

Exercise 2: Opening of an animal feed silo Solutions



Name: Date:


Initial position

The 3/2-way valve is open in the direction of flow and the piston chamber is

pressurised. The piston rod of the cylinder is extended.

Steps 1-2

If pushbutton 1S1 is pressed, the piston exhausts via the 3/2-way valve and the

cylinder retracts.

Steps 2-3

If the pushbutton is released again, the spring pushes the 3/2-way valve into the

normal position, the piston is pressurised and the cylinder advances again.

Safety note


this experiment.




Name: Date:



an equipment list .


below.




1 Manifold



Equipment list




Name: Date:


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

The 3/2-way valve has 3 working ports and 2 switching positions. It is shown in the

normal position.

In this example, the valve is in the normally open position, which means that

compressed air can flow to the piston through the valve. If the pushbutton is

pressed, the valve blocks the air flow and the piston of a connected cylinder can

exhaust via the valve.



Name: Date:


2

2

3

3

1

1

1A1

1S1

0Z2

0Z1


Correct solution = a).

Reason

No load on the reset spring of the cylinder in the normal position, which prevents

wear.


Solutions

Solution

Exercise 3: Testing of key blanks Solutions



Name: Date:


Initial position

The direction of flow is closed in the valve. The cylinder piston rod is retracted.

Steps 1-2

If the selector switch 1S1 is actuated, compressed air flows into the piston chamber

and the cylinder advances.

Steps 2-3

If the selector switch is reset, the valve exhausts and the cylinder returns into the

initial position as a result of the effect of the reset spring.

Safety note


this experiment.




Name: Date:



an equipment list .

– Amend the equipment list by entering the required equipment in the table below.



1 3/2-way valve with selector switch, normally closed

1 Manifold



Equipment list




Name: Date:


Assembly errors

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

Tubing errors



• Tubing is not properly clipped in. � Compressed air escapes.



Name: Date:


2

31

1A1

1S1

0Z2

0Z1

24

35

1


Actuator = Selector switch

Reason

A pushbutton cannot be held whilst the containers are being exchanged.


Solutions

Solution

Exercise 4: Sorting of packages Solutions



Name: Date:


Initial position

The righthand supply port of the cylinder is pressurised and the lefthand port

exhausted. The piston is retained in the retracted end position.

Steps 1-2

If the selector switch is actuated the valve switches and the lefthand port of the

cylinder is pressurised and the righthand port exhausted. The cylinder moves into

the forward end position. The cylinder remains in this position even if the selector

switch is not held.

Steps 2-3

If the selector switch is reset the cylinder returns into the initial position.

Safety note


this experiment.




Name: Date:



an equipment list .


below.


1 Cylinder, double-acting

1 5/2-way valve with selector switch

1 Manifold



Equipment list




Name: Date:


Assembly error

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

Tubing errors




• Connections 2 and 4 at the 5/2-way valve mixed up � Cylinder advances in initial

the position.

Mode of operation of a double-acting cylinder.

Compressed air flow through port 2 into the cylinder piston chamber on the primary

side, where pressure builds up and generates a force via the piston surface. If this

force increase beyond the static friction, then the piston advances and the air in the

piston chamber on the secondary side escapes via port 2. Only once the piston is

completely advanced is it possible for pressure to build up to full operating

pressure.

If reversed, the air flow into port 2 of the secondary side and builds up pressure

there until the piston moves back. The air on the primary side escapes through

port 1.

More air is consumed compared to a single-acting cylinder. Since the cylinder

surfaces are of different sizes, the magnitude of the acting forces therefore varies

with identical pressure.




Name: Date:


Calculation of piston force

The following applies for double-acting cylinders:

Forward stroke

Feff = (A • p) – FR

Feff = 0.9 • A • p

Feff = 0.9 • (π • 0.012) • 600.000

Feff = 169.66 N

Data in data sheet: 189 N

Return stroke

Feff = (A' • p) – FR

Feff = 0.9 • [(π • 0012) – (π • 0.004

2)] • 600.000

Feff = 142.5 N

Monitoring of advance and return movement

The double-acting cylinder advances and returns quickly.

Reason

During the advance and return motion, the compressed air can quickly build up the

working pressure against the air cushion and extend and return the piston.




Name: Date:


2 3 4 5

6

1

9 8 7

Schematic representation of a double-acting cylinder

– Allocate designations to the individual components.

No. Designation

1 Supply port of piston chamber

2 Piston

3 Cylinder barrel

4 Supply port of piston rod chamber

5 Piston rod

6 Bearing cap

7, 8 Adjusting screws of end position cushioning

9 End cap





Name: Date:


Requirements for the directional control valve

Compressed air must be available in both switching positions since the double-

acting cylinder cannot retract without compressed air.

The 5/2-way valve have five working ports and two switching positions. It is mainly

used as a control element for the actuation of cylinders.

Why is a double-acting cylinder more cost effective?

The reset spring is omitted.

Actuating function of a selector switch

Explain why a switch is selected for the actuating function on the directional control

valve!

This has to be a switch, since a pushbutton cannot be kept actuated whilst the

containers are being exchanged.




Exercise 5: Stopping of crates of drinks

Name: Date:


2

31

1A1

1V1

0Z2

0Z1

24

35

1

14

2

31

1S1



Solutions

Exercise 5: Stopping crates of drinks Solutions



Name: Date:


Initial position

Both the signalling element and control element are in the position created by the

reset spring.

Steps 1-2

If the selector switch of the 3/2-way valve 1S1 is actuated, this switches through

and the pneumatic control port 14 of the 5/2-way valve 1V1 is pressurised, thereby

switching the 5/2-way valve.

The lefthand port (piston side) of the double-acting cylinder is pressurised, the

righthand port (piston rod side) is exhausted and the cylinder advances.

Steps 2-3

If the selector switch is reset, the compressed air in the 3/2-way valve is blocked,

the 5/2-way valve loses pressure at the control port 14 and switches.

This causes the piston side of the cylinder to exhaust and the piston rod side to be

pressurised. The cylinder moves into the retracted end position.




Name: Date:



an equipment list .


below.



1 5/2-way valve, pneumatic, with reset spring

1 3/2-way valve, selector switch, normally closed

1 Manifold



Equipment list




Name: Date:


Assembly error

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

Tubing errors and effect

• The 5/2-way valve is without air � The cylinder does not advance

• On 3/2-way valve, connections 1 and 2 mixed up � Circuit

not functioning, merely blowing air.

• At 5/2-way valve, connections 2 and 14 mixed up. � circuit not functioning,

merely blowing air.

• At 5/2-way valve, connections 4 and 14 mixed up. � Piston oscillating

Pilot control

Large volumetric flow rates are to be controlled via pilot control using a low signal

flow. A small pilot valve switches the pilot air flow, which in turn acts on the main

valve for high volumetric flow rates.

Remote control

The directional control valve for the control of a cylinder is to be installed close to

the cylinder so that the piston can advance rapidly whilst conserving air. Since no

work is carried out in the lines and these are only used to transmit signals, they

should be as short as possible. Since larger systems by definition involve greater

distances between the point of actuation and the cylinder, the directional control

valve is remotely controlled with pneumatic actuation at one end.



Name: Date:


1A1

1S1 2

1 1

2 2

4

35

1

1V1 1V2

1Z2

1Z1


Supply air flow control

• The compressed air flow to the cylinder is restricted.

