Pneumatics Advanced Level - Festo · Pneumatics Advanced Level. ... precautions specified in this workbook. Festo Didactic hereby disclaims any legal liability for damages or

Workbook TP 102

CD-ROM included

Festo Didactic

541089 en

PneumaticsAdvanced Level

2 © Festo Didactic GmbH & Co. KG • 541089

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 need to ensure that trainees observe the safety

precautions specified in this workbook.

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

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

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

damages are caused with intention or through gross negligence on the part of Festo

Didactic.

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

541089 04/2005 W. Haring, M. Metzger, R.-C. Weber Frank Ebel Doris Schwarzenberger 10/2005

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

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

Parts of this document may be copied by the authorised user exclusively for training purposes.

Intended use

© Festo Didactic GmbH & Co. KG • 541089 3

Preface______________________________________________________________ 5

Introduction__________________________________________________________ 7

Notes on safety and operation ___________________________________________ 9

Technology package for pneumatics (TP100) ______________________________ 11

Training aims – Advanced Level (TP102) __________________________________ 13

Allocation of training aims and exercises _________________________________ 15

Equipment set – Advanced Level (TP102) _________________________________ 17

Allocation of equipment and exercises ___________________________________ 20

Methodological help for the trainer ______________________________________ 22

Methodological structure of the exercises_________________________________ 24

Designation of equipment _____________________________________________ 25

Equipment set – Basic Level (TP101) _____________________________________ 26

Training aims – Basic Level (TP101)______________________________________ 27

Part A – Exercises

Exercise 1: Opening and closing of an oven door ___________________________A-3

Exercise 2: Separating of drinks bottles __________________________________A-9

Exercise 3: Drilling of valve manifold blocks ______________________________A-17

Exercise 4: Filling of drinks bottles______________________________________A-25

Exercise 5: Cleaning of workpieces _____________________________________A-35

Exercise 6: Printing of mobile phone housings ____________________________A-43

Exercise 7: Packaging of spark plugs ____________________________________A-49

Exercise 8: Sealing of guide bushes_____________________________________A-55

Exercise 9: Hardening of material test specimens__________________________A-63

Exercise 10: Bending of sheet metal strips _______________________________A-69

Contents

Contents


Part B – Fundamentals

Part C – Solutions

Exercise 1: Opening and closing of an over door____________________________C-3

Exercise 2: Separating of drinks bottles __________________________________C-7

Exercise 3: Drilling of valve manifold blocks ______________________________C-11

Exercise 4: Filling of drinks bottles______________________________________C-17

Exercise 5: Cleaning of workpieces _____________________________________C-27

Exercise 6: Printing of mobile phone housings ____________________________C-35

Exercise 7: Packaging of spark plugs ____________________________________C-41

Exercise 8: Sealing of guide bushes ____________________________________C-47

Exercise 9: Hardening of material test specimens__________________________C-53

Exercise 10: Bending of sheet metal strips _______________________________C-59

Part D – Appendix

Organiser __________________________________________________________ D-2

Assembly technology ________________________________________________ D-3

Plastic tubing_______________________________________________________ D-4

Data sheets

Circuit diagrams


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 technology-spanning basic knowledge

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

technology

• Function packages to explain the basic functions of automated systems

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

industrial applications

The technology packages deal with the following technologies: Pneumatics,

electropneumatics, programmable logic controllers, automation using a personal

computer, hydraulics, electrohydraulics, proportional hydraulics and handling

technology.

Preface

Preface


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

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

hydraulic and electrical drives.

All the training packages are of identical structure:

• Hardware

• Teachware

• Software

• Seminars

The hardware consists of didactically designed industrial components and systems.

The didactic, methodological design of the teachware is harmonised with the

training hardware and comprises:

• Textbooks (with exercises and examples)

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

sheets)

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

environment)

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

use both in the classroom and for self-tuition.

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

software for programmable logic controllers.

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

packages completes the range of vocational and further training available.


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

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

practice-oriented vocational and further training. Technology package TP100 is

comprised exclusively of electropneumatic 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 components. 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 combinatorial circuits with

logic operations of input and output signals as well as control systems with

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 spaced 50 mm apart. A mobile,

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

air supply.

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

Optimal operational reliability is achieved if the control system is operated on

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

The equipment set of Advanced Level TP102 is used to construct complete control

systems for all of the 10 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 in respect 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 the

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 always be mounted laterally to the trip cam (not to the

front).

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

• Pneumatic circuit assembly: Connect the components using the silver-metallic

plastic tubing of 4 mm outer diameter; the tubing is plugged into the push-in

fitting up to the stop, no additional securing required!

• 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 in the form of mounting variants A, B or C:

Variant A, latching system

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

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

the blue lever.

Variant B, rotary system

For 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

achieved by means of the blue knurled nut.

Variant C, screw system

For heavy loadable devices rarely removed from the profile plate (e.g. on/off

valve with filter regulating valve). These components are mounted by means of

socket head screws and T-head bolts.

• The data for the individual devices, as 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 for the evaluation of the assembled control systems, i.e.:

• To adjust one-way flow control valves such that the cylinder stroke time complies

with the specified values,

• To adjust time delay valves.


The technology package TP100 consists of numerous individual training media as

well as seminars. The subject matter 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 set or 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 set-ups

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®

Pneumatics

WBT Fluid Studio Pneumatics

Cutaway model sets 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 different types of end position sensing.

• To familiarise yourself with the options of designing control systems with a

memory function.

• To be able to convert 3/2- and/or 5/2-way valves (normally closed/normally

open).

• To familiarise yourself with displacement-step diagrams and to be able to design

these for a specified circuit.

• To be able to realise circuits with parallel movements in push-pull mode.

• To be able to use pneumatic decrementing counters.

• To be able to design indirect cylinder actuation.

• To be able to select appropriate sensors for applications and adjust such

sensors.

• To familiarise yourself with the design and function of stepper modules.

• To be able to design the basic „continuous cycle“ stepper control system.

• To be able to install one-way flow control valves dependent on given parameters.

• To be able to realise the OR function of feedback signals.

• To be able to set time delays according to specifications.

• To familiarise yourself with circuits in order to cancel time delays via signal input.

• To be able to realise the following input commands:

EMERGENCY-STOP, acknowledge EMERGENCY-STOP, START, RESET, STOP at

CYCLE END and AUTOMATIC/MANUAL.

• To be able to design a stepper control with idle step.

• To familiarise yourself with the option of facilitating variable step repetitions

within a motion sequence and to assemble this circuit.

• To be able to develop input circuits with self-latching loop

• To familiarise yourself with the option of realising the double stroke of a cylinder

and to be able to assemble this circuit.

• To familiarise yourself with circuits in order to realise the reversal of a cylinder

movement in the partial stroke range.

• To be able to develop an input circuit for a stepper control with protected pilot

air.

• To be able to stop a double-acting cylinder in the partial stroke range.

• To understand how valve output signals can be inverted.

• To be able to realise a control system with control behaviour in combination with

a sequence control in stepper design.

Training aims of Advanced Level (TP102)

Training aims of Advanced Level (TP102)



Exercise 1 2 3 4 5 6 7 8 9 10

Training aims

To familiarise yourself with different types of end position

sensing.

•

To familiarise yourself with the options of designing

control systems with a memory function.

•

To be able to convert 3/2- and/or 5/2-way valves

(normally closed/normally open).

•

To familiarise yourself with displacement-step diagrams

and to be able to design these for a specified circuit.

•

To be able to realise circuits with parallel movements in

push-pull mode.

•

To be able to use pneumatic decrementing counters. •

To be able to design indirect cylinder actuation. • •

To be able to select appropriate sensors for applications

and adjust such sensors.

• • • •

To familiarise yourself with the design and function of

stepper modules.

•

To be able to design the basic „continuous cycle“ stepper

control system.

•

To be able to install one-way flow control valves

dependent on given parameters.

•

To be able to realise the OR function of feedback signals. •

To be able to set time delays according to specifications. •

To familiarise yourself with circuits in order to cancel time

delays via signal input.

•

To be able to design a stepper control with the input

commands AUTOMATIC/MANUAL, START and RESET.

•

To be able to realise the following input commands:

EMERGENCY-STOP, acknowledge EMERGENCY-STOP,

START, RESET, STOP at CYCLE END and

AUTOMATIC/MANUAL.