• The exhaust air flows unrestricted from the cylinder via the non-return valve flow.

• In the case of load fluctuations on the piston rod (e.g.traversing of a limit switch),

this results in irregularities in the feed speed.

Exhaust air flow control

• The compressed air flows to the cylinder unrestricted via the non-return valve.

• The exhaust air flows from the cylinder restricted.

• The piston is clamped between two air cushions.

• Improved feed/return stroke performance


Solutions

Exercise 6: Öffnen und Schließen einer Rohrleitung Solutions



Name: Date:


Initial position

In the initial position the piston assumes the retracted end position. The piston

chamber is exhausted via the 5/2-way valve using selector switch 1S1.

Steps 1-2

Switching of the 5/2-way valve causes the cylinder piston chamber to be pressurised

via the one-way flow control valve. The double-acting cylinder moves into the

forward end position.

The required advancing time is set via the one-way for flow control valve. Use a stop

watch to do so.

The required setting can be fixed via the lock nut.

Steps 2-3

When the selector switch is reset the cylinder piston chamber is pressurised via the

one-way flow control valve and the 5/2-way valve. The cylinder moves into the


Pressure behaviour

The pressure gauge upstream of the one-way flow control valve indicates the

operating pressure while the cylinder advances and remains in the forward end

position.

Whereas the pressure gauge downstream of the one-way flow control valve

indicates a rising pressure during advancing. Pressure continues to rise even after

the advancing movement until the operating pressure is obtained.




Name: Date:



an equipment list .


below.



2 One-way flow control valve

2 Pressure gauge


1 Manifold



Equipment list




Name: Date:


Assembly error


Tubing errors


than 100 km/h hin-. Risk of injury.


• Connections at one-way flow control valve mixed up � Inverted effect.

Describe what causes juddering operation.

Juddering operation is often also referred to as stick-slip operation and sometimes

occurs during very slowly advancing or retracting pistons.

The reasons for this is that the build-up of pressure acts against the static or sliding

friction.

Pressure builds up at the stationary piston and acts against the static friction. If the

pressure force is greater than the coefficient of friction or static friction, the piston

extends whereby the lesser sliding friction acts. However, this causes the air to

expand again and the pressure to drop since it cannot be built up again quickly

enough. The piston remains stationary and the process is repeated, i.e. the piston

judders.

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

The one-way flow control valve is a combination of two components.

With a one-way flow control valve, air is only restricted in one direction. The non-

return valve closes air flow in one direction and air is only able to flow via the set

cross section. In the opposite direction, air is able to flow freely via the open non-

return valve. These valves are used to regulate the speed of pneumatic cylinders

and, if possible, should be mounted directly on the cylinder.


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

Name: Date:


1A1

1S1 2

1 1

2 2

4

35

1

1V1 1V2

1Z2

1Z1



Solutions

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



Name: Date:


Initial position

In the initial position, the piston assumes the retracted end position. The piston

chamber is exhausted via the 5/2-way valve 1S1.

Steps 1-2

Switching of the 5/2-way valve causes the cylinder piston chamber to be pressurised

via the one-way flow control valve. The cylinder advances into the forward end

position.

Steps 2-3

Resetting of the selector switch causes the cylinder piston chamber to be

pressurised via the one-way flow control valve and the 5/2-way valve. The cylinder

moves into the retracted end position.

The required retracting time is set via the one-way flow control valve. Use a stop

watch to do so.

The required setting can be fixed using the lock nut.

Note

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



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

Name: Date:



an equipment list .


below.




2 Pressure gauge


1 Manifold



Equipment list




Name: Date:


Assembly error


Tubing errors

• Tubing not properly clipped in. � Tubing ends can whip to and fro at more than

100 km/h. Risk of injury.

• Tubing not properly clipped in. � Compressed air escapes.

• Connections at one-way flow control valve mixed up � Inverted effect


Exercise 8: Actuating a shut-off device

Name: Date:


1A1

1V2

1V3

1Z1

2

1/31

1

2

1V1 24

351

14 12

2

2

31

1S1 2

31

1S2



Solutions

Exercise 8: Actuating a shut-off device Solutions



Name: Date:


Initial position

In the initial position the piston assumes the retracted end position. The piston

chamber is exhausted via the 5/2-way double-pilot valve and the piston rod

chamber is pressurised.

Steps 1-2

Actuation of the 3/2-way valve 1S1 causes the 5/2-way double pilot valve to

reverse, the cylinder piston chamber is pressurised via the one-way flow control

valve. The double-acting cylinder advances into the forward end position. The piston

rod chamber is exhausted via the quick exhaust valve.

Steps 2-3

Actuation of the 3/2-way valve 1S2 causes the 5/2-way double pilot valve to be

reversed. The piston rod chamber of the cylinder is pressurised via the quick

exhaust valve. The cylinder piston chamber is exhausted via the one-way flow

control valve and the 5/2-way double pilot valve. The cylinder moves into the


Retracting time

The required retracting time is set via the one-way flow control valve. Use a stop

watch to do so.

The required flow control setting can be fixed using the lock nut.




Name: Date:



an equipment list .


below!




1 Quick exhaust valve

1 Pressure gauge

1 5/2-way double pilot valve


1 Manifold



Equipment list



Exercise 8: Actuating of a shut-off device

Name: Date:


Assembly error


Tubing errors

• Tubing not properly clipped in. � Tubing ends can whip to an fro at more than



• Connections at one-way flow control valve mixed up � Inverted effect.

• Connections at quick exhaust valve mixed up � Compressed air exhaustes.

Describe the mode of operation of a quick exhaust valve.

Quick exhaust valves are used to increase the piston speed of cylinders. Lengthy

retraction times, particularly in the case of single-acting cylinders, are thereby

reduced. The piston rod is able to retract at almost full speed since the exhaust air

flow resistance during the retracting movement is reduced via the quick exhaust

valve. The valve has a blockable pressure port 1, a blockable exhaust port 3 and an

output 2.

Describe the mode of operation of a 5/2-way double pilot valve.

The 5/2-way double pilot valve has 5 working ports and 2 switching positions.

The valve has a storing characteristic in that a brief signal (pulse) is sufficient for

reversing. A pneumatic signal at control port 12 effects flow from port 1 to port 2. A

pneumatic signal at control port 14 effects flow from port 1 to port 4.

If signals are applied at both control ports, then the first incoming signal is

dominant.



Name: Date:


2

31

1V3

1V2

0Z2

0Z1

24

351

14

2

31

1S2

1V1

2

31

12

2

1/31

2

31

1S1

1A1

1V4 1V51 1

2 2



Solutions

Exercise 9: Brushing of cheese wheels Solutions



Name: Date:


1V3

1V2

24

351

14

2

31

1S2

1V1

2

31

12

2

1/31

2

31

1S1

1A1

1V4 1V51 1

2 2

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




Name: Date:


Self-latching loop

The 1S1, 1S2, 1V1 and 1V2 valve group is a self-latching loop. Actuation of the

pushbutton 1S1 triggers a constant signal at the output of valve 1V2.

The self-latching loop is interrupted if the normally open 3/2-way valve 1S2 is

actuated. A signal is no longer applied at the output of valve 1V2. If both

pushbuttons 1S1 and 1S2 are actuated simultaneously, a signal is similarly not

applied at the output. This circuit is known as an RS-flip-flop.