•

Allocation of training aims and exercises

Allocation of training aims and exercises


Exercise 1 2 3 4 5 6 7 8 9 10

Training aims

To be able to develop an input circuit with self-latching

loop, that enables the following inputs:

AUTOMATIC/MANUAL, START, STOP at CYCLE END and

RESET.

•

To be able to design a stepper control with idle step. •

To familiarise yourself with the option of facilitating a

variable motion sequence and to be able to design this

circuit.

•

To familiarise yourself with the option of realising the

double stroke of a cylinder and to be able to assemble this

circuit.

•

To familiarise yourself with circuits in order to realise the

reversal of a cylinder movement in the partial stroke

range.

•

To be able to develop an input circuit for a stepper control

with protected pilot air with the inputs START,

AUTOMATIC/MANUAL and RESET.

•

To be able to stop a double-acting cylinder in the partial

stroke range.

•

To be able to adjust proximity sensors in the end positions

and in the partial stroke range.

To understand how valve output signals can be inverted. •

To be able to realise a control system with control

behaviour in combination with a sequence control in

stepper design.

•


This equipment set for the advanced level has been compiled for further training in

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

all the components required to meet the specified training aims and can be

expanded as desired 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, convertible 539768 4

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

3/2-way valve with mushroom actuator, normally open

(EMERGENCY-STOP)

152864 1

5/2-way pneumatic double pilot valve 539769 2

Back pressure valve 152868 1

Double-acting cylinder 152888 2

Dual pressure valve, 3-fold 152883 1

Non-return valve, piloted 540715 2

One-way flow control valve 539773 2

Plastic tubing 4 x 0.75, 10 m 151496 2

Predetermining counter, pneumatic 152877 1

Push-in sleeve 153251 10

Push-in T-connector 153128 20

Shuttle valve 539771 1

Shuttle valve, 3-fold 152882 1

Stepper module 152886 1

Time delay valve, normally open 539759 1

Equipment set – Advanced Level (TP102)

Equipment set – Advanced

Level (TP102

Order No.: 540711)



Desccription Symbol

3/2-way valve with pushbutton,

normally closed

2

31

3/2-way valve with mushroom

actuator,

normally open (EMERGENCY-STOP)

2

31

3/2-way roller lever valve with idle

return

2

31

Back pressure valve

31

2

3/2-way pneumatic valve,

normally closed

2

31

12

5/2-way double pilot valve 24

35 1

14 12

Predetermining counter, pneumatic 2

1

12 10

Time delay valve,

normally open 10

2

31

One-way flow control valve 21

Equipment set symbols



Description Symbol

Shuttle valve, 3-fold 2 2 2

1 1/31/31/3 1 1

Shuttle valve 2

1/31

Dual pressure valve, 3-fold 2 2 2

1 1/31/31/3 1 1

Double-acting cylinder

Non-return valve, piloted 2

1 21

Description Symbol

Stepper module

L L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

A1

X1

YnY Yn+1 Yn+1Yn

Zn Zn Zn+1Z Z

L LLL

P PP P PP

Y

TABTAATAATAA

Zn+1


Exercise 1 2 3 4 5 6 7 8 9 10

Equipment

Cylinder, double-acting 1 2 2 2 2 2 2 1 1 2

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

Non-return valve, piloted 2

3/2-way pneumatic valve, convertible 2 1 1 3 3 4 3 1

5/2-way double pilot valve 2 2 2 2 2 2 2 2 2

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

Back pressure valve 1 1 1

3/2-way valve with push button, normally closed 1 1 2 2 2 2 1 1

3/2-way valve with mushroom actuator, normally open

(EMERGENCY-STOP)