Initial position

Pressure is available. The piston chamber of the double-acting cylinder is exhausted,

the piston rod chamber is pressurised and the cylinder is in the retracted end

position.

Steps 1-2

If the pushbutton of valve 1S1 is actuated, the cylinder 1A1 advances. The cylinder

remains in the forward end position as a result of the self-latching loop.

Steps 2-3

Once the pushbutton of the normally open valve 1S2 is actuated the cylinder

retracts again.

The self-latching loop is switched off. The 5/2-way valve switches to normal position

and the piston rod chamber is pressurised. The cylinder moves into the retracted

end position.




Name: Date:



an equipment list .


below!




1 5/2-way valve, pneumatic, with spring return



1 3/2-way valve, pneumatic, normally closed

1 Shuttle valve (OR)

1 Manifold


1 Compessed air supply

Equipment list




Name: Date:


Assembly error


Tubing errors

• Tubing not properly clipped in. � Tubing ends can whip to and from at more than


• Tubing not properly clipped in. � Compressed air excapes.

• Connections at double-acting cylinder mixed up. � Direction of movement of

cylinder reversed.

Describe the mode of operation of the self-latching loop.

Actuation of the pushbutton at valve 1S1 causes the ball in the shuttle valve (OR)

1V1 to release compressed air flow. Since the valve 1S2 is switched through in the

normal condition, the compressed air is able to actuate the 3/2-way valve 1V2. This

causes the 5/2-way valve 1V3 to reverse and the cylinder piston to advance. The

condition simultaneously becomes true via the return line to the shuttle valve (OR)

1V1. The pressure in the lines remains stored and maintains the valve 1V2 actuated.

If the pushbutton at valve 1S2 is actuated, the pressure in the lines is exhausted, the

valve 1V2 is de-energised, as well as the 5/2-way valve. The cylinder piston retracts

again.

Describe the mode of operation of a shuttle valve.

The shuttle valve is used for the logic OR function.

Pneumatic signals at input 1, input 1(3) or at both inputs trigger a signal at output 2.

There is no output signal if there is no input signal.

Output signals

• If signals are applied at both inputs, the signal with the higher pressure reaches

the output.





Name: Date:


1A1

1V2 24

351

1V3 1V4

1Z1 1Z2

14

1V1 2

1/31

2

31

1S1

1B1

1 1

2 2

2

31

1B1

12

2

31

1S2



Solutions

Exercise 10: Clamping of a workpiece Solutions



Name: Date:


Initial position

Pressure is available. The piston chamber of the double-acting cylinder is exhausted

and the piston rod chamber is pressurised. The 3/2-way roller lever valve 1B1 is

actuated. The cylinder is in the retracted end position.

Steps 1-2

If the pushbutton of the 3/2-way valve 1S1 is actuated, compressed air is applied at

both inputs of the dual pressure valve 1V1 and compressed air is now available at

the output of the dual pressure valve. The 5/2-way double pilot valve 1V2 is

reversed via the signal applied at the control port 14.This causes the cylinder to

reverse and the piston to advance. The 3/2-way roller lever valve switches to normal

position and the output signal at the dual pressure valve is switched off. The

cylinder remains in the forward end position due to the self-latching circuit.

Steps 2-3

Actuation of the pushbutton on the 3/2-way valve 1S2 causes the 5/2-way double

pilot valve 1V2 to reverse again (signal at pilot port 12).The piston rod chamber of

the cylinder is pressurised and the cylinder moves into the retracted end position.

The 3/2-way roller lever valve 1B1 is actuated again.




Name: Date:



an equipment list.





2 Pressure gauge

1 5/2-way valve, pneumatic

1 Dual pressure valve (AND)

1 3/2-way roller lever valve, normally closed


1 Manifold



Equipment list




Name: Date:


Assembly error


Tubing errors

• Tubing not properly clipped in. � Tubing ends can whip to and fro at more than



• Connections at double-acting cylinder mixed up � Direction of movement of

cylinder reversed.

Describe the mode of operation of a 3/2-way roller lever valve.

The 3/2-way roller lever valve has 3 control ports and 2 switching positions. The

roller lever valve is for instance actuated by the switching cams of a cylinder. A

reduced actuating force is obtained as a result of the pilot control.

What is the effect of adjusting the 3/2-way roller lever valve?

Depending on the position of the roller lever valve the circuit no longer functions

since the AND condition is no longer fulfilled.

Describe the mode of operation of a dual pressure valve.

The dual pressure valve is used for the logic AND operation.

Pneumatic signals at inputs 1 and 1(3) cause a signal at output 2. There is no output

signal if there are no input signals or only one input signal.

Output signals

• With time-related differences in input signals, the last incoming signal reaches

the output.

• With pressure-related differences in input signals, the signal with lower pressure

reaches the output.



Name: Date:


1A1

1V4 24

351

1V5

14 12

1V1

1V2 1V3

2

2 2

1/3

1/3 1/3

1

1 1

3 31 1

2 2

3 31 1

1S11B1 1S2 1B2

1B1 1B2

1V6

2 2

1 1

2 2



Solutions

Exercise 11: Actuation of a sliding door Solutions



Name: Date:


Initial position

The cylinder is in the retracted end position. The pneumatic proximity sensor 1B1 is

attenuated. A pneumatic signal is applied at one input of dual pressure valve 1V2.

Steps 1-2

The shuttle valve 1V1 supplies an output signal if one of the two pushbuttons is

actuated. A signal is now applied at pilot port 14 of the 5/2-way double pilot valve

and the valve switches. The cylinder advances.

When the cylinder reaches the forward end position, the pneumatic proximity sensor

1B2 is attenuated.

Steps 2-3

The shuttle valve 1V1 supplies an output signal if one of the two pushbuttons is

actuated. A signal is now applied at pilot port 12 of the 5/2-way double pilot valve.

The valve switches and the cylinder advances.

The pneumatic proximity sensors 1B1 is attenuated when the cylinder reaches the





Name: Date:



an equipment list .


below!




1 5/2-way double pilot valve, pneumatic

2 Proximity sensor, pneumatic




1 Manifold



Equipment list




Name: Date:


Assembly error


Tubing errors




• Connections at double-acting cylinder mixed up � Circuit malfunctions.

• Connections at 5/2-way valve mixed up � Circuit malfunctions.

Function of the pneumatic proximity sensor

The proximity sensor consists of a 3/2-way stem actuated valve, normally open, and

a rocker with 2 permanent magnets. The stem of the valve is actuated via the rocker

by means of a compression spring. The magnetic field of the magnet on the cylinder

piston causes the rocker to tilt. The valve is no longer actuated and a pneumatic

signal is applied at the output of the valve.

What happens if the compressed air supply fails during the advance or return

movement?

The door stops its actual position.

How can the circuit be re-started and what needs to be done for this?

The door needs to be pushed into one of the end positions for a re-start since the

start conditions (door in one of the two end positions) is otherwise not fulfilled.



Name: Date:


2

31

1S1

1A1

1V3 24

351

1V4

14 12

1V1

1V2 2

2

1/3

1/3

1

1

3 31 1

2

31

1B1 1S2 1B2

1B1 1B2

1V5

2 2

1 1

2 2



Solutions

Exercise 12: Feeding of workpieces Solutions


Exercise 12: Supplying of workpieces

Name: Date:


Initial position

Compressed air is available. The cylinder is in the retracted end position. The

pneumatic proximity sensor 1B1 is attenuated and switched in free-flow direction.

The piston rod chamber is pressurised.

Steps 1-2

The 3/2-way valve 1S2 is not actuated unless the withdrawal area is free. The dual

pressure valve 1V1 does not supply an output signal, the 5/2-way double pilot valve

cannot be reversed.

The 3/2-way valve 1S2 is actuated if the withdrawal area is free. The dual pressure

valve 1V1 supplies an output signal. If the pushbutton of the 3/2-way valve 1S1 is

actuated, the dual pressure valve 1V2 supplies an output signal and a signal is

applied at pilot port 14 of the 5/2-way double pilot valve. The 5/2-way double pilot

valve reverses and the cylinder advances.

Steps 2-3

The pneumatic proximity sensor 1B2 is attenuated and switches in the free-flow

direction. A signal is applied at pilot port 12 of the 5/2-way double pilot valve. The

5/2-way double pilot valve 1V3 reverses and the cylinder moves into the retracted

end position. The pneumatic limit switch 1B1 is attenuated and switches in the free-

flow direction.

Steps 3-1

Same as step 1




Name: Date:



an equipment list .


below.







1 3/2-way valve with selector switch, normally closed


1 Manifold



Equipment list




Name: Date:


Assembly error


Tubing errors




• Connections at the double-acting cylinder mixed up � Circuit malfunctions.

• Connections at the 5/2-wau double pilot valve mixed up � Circuit malfunctions.

• Connections at the one-way flow control valve mixed up � No exhaust air- but

instead throttled supply air.

How would you need to modify the circuit if the ejecting function is to start only if a

part is present in the magazine and the withdrawal position is free?

An additional sensor needs to be linked with the workpiece sensing. This requires

the appropriate sensor (roller lever valve) and a shuttle valve (AND). Instead of the

3/2-way valve 1S2, the AND operation of the sensors is inserted.



Name: Date:


1V4

1V5 24

351

1V6

14 12

2

1/31

3 31 1

1V3 2

1/31

2

2

2

3

3

31

1

1

1S1

1V2

1V1

1B1 1S2 1B2

1V7

2 2

2

3112

1 1

2 2

1A1

1B1 1B2



Solutions

Exercise 13: Crushing of drinks cans Solutions



Name: Date:


Initial position

The double-acting cylinder is in the retracted end position. The pneumatic proximity

sensor 1B1 is actuated and switched to free-flow direction. Compressed air is

available. The required pressure is preset at the pressure regulating valve of the

service unit. The required pressure is set at the pressure sequence valve.

Steps 1-2

The pushbutton of valve 1S1 is actuated whereby the condition at the dual pressure

valve (AND) 1V3 becomes true. The 5/2-way double pilot valve 1V5 is switched into

the operating position and the double-acting cylinder advances.

Steps 2-3

The pneumatic proximity sensor 1B2 is actuated and switches into the operating

position. The 5/2-way double pilot valve 1V5 is reversed via the shuttle valve (OR)

1V4.

Alternatively, this process can be initiated via the pushbutton of valve 1S2. The 5/2-

way double pilot valve is reversed via the shuttle valve (OR) 1V4.

The double-acting cylinder moves into the initial position and the process is

completed when the pneumatic proximity sensor 1B1 is actuated.




Name: Date:



an equipment list.


below.









1 Pressure sequence valve

1 Pressure regulating valve

1 Manifold



Equipment list

Note

The equipment set only contains 1 pressure regulating valve. Use the pressure

regulating valve, built into the Start-up valve with filter control valve, as valve 1V1 in

the circuit assembly.




Name: Date:


Assembly error


Tubing errors






• Pressure at the pressure regulating valve is lower than that at the pressure

sequence valve � Circuit malfunctions.

Describe the function of a pressure sequence valve.

The actuated 3/2-way valve switches if pressure at pilot port exceeds a specific,

adjustable value; compressed air is available at working port 2.

The 3/2-way valve reverses if the pressure at the control port falls below the set

value.



Name: Date:


1V4 24

351

14 12

2

31

1V6

1V7

1A1

1V3 2

1/31

31

2 2

3 31 1

1B1 1S1 1S2

1B1

2

2

31

1V2

1V1

2

3112

1

1V5 1

2

2



Solutions

Exercise 14: Packaging of brochures Solutions



Name: Date:


Initial position

The double-acting cylinder is in the retracted end position. The pneumatic limit

switch 1B1 is attenuated and switched in free-flow direction. Compressed air is

available. The desired pressure is preset at the pressure regulating valve of the

service unit, the pressure sequence valve and at the pressure regulating valve in the

cylinder supply air.

Steps 1-2

Pushbutton valve 1S1 is actuated and switches in the free-flow direction. The

pneumatic proximity sensor 1B1 is switched to operating position and consequently

the condition at the dual pressure valve (AND) 1V3 becomes true and the 5/2-way

double pilot valve 1V4 is switched to operating position. The double-acting cylinder

advances pressure regulated.

Steps 2-3

Pushbutton 1S2 is actuated and switches in free-flow direction. This causes the

5/2-way double pilot valve to reverse. The double-acting cylinder returns to the

initial position. The process is completed if the pneumatic proximity sensor 1B1 is

attenuated.

Note

The one-way flow control valve 1V7 is used to by-pass the pressure regulating valve.

The throttle is fully closed. The compressed air is able escape via the non-return

valve when the cylinder retracts.




Name: Date:



an equipment list.

– Compile the equipment list by entering by entering the required equipment in the

table below.




1 5/2-way double-pilot valve, pneumatic






1 Manifold



Equipment list




Name: Date:


Assembly error


Tubing errors






• Pressure at the pressure regulating valve is lower than that at the pressure

sequence valve � Circuit malfunctions.

Describe the function of a pressure regulating valve.

Input pressure (primary pressure) at the pressure regulating valve must always be

higher than output pressure (secondary pressure). Pressure regulation as such is

effected via a diaphragm. Output pressure acts on the one side of the diaphragm

and the force of a spring on the other. The spring force is adjustable via an adjusting

screw.

If pressure increases on the secondary side, e.g. with a load change on the cylinder,

the diaphragm is pressed against the spring and the outlet cross-sectional area is

reduced or closed. The valve seat of the diaphragm opens and compressed air is

able to escape via the relief ports in the housing.

If pressure drops on the secondary side, the spring force opens the valve. Regulating

the air pressure to the preset operating pressure therefore means a constant

opening and closing of the valve seat, triggered by the air volume flowing through.

The operating pressure is indicated on the pressure gauge.



Name: Date:


1A1

1V6 2

1 1

2 2

4

351

1V7

14 12

1V3

1V5 2

2

1/3

1/3

1

1

3 31 1

2

31

1B1 1S1 1B2

1B1 1B2

1V8

2 2

10

2

31

1V4

1V2 2

3112

2

31

1V1



Solutions

Exercise 15: Fitting of locking clips Solutions



Name: Date:


Initial position


sensor 1B1 is attenuated. Compressed air is available. The required pressure is set

at the pressure regulating valve and pressure sequence valve.

Steps 1-2

Pushbutton 1S1 is actuated and the pneumatic proximity sensor 1B1 is attenuated,

consequently the condition at the first dual pressure valve (AND) 1V3 becomes true.