1 1

Stepper module 1 1 1 1 1 1

Time delay valve, normallyopen 1 1

Predetermining counter, pneumatic 1 1

Shuttle valve 1 1 1

Shuttle valve, 3-fold 3 3 3 3 2

Dual pressure valve, 3-fold 1 2 3 3 1 1 2

Allocation of equipment and exercises

Equipment set TP102

Allocation of equipment and exercises


Exercise 1 2 3 4 5 6 7 8 9 10

Equipment

Cylinder, double-acting 1

Cylinder, single-acting 1

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

3/2-way pneumatic valve 1

5/2-way pneumatic valve 1*

5/2-way double pilot valve 1 3 2*

3/2-way roller lever valve with idle return 1 2 2 2 2 2 2 2

Pneumatic proximity sensor 2 1 2 2 2 2 1 1 2

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

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

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

Time delay valve, normally closed 1 1

Shuttle valve 1 1

Dual pressure valve 1

Manifold 1 1 1 1 1 1 1 1 1 1

ON/off valve with filter regulating valve 1 1 1 1 1 1 1 1 1 1

* Convert the available valve into the required valve.

Equipment set TP101


• Training

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

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

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

Naturally questions and problems arise, which will vary from training group to

training group and these provide a very useful platform for you to discuss the

training aims addressed at the time.

• Variations in training aims

The above training aim can be varied in various different ways. For many

vocational groups, the designing of a control system is only of secondary

importance.

For instance, if the circuit diagram is added to the exercise definition, the

vocational or further training focus can then be shifted to the assembly and

commissioning of the control system.

Other possible main areas of focus in vocational and further training are for

instance fault finding on assembled control systems or the modification of circuit

diagrams, such as circuit documentation due to an altered exercise definition.

Parts of the documentation of a control system can be prepared during the

theoretical part of training.

The preparation of complete solution descriptions or sections thereof based on

the circuit documentation or the assembled control system also facilitates

interdisciplinary tuition.

• Time required

The time required to work through the 10 exercises depends on the prior

knowledge of the trainees:

– Trainees who have undergone vocational training in the engineering and

electrical field:

Just under 160 hours,

– Trainees with technician’s or engineering training:

up to 80 hours.

Whereby the second group is to be involved more in the designing of circuit

diagrams or sections of circuit diagrams.

Methodological help for the trainer

Methodological help for the trainer


• Components of the equipment set

The collection of exercises in TP102 is didactically and methodologically

harmonised with the training hardware (equipment set of Basic Level TP101 and

Advanced Level TP102).

These two equipment sets are all you require for all the exercises.

• Representation

Abbreviated notation, possibly divided into groups, as well as motion diagrams

are used for the representation of motion sequences and switching statuses.


All 10 exercises in Part A are of the same 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 design

• Equipment list

Enlarged circuit diagrams on DIN-A3 sheets are enclosed for exercises 4 to 10.

Methodological structure of exercises


The designation of components in a circuit diagram is effected in accordance with

the DIN-ISO 1219-2 standard. All components of a circuit have the same main code

number. Letters are assigned depending on component. Several components within

a circuit are number consecutively. The designation of multiple pressure ports is P

and these are consecutively numbered separately.

Cylinders: 1A1, 2A1, 2A2, ...

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

Sensors: 1B1, 1B2, ...

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

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

Designation of equipment


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

technology. It comprises all the components required for the training aims specified

and can be expanded in any way using other equipment sets. In addition you will

also need a profile plate and compressed air supply to assemble a fully functional

control system.

Description Order No. Quantity

3/2-way pneumatic valve, convertible 539768 1

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

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

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

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

5/2-way double solenoid valve 539769 3

5/2-way pneumatic valve 538694 1

5/2-way valve with selector switch 152862 1

Double-acting cylinder 152888 1

Dual pressure valve 539770 2

Manifold 152896 1

One-way flow control valve 539773 2

On-off valve with filter regulating valve 540691 1

Plastic tubing 4 x 0.75, 10 m 151496 2

Pneumatic proximity sensor 539775 2

Pressure gauge 152865 2

Pressure regulating valve with pressure gauge 539756 1

Pressure sequence valve 152884 1

Push-in sleeve 153251 10

Push-in T-connector 153128 10

Quick exhaust valve 539772 1

Shuttle valve 539771 1

Single-acting cylinder 152887 1

Time delay valve, normally closed 540694 1

Equipment set – Basic Level (TP101)

Equipment set – Basic Level

(TP101

Order No.: 540710)


• To familiarise yourself with the design and function 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 able to explain and design an example of 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 familiarise yourself with the design and mode of operation of a 5/2-way 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 familiarise yourself with the difference between a signalling element and a

control element.