When the pressure sequence valve has switched with sufficient pressure, the

3/2-way valve is switched into the operating position. The condition at the second

two-way valve (AND) 1V5 consequently becomes true and the 5/2-way double pilot

valve switches reverses into the operating position. The double-acting cylinder

advances.

Steps 2-3

The pneumatic proximity sensor 1B2 is attenuated and switches into the operating

position. The 5/2-way double pilot valve is reversed. The double-acting cylinder

returns into the initial position. The process is completed if the pneumatic proximity

sensor 1B1 is attenuated.




Name: Date:



an equipment list .


below.






1 3/2-way valve, pneumatic, normally open





1 Manifold



Equipment list




Name: Date:


Assembly error


Tubing errors






• Pressure at pressure regulating valve is lower than at the pressure sequence

valve � Circuit malfunctions.

Check whether the circuit from sheet 1 „Analysing the pneumatic circuit diagram“

can also be operated using this configuration. Answer: Yes.

However there is a risk of the pressure being incorrectly set at the pressure

regulating valve in the cylinder supply air and of the clip being damaged.

Where does the different lie between the circuit on sheet 1 „Analysing the

pneumatic circuit diagram“?

There is an economical advantage: The circuit can be operated without the second

limit switch and without a dual pressure valve.



Name: Date:


1V5

1V6

1Z1

2

1/31

1V4

1V3

24

351

14 12

1V2 2

1/31

3 31 1

2

31

1B1 1B21S12 2

2

31

1V1

2

31

1A1

1B1 1B2

2

1



Solutions

Exercise 16: Labelling of paint pots Solutions



Name: Date:


Initial position


sensor 1B1 is attenuated. Compressed air is available. The desired pressure is set at

the pressure regulating valve.

Steps 1-2

Pushbutton 1S1 is actuated and the pneumatic proximity sensor 1B1 is attenuated;

consequently the condition at the first dual pressure valve (AND) 1V2 becomes true

and the 5/2-way double pilot valve 1V4 switches into the operating position. The

double-acting cylinder advances using minimal pressure.

Steps 2-3

The pneumatic proximity sensor 1B2 is attenuated and switches into the operating

position. This causes compressed air to be supplied to the time delay valve 1V3 and

to switch after a preset time interval. The 5/2-way pilot valve is switched back and

the double-acting cylinder returns to the initial position using minimal pressure. The

piston chamber is exhausted via the quick exhaust valve. The process is completed

if the pneumatic proximity sensor 1B1 is attenuated.




Name: Date:



an equipment list .


below.




1 Quick exhaust valve




1 Time delay valve


1 Pressure regulating valve with pressure gauge

1 Pressure gauge

1 Manifold



Equipment list




Name: Date:


Assembly error


Tubing errors

• Tubing is not properly clipped in. � Tubing ends can whip to an fro at more than





• Ports at time delay valve mixed up � Time not adjustable, cylinder does not

return.

Describe the mode of operation of a time delay valve.

The functions of three components are combined in a time delay valve.

a) 3/2-way valve with spring return

b) One-way flow control valve

c) Air reservoir

If pressure is applied at the input, compressed air flows to the 3/2-way valve and

into the air reservoir via the one-way flow control valve. There, a pressure gradually

builds up which acts against the spring force of the reset spring at the 3/2-way

valve. The 3/2-way valve switches if pressure exceeds the spring force.

If pressure is no longer applied at the input, the air reservoir is able to exhaust via

the non-return valve.



Name: Date:


1V3 2

1/31

2

31

1S1

1V2

1V1

2

31

10 12

2

31

31

1B1 2

31

1B3 2

31

1B2 2

1V4 24

351

14 12

1V6

1B11B3

1

1V5 1

2

2

1A1

1B2



Solutions

Exercise 17: Cleaning of workpieces Solutions



Name: Date:


Initial position

The cylinder assumes the retracted end position in the initial position and actuates

the 3/2-way roller lever valve 1B1. The control element 1V4 (5/2-way double pilot

valve) assumes the righthand switching position. The signal latch 1V2 (3/2-way

double pilot valve) is also in the righthand switching position. The desired pressure

is set at the pressure regulating valve.

Steps 1-2

Actuation of START button 1S1 causes the signal latch 1V2 to switch. Compressed

air is applied at the input of the time delay valve 1V1. The 5/2-way double pilot

valve 1V4 is reversed via the actuated 3/2-way roller lever valve 1B1 and the shuttle

valve (OR) 1V3; the cylinder advances. Overtravelling of the middle pneumatic

proximity sensor 1B3 has no effect since the same pilot input of the control element

is actuated.

Steps 2-3

The pneumatic proximity sensor 1B2 is actuated in the forward end position. The

control element (5/2-way double solenoid valve) reverses. The cylinder partially

retracts and actuates the middle pneumatic proximity sensor 1B3.

Steps 3-4

Actuation of the middle pneumatic proximity sensor causes the cylinder to reverse

again. The switching function takes only a few milliseconds so that the switching

cam does not overtravel the pneumatic proximity sensor 1B3.

Steps 4-5

See steps 2-3.




Name: Date:


Oscillating movement

The cylinder oscillates between the pneumatic proximity sensors 1B3 and 1B2 until

the time set on the time delay valve has expired.

Steps n-2 to n

Once the time delay valve switches through, the signal latch 1V2 (3/2-way double

pilot valve) is reversed. The pneumatic proximity sensor 1B3 and the 3/2-way roller

lever valve 1B1 are no longer supplied with compressed air. The cylinder moves into

the initial position (retracted end position). The process is completed when the 3/2-

way roller lever valve 1B1 is actuated.




Name: Date:



an equipment list .


below .









1 Time delay valve


1 Manifold



Equipment list

Note

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

pilot valve, pneumatic.




Name: Date:


Assembly error


Tubing errors




• Connections at double-acting cylinder mixed up � Cylinder in wrong end

position.

• Connections at 5/2-way double pilot valve mixed up � Circuit malfunctions.

• Connections at time delay valve mixed up � Time not adjustable, process is not

completed.

Convert a 5/2-way double pilot valve into a 3/2-way double pilot valve.

What do you need to do?

Output 4 is to be sealed with a plug.





Name: Date:


1V3

1V1 2

1/31

2

31

1S1

1A1

1V2 2

31

12 10

31

2B1 2

2

1

1

1B2 2

2A1

2V2

2B1 2B2

1

2

2V1 24

351

14 12

3 31

2B2 2

1B2



Solutions

Exercise 18: Pressing in of lids Solutions



Name: Date:


Initial position

Pressure is available. Both cylinders assume the retracted end position in the initial

position. The piston of the double-acting cylinder attenuates the pneumatic

proximity sensor (2B1); this switches in free-flow direction.

The control elements 1V2 and 2V1 (5/2-way double pilot valve and 3/2-way double

pilot valve) assume the righthand switching position.

Steps 1-2

Actuation of pushbutton 1S1 causes the condition at the dual pressure valve (AND)

1V1 to become true. The 3/2-way double pilot valve 1V2 reverses. The single-acting

cylinder advances with supply air restricted.

Steps 2-3

Roller lever valve 1B2 is actuated when the single-acting cylinder reaches is forward

end position and switches the 5/2-way double pilot valve 2V1. The double-acting

cylinder advances into the forward end position, where it attenuates the pneumatic

proximity sensor 2B2. This switches to free-flow direction.

Steps 3-4

The 5/2-way double pilot valve 2V1 and 3/2-way double pilot valve 1V2 reverse.

Both cylinders retract. The process is completed when the piston of the double-

acting cylinder attenuates the pneumatic proximity sensor (2B1) and this switches in

free-flow direction.

Note

The single-acting cylinder 1A1 retracts slightly sooner than the double-acting

cylinder 2A1. This is due to the control signal overlap at the pilot ports 14 and 12 of

the 5/2-way double solenoid valve 2V1. Only once the single-acting cylinder 1A1 has

moved from the forward end position and the 3/2-way roller lever valve 1B2 is no

longer actuated, can the 5/2-way double pilot valve 2V1 reverse.




Name: Date:



an equipment list .


below.











1 Manifold



Equipment list

Note

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

pneumatic.




Name: Date:


Assembly error


Tubing errors




• Connections at double-acting cylinder mixed up � Cylinder in wrong end

position.


• Connections at one-way flow control valve mixed up � Cylinders not advancing

with supply air restricted.

What happens if the pneumatic proximity sensor 1B2 at the cylinder is moved?

The pneumatic proximity sensor 1B2 is not attenuated and the 5/2-way double pilot

valve and, consequently, the 3/2-way double pilot valve are no longer reset. The

cylinder no longer moves into the retracted end position; the proximity sensor 1B1 is

therefore not attenuated and the circuit cannot longer be re-started.

© Festo Didactic GmbH & Co. KG • 541088 D-1

Organiser __________________________________________________________ D-2

Assembly technology ________________________________________________ D-3

Plastic tubing_______________________________________________________ D-4

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

3/2-way valve with pushbutton actuator, normally open_________________ 152861

5/2-way valve with selector switch __________________________________ 152862

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

Pressure gauge __________________________________________________ 152865

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

Pressure sequence valve __________________________________________ 152884

Single-acting cylinder _____________________________________________ 152887

Double-acting cylinder ____________________________________________ 152888

Manifold________________________________________________________ 152896

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

Pressure regulator valve with gauge _________________________________ 539756

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

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

Dual pressure valve (AND) _________________________________________ 539770

Shuttle valve (OR) ________________________________________________ 539771

Quick exhaust valve ______________________________________________ 539772

One-way flow control valve_________________________________________ 539773

Proximity switch, pneumatic, with cylinder attachment __________________ 539775

Start-up valve with filter control valve ________________________________ 540691

Time delay valve, normally closed ___________________________________ 540694

Part D – Appendix

Data sheets

D-2 © Festo Didactic GmbH & Co. KG • 541088

Equipment set in the organiser

All components of the equipment set for the technology package TP101 are stored in

an organiser in the Systainer. The organiser also serves as a drawer insert for use in

conjunction with our range of laboratory furniture.

Organiser

© Festo Didactic GmbH & Co. KG • 541088 D-3

The components of the equipment set are intended for assembly on the Festo

Didactic profile plate, which consists of 14 parallel T-slots in gaps of 50 mm.

Three variants are available for the assembly of equipment on the profile plate:

Variant A

A latching system, without auxiliary means, clamping mechanism using a lever and

spring,

Adjustable in the direction of the slot, for lightweight non loadable components .

Variant B

A rotary system, without auxiliary means, knurled nut with locking disk and T-head

bolts,

vertical and horizontal alignment, for medium weight loadable components.

Variant C

A screw system, with auxiliary means, socket head screw with T-head bolt, vertical

and horizontal alignment, for heavy loadable components and equipment which is

rarely released from the profile plate.

The proven ER units on plug-in board can be attached to the profile plate with

adapters.

In the case of variant A, a slide is engaged in the T-slot of the profile plate. The slide

is pre-tensioned by means of a spring and, by pressing the blue lever, is pulled back

whereby the component can be removed from or attached to the profile plate.

Components are aligned along the slot and can be moved in the direction of the slot.

With variant B, components are attached to the profile plate by means of a T-head

bolt and blue knurled nut. A locking disc serves to fix the device in position, which

can be secured in any 90° direction. Devices can thus be mounted on the profile

plated either lengthwise or diagonally to the slot.

Once the desired locking disc position is set, the device is mounted on the profile

plate. Turning of the knurled nut in a clockwise direction causes the T-head bolt to

be turned in the slot by 90° owing to thread friction. The component is pressed

against the profile plate by further turning the knurled nut.

Assembly technology

D-4 © Festo Didactic GmbH & Co. KG • 541088

Variant C is used for heavy or similar devices, screwed on to the profile plate only

once or very seldom. Components are attached by means of socket head screws

with internal hex and T-head bolts.

The time-tested ER units on a plug-in board with locating pins in a 50 mm grid can be

mounted on the profile plate with adapters. A black plastic adapter is required for

each locating pin. The adapters are plugged into the T-slot, positioned at intervals of

50 mm and secured by means of a 90° turn. The locating pins of the ER unit are

plugged into the adapter holes.

The polyurethane tubing is particularly flexible and kink resistant.

Technical data

Pneumatics

Colour silver metallic

Outer diameterr 4 mm

Inner diameter 2.6 mm

Minimum bending radius within

temperature range of -35 to +60°C

17 mm

Maximum operating pressure

within temperature range of -35 to +30°C

within temperature range of +30 to +40°C

within temperature range of +40 to +60°C

10 bar (1000 kPa)

9 bar (900 kPa)

7 bar (700 kPa)

Subject to change

Plastic tubing

152860

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

© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/1

The 3/2-way valve with pushbutton actuator, normally closed is assembled in a

polymer housing. The unit is mounted on the profile plate via a quick release detent

system with blue lever (mounting alternative "A").

The valve is actuated by pressing the pushbutton. Releasing of the pushbutton

returns the valve to the normal position via a return spring.

Pneumatic

Medium Compressed air, filtered (lubricated or unlubricated)

(or vacuum; port 1)

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

Actuation Pushbutton

Pressure range -95 – 800 kPa (-0.95 – 8 bar)

Standard nominal flow rate 1...2 60 l/min

Actuating force at 600 kPa (6 bar) 6 N

Connection QSM-4 fittings for plastic tubing PUN 4 x 0.75

2

31

Design

Function

Technical data

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

152861

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


The 3/2-way valve with plug-in connections is assembled in a plastic housing. The

unit is mounted on the profile plate via a quick release detent system with blue lever

(mounting alternative "A").

The valve is actuated by pressing the push button. Releasing the push button

returns the valve to the normal position via a return spring.

Pneumatic


(or vacuum; port 1)


Actuation Push button





2

31

Design

Function

Technical data

© Festo Didactic GmbH & Co. KG, 2005

152862

5/2-way valve with selector switch


The two 3/2-way valves with plug-in connections are assembled in a plastic housing.

The unit is mounted on the profile plate via a quick release detent system with blue

lever (mounting alternative "A").

This valve combination operates in the same way as the 5/2-Way valve. It is

actuated by turning the selector switch. The switching status is maintained after the

selector switch has been released. If the selector switch is reversed, the valve

resumes its normal position via the return spring.

Pneumatic



Actuation Selector switch





2

31

Design

Function

Technical data


152863

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


The 3/2-way valve with plug-in connections is assembled in a polymer housing. The

unit is mounted on the profile plate via a quick release detent system with blue lever

(mounting alternative „A“).