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

• 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 circuits.

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

• To be able to explain and configure latching circuits.

• To familiarise yourself with one option 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

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 pressure

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.

Training aims – Basic Level (TP101)


© Festo Didactic GmbH & Co. KG • 541089 A-1

Part A – Exercises

Exercise 1: Opening and closing of an oven door ___________________________A-3

Exercise 2: Separating of drinks bottles __________________________________A-9

Exercise 3: Drilling of valve manifold blocks ______________________________A-17

Exercise 4: Filling of drinks bottles______________________________________A-25

Exercise 5: Cleaning of workpieces _____________________________________A-35

Exercise 6: Printing of mobile phone housings ____________________________A-43

Exercise 7: Packaging spark plugs ______________________________________A-49

Exercise 8: Sealing of guide bushes_____________________________________A-55

Exercise 9: Hardening of material test specimens__________________________A-63

Exercise 10: Bending of sheet metal strips _______________________________A-69

Contents

Contents

A-2 © Festo Didactic GmbH & Co. KG • 541089


• To familiarise yourself with different types of end position sensing.

• To familiarise yourself with the options of designing control systems with a

memory function.

• To be able to convert 3/2- and/or 5/2-way valves (normally closed/normally

open).

The hardening system is designed for the continual hardening of mass produced

metal parts. The workpieces are hardened and subsequently quenched in an oil-

quenching bath. The flaps at the entry and exit of the hardening system are to be

closed and opened using double-acting cylinders.

• Due to the heat build-up, no limit switches are to be used. The pressure is to be

sensed when the cylinder moves into one of the two end positions.

1. Complete the pneumatic circuit diagram.

2. Convert the directional control valves contained in the equipment set.

3. Carry out the assembly.

4. Check the assembled circuit.

5. Describe the mode of operation of the circuit.

6. Compile the equipment list.

Exercise 1: Opening and closing of an oven door

Training aims

Problem definition

Parameters

Project task



Hardening oven

1. The opening and closing function is to be started using a pushbutton 1S1.

2. A 5/2-way double pilot valve controls the double-acting cylinder. The control

pulse for this is to be the pressure that builds up when the cylinder moves into

one of the two end positions.

A pulse occurs either via valves 1V1, 1V3 to1V4: "Retract";

or a pulse occurs via valves 1V2, 1V3 to 1V4: "Advance"

3. The cylinder movement in abbreviated annotation is

1A1+ 1A1–

• What faults may occur when tubing up the circuit?

What are the effects of such faults? Describe these.

• The convertible 3/2-way pneumatic valves are intended for the required

3/2 way valves 1V1 and 1V2. These valves are supplied in normally closed

position. How do they need to be converted in order to fulfil the necessary

function?

• As an alternative, use the 5/2-way pneumatic valves. How do these need to be

converted?

• How does the circuit react after a pressure loss?

• What is a binary reducing stage?

Positional sketch

Additional exercises




Name: Date:

Completing the pneumatic circuit diagram Sheet 1 of 1

– Complete the pneumatic circuit diagram and enter the port designations.

1V4

1V3

2

1 1

2 2

2

4

4

3

3

5

5

1

1

1V5

14

14

12

12

1V6

1A1

2

31

1S1

10

10

2

2

3

3

1

1

1V2

1V1

Pneumatic circuit diagram




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




Name: Date:

Carrying out additional exercises Sheet 1 of 2

– What faults can occur when tubing up the circuit?

What are the effects of such faults? Describe these.

– The convertible 3/2-way pneumatic valves are intended for the required

3/2-way valves 1V1 and 1V2. These valves are supplied in the normally closed

position. How do they need to be converted in order to fulfill the necessary

function?

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Exercise 1: Opening and closing of an over door

Name: Date:

Carrying out additional exercises Sheet 2 of 2

– As an alternative, use the 5/2-way pneumatic valves for this. How do these need

to be converted?

– How does the circuit react after a loss of pressure?

– What is a binary reducing stage?

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Documents

Pneumatics Advanced Level - Festo · Pneumatics Advanced Level. ... precautions specified in this workbook. Festo Didactic hereby disclaims any legal liability for damages or