The valve is actuated by turning the selector switch. The switching status is

maintained after the selector switch has been released. Rotating the selector switch

to its basic setting, returns the valve to the initial position via a return spring.

Pneumatic



Actuation Selector switch





2

31

Design

Function

Technical data


152865

Pressure gauge


The pressure gauge is screwed to the function plate which is fitted with two directly

linked push-in fittings. The unit is mounted on the profile plate via a quick release

detent system with the blue lever, (mounting alternative “A”).

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

During continuous operation the pressure gauge must only be loaded to 75 % of

maximum scale reading, and in the case of an alternating load, 66 % of maximum

scale reading.

Pneumatic


Design Bourdon tube pressure gauge

Indicating range 0 – 1000 kPa (0 – 10 bar)

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

Quality grade 1.6

Design

Function

Note

Technical data

© Festo Didactic GmbH & Co., 07/2005

152866

3/2-way roller lever valve, normally closed


The 3/2-way roller lever valve with push-in elbow fittings is screwed onto a polymer

base The unit is mounted on the profile plate via a rotary detent system with blue

triple grip nut (mounting alternative "B").

The valve is actuated by pressing the roller lever e.g. by means of cylinder trip cam.

The valve is returned to the normal position via return spring after release of the

roller lever.

This valve can be changed from “normally closed” (RS valve type) to “normally

open” (ROS valve type).

Normally closed (RS valve type)

Actuator attachment at the left

(number 1 on the actuator attachment above number 1 on housing)

Normally open (ROS valve type)

Actuator attachment at the right

(number 2 on the actuator attachment above number 2 on housing)

Pneumatic



Pressure range 280 – 800 kPa (2.8 – 8 bar)


Actuating force at 600 kPa (6 bar) 1.8 N

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

31

2

Design

Function

Modification

1

�

2

�

Technical data


152884

Pressure sequence valve


The pressure sequence valve is screwed on to a function plates, which includes the

required push-in fittings. The unit is mounted on the profile plate via a quick release

detent system with blue lever (mounting alternative "A").

The pressure sequence valve (sequence valve) is reversed once the pilot pressure

has been reached at port 12, and switched to the initial position via return spring

after the signal has been removed. The pressure of the control signal is infinitely

adjustable by means of a pressure adjustment screw.

Pneumatic


Design Poppet valve with return spring

Operating pressure range 180 – 800 kPa (1.8 – 8 bar)

Pilot pressure range 100 – 800 kPa (1 – 8 bar)


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

2

3112

Design

Function

Technical data


152887

Single-acting cylinder


The single-acting cylinder with trip cam and push-in fitting is mounted on a plastic

retainer. The unit is mounted on the profile plate via quick release detent system

with two blue trip grip nuts (mounting alternative "B").

The piston rod of the single-acting cylinder moves into the forward end position

through the supply of compressed air. When the compressed air is switched off, the

piston is returned to the retracted end position via a return spring.

The magnetic field of a permanent magnet, which is attached to the cylinder piston,

actuates the proximity switches.

Pneumatic


Design Piston cylinder

Operating pressure max. 1000 kPa (10 bar)

Piston diameter 20 mm

Max. stroke length 50 mm

Thrust at 600 kPa (6 bar) 139 N

Spring return force min. 13.6 N

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

Design

Function

Technical data


152888

Double-acting cylinder


The double-acting cylinder with trip cam and push-in fittings is mounted on a plastic

retainer. The unit is mounted on the profile plate via a quick release detent system

with two triple grip nuts (mounting alternative "B").

The piston rod of the double-acting cylinder is reversed by means of alternating

supply of compressed air. End position cushioning at both ends prevents a sudden

impact of the piston on the cylinder housing. The end position cushioning can be

adjusted by means of two regulating screws.

The magnetic field of a permanent magnet attached to the cylinder piston actuates

the proximity switches.

Pneumatic


Design Piston cylinder

Operating pressure max. 1000 kPa (10 bar)

Piston diameter 20 mm

Max. stroke length 100 mm

Thrust at 600 kPa (6 bar) 189 N

Return force at 600 kPa (6 bar) 158 N

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

Design

Function

Technical data


152896

Manifold


The manifold with eight self-sealing push-in fittings is screwed on to a universal

plate. The unit is mounted on the profile plate via a quick release detent system with

blue lever (mounting alternative "A").

The manifold with a common P-supply enables a control system to be supplied with

compressed air eight individual connections.

Pneumatic

Connection 1 QS-1/8-6 for plastic tubing PUN 6 x 1

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

Design

Function

Technical data


538694

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


The 5/2-way single pilot valve with push-in fittings is screwed onto the function

plate, which is equipped with P-connection and silencers. The unit is mounted on the

profile plate via a quick release detent system with blue lever (mounting alternative

"A").

The single pilot valve is actuated by applying pressure at port 14 (Z). When the

signal is removed the valve is returned to the normal position via return spring.

Pneumatic

Medium Compressed air, filtered (lubricated or unlubricated) or vacuum

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

Control pressure range 300 to 1000 kPa (3 to 10 bar)

Operating pressure range -90 to 1000 kPa (-0.9 to 10 bar)


Response time at 600 kPa (6 bar) On: 8 ms

OFF: 18 ms

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

24

35 1

14

Symbol used in circuit diagrams

24

35 1

14

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

Design

Function

Technical data


539756

Pressure regulator valve with gauge


The pressure regulator with pressure gauge and push-in elbow fittings is screwed on

to a function plate. The unit is slotted into the profile plate via a quick release detent

system with blue levers (mounting alternative “A).

The pressure regulator adjusts the supply of compressed air to the operating

pressure and compensates any pressure fluctuations. The direction of flow is

indicated by arrows on the housing.

The pressure gauge indicates the pressure set.

The pressure regulator is fitted with an adjusting knob, which can be turned to set

the required pressure. By sliding the adjusting knob towards the housing, the

setting can be locked.

Pneumatic


Design Diaphragm control valve

Standard nominal flow rate* 300 l/min

Upstream pressure max. 100 to 1000 kPa (1 to 10 bar)

Operating pressure max. 50 to 700 kPa (0.5 to 7 bar)

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

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

Differential pressure 100 kPa (1 bar)

2

31

Design

Function

Note

Technical Data


539768

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


The 5/2-way pneumatic valve with push-in connectors and a single blanking plug is

screwed on to an assembly base, which is equipped with P-connection and silencers.


lever (mounting alternative „A“).

The pneumatic valve switches at port 14 (Z) (10 (Z)) via a pneumatic signal and is

returned to the initial position via a spring when the signal has been removed.

The valve ports are identified by numbers:

1 = Supply port

2, 4 = Working or outlet ports

3, 5 = Exhausts (via silencers in function plate)

14, 10 = Pilot port

By blocking a working line (2 or 4), the 5/2-way valve can be converted into a

3/2-way valve:

Blanking plug in outlet 4 = normally open

Blanking plug in outlet 2 = normally closed

2

31

12

or 2

31

10

Symbol used in circuit diagrams.

24

35 1

14

The internal structure of this valve

Design

Function

Note

539768

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

2/2 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005

Pneumatic

Medium Compressed air, filtered

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

Pressure range 200 to 1000 kPa (2 to 10 bar)


Standard nominal

flow rate 1…2, 1...4

500 l/min

Switching time at 600 kPa (6 bar) On: 8 ms

Off: 18 ms


Technical Data

539769

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


The 5/2-way double pilot valve with push-in fittings is screwed onto the function

plate, which is equipped with P-connection and silencers. The unit is mounted on the

profile plate via a quick release detent system with blue lever (mounting alternative

"A").

The double pilot valve is actuated by applying pneumatic signals alternately to ports

14 and 12. It remains in its last switched position until a counter signal is received.

Pneumatic

Medium Compressed air, filtered (lubricated or unlubricated) or vacuum

Design Spool valve, directly actuated on both sides

Control pressure range 200 to 1000 kPa (2 to 10 bar)


Standard nominal

flow rate 1...2, 1...4

500 l/min

Response time at 600 kPa (6 bar) 6 ms


24

35 1

14 12

Symbol used in circuit diagrams

24

35 1

14 12

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

Design

Function

Technical Data


539770

Dual-pressure valve (AND)


The dual-pressure valve with push-in elbow fittings is mounted on a function plate.


lever (mounting alternative "A").

The dual-pressure valve is switched through (AND function) when signals are

applied to both inputs 1 and 1/3. If different pressures are applied to the two inputs,

then the lower pressure reaches the output 2.

Pneumatic


Design AND-Gate (Dual-pressure valve)


Standard nominal flow rate 1, 1/3...2 550 l/min

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

2

1/31

Design

Function

Technical Data


539771

Shuttle valve (OR)


The shuttle valve with push-in elbow fittings is mounted on a function plate. The unit

is mounted on the profile plate via a quick release detent system with blue lever

(mounting alternative "A").

The shuttle valve is switched through to output 2 by applying a signal either to input

1 or 1/3 (OR-Function). If both inputs are pressurised simultaneously, then the

higher pressure reaches the output.

Pneumatic


Design OR-Gate (Shuttle valve)


Standard nominal flow rate 1, 1/3...2 500 l/min

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

2

1/31

Design

Function

Technical Data


539772

Quick exhaust valve


The quick exhaust valve with built-in silencer and push-in elbow fitting is screwed on

to the function plate, which includes a straight push-in fitting. The unit is mounted

on the profile plate via a quick release detent system with blue lever (mounting

alternative "A").

The compressed air flow via port 1 to port 2. If pressure drops at port 1, then the

compressed air from port 2 escapes to atmosphere via the built-in silencer.

Pneumatic


Design Poppet valve

Pressure range 50 to 1000 kPa (0.5 to 10 bar)

Standard nominal flow rate 1...2

2...3

300 l/min

550 l/min

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

2

1/31

Design

Function

Technical Data


539773

One-way flow control valve


The adjustable one-way flow control valve is screwed into the function plate,

incorporating a straight push-in fitting. The unit is slotted into the profile plate via a

quick release detent system with a blue lever (mounting alternative “A”).

The one-way flow control valve consists of a combination of a flow control valve and

a non-return valve.

The non-return valve blocks the flow of air in one direction, whereby the air flows via

the flow control valve. The throttle cross section is adjustable by means of a knurled

screw. The setting can be fixed by means of a knurled nut. Two arrows indicate the

direction of flow control on the housing. In the opposite direction, the air flow is

unrestricted via the non-return valve.

Pneumatic

Medium Compressed air, filtered, (lubricated or unlubricated)

Design One-way flow control valve

Pressure range 20 to 1000 kPa (0.2 to 10 bar)

Standard nominal flow rate in throttled direction: 0 – 110 l/min

free flow direction: 110 l/min (Throttle open)

65 l/min (Throttle closed)

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

21

Design

Function

Technical Data


539775

Proximity switch, pneumatic, with cylinder attachment


The pneumatic proximity sensor switch comes equipped with push-in fittings and a

mounting kit for attachment to cylinders.

A permanent magnet attached to the cylinder piston actuates a pneumatic 3/2-way

valve when overtravelled, thus triggering a control signal.

The pneumatic proximity switch complete with mounting kit, is attached direct to the

cylinder barrel by clipping on the plastic fixture. The switch can be attached to a

linear drive without this mounting kit. A reproducible switching accuracy of ±0.1 mm

can be achieved, if the signal generator is approached from the connection side.

31

2

Design

Function

Note

539775 Proximity switch, pneumatic, with cylinder attachment


Pneumatic

Medium Compressed air, filtered (unlubricated) 40 µm, free of

contamination

Design Pneumatic signal generator for contactless position indication

by means of magnetic field

Display Visual position indication

Temperature range -15 – +60 °C to DIN 40040

Mounting position any


Standard nominal flow rate 60 l/min

Reproducibility of switching value* ±0,1 mm

response time On: 22 ms

Off: 52 ms

Connection QS-4 fittings for plastic tubing PUN 4 x 0.75

* Applies only to drives with protection against torsion

Technical Data

540691



The filter regulator with pressure gauge, on/off valve, push-in fitting and quick

coupling plug is mounted on a swivelling retainer. The filter bowl is fitted with a

metal bowl guard. The unit is mounted on the profile plate by means of cheese head

screws and T-head nuts (mounting alternative “C”). Attached is a quick coupling

socket with threaded bush and connector nut for plastic tubing PUN 6 x 1.

The filter with water separator cleans the compressed air of dirt, pipe scale, rust and

condensate.

The pressure regulator adjusts the compressed air supplied to the set operating

pressure and compensates for pressure fluctuations. An arrow on the housing

indicates the direction of flow. The filter bowl is fitted with a filter drain screw. The

pressure gauge shows the preset pressure. The on/off valve exhausts the entire

control. The 3/2-way valve is actuated via the blue sliding sleeve.

2

31

2

31

Design

Function

540691



When constructing a circuit, please ensure that the filter regulator is installed in the

vertical position. The pressure regulator is fitted with an adjusting knob, which can

be turned to set the required pressure. By sliding the adjusting knob towards the

housing, the setting can be locked.

Pneumatic

Medium Compressed air

Design Sintered filter with water separator, diaphragm control valve

Assembly position Vertical ±5°

Standard nominal flow rate * 110 l/min

Upstream pressure 100 to 1000 kPa (1 to 10 bar)

Operating pressure 50 to 700 kPa (0.5 to 7 bar)

Connection Coupling plug for coupling socket G1/8 QS push-in fitting for

plastic tubing PUN 6 x 1

* Upstream pressure: 1000 kPa (10 bar), Operating pressure: 600 kPa (6 bar),

Differential pressure: 100 kPa (1 bar).

Note

Technical Data

540694

Time delay valve, normally closed


The time delay valve is mounted on a function plate which has been equipped with

the required push-in fittings. The unit is mounted on the profile plate via a quick

release detent system with blue lever (mounting alternative "A").

The time delay valve is actuated by a pneumatic signal at port 12 after a preset time

delay has elapsed. It is returned to the normal position via return spring when the

signal is removed. The time delay is infinitely adjustable by means of a regulating

screw.

The valve ports are identified by numerals:

1 = Air supply port

2 = Working port

3 = Exhaust port

2

31

Design

Function

Note

540694

Time delay valve, normally closed


Pneumatic


Design Poppet valve with return spring


switch-on pressure >160 kPa (1.6 bar)


Delay time 0.2 to 3 s (adjustable)

Setting accuracy ±0.3 ms

Time delay to reset >200 ms

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

Technical Data

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