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Book of exercisesTP 101
Festo Didactic
570691 EN
PneumaticsBasic level
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Festo worldwide
ArgentinaFesto S.A.Edison 2392(B1640 HRV) MartinezProv. Buenos AiresTel. ++54 (0)11/47 17 82 00, Fax 47 17 82 82 E-mail: [email protected]
AustraliaFesto Pty. Ltd.Head Office (Melbourne)179-187 Browns Road, P.O. Box 261Noble Park Vic. 3174Call Toll Free 1300 88 96 96Fax Toll Free 1300 88 95 95Tel. ++ 61(0)3/97 95 95 55, Fax 97 95 97 87 E-mail: [email protected]
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CanadaFesto Inc.5300 Explorer DriveMississauga, Ontario L4W 5G4Tel. ++1 (0)905/624 90 00, Fax 624 90 01 E-mail: [email protected]
ChileFesto S.A.Mapocho 19016500151 Santiago de ChileTel. ++56 (0)2/690 28 00, Fax 695 75 90 E-mail: [email protected]
ChinaFesto (China) Ltd.1156 Yunqiao RoadJinqiao Export Processing ZonePudong,201206 Shanghai, PRCTel. ++86 (0)21/58 54 90 01, Fax 58 54 03 00 E-mail: [email protected]
ColombiaFesto Ltda.Avenida El Dorado No. 98-43BogotáTel. ++57 (0)1/404 80 88, Fax 404 81 01 E-mail: [email protected]
CroatiaFesto d.o.o.Nova Cesta 18110000 ZagrebTel. ++385 (0)1/619 19 69, Fax 619 18 18 E-mail: [email protected]
Czech RepublicFesto, s.r.o.Modøanská 543/76147 00 Praha 4Tel. ++420 261 09 96 11, Fax 241 77 33 84 E-mail: [email protected]
DenmarkFesto A/SIslevdalvej 1802610 RødovreTel. ++45 70 21 10 90, Fax ++45 44 88 81 10 E-mail: [email protected]
EstoniaFesto OY AB Eesti FiliaalLaki 11B12915 TallinnTel. ++372 666 15 60, Fax ++372 666 15 61 E-mail: [email protected]
FinlandFesto OYMäkituvantie 9, P.O. Box 8601511 VantaaTel. ++358 (09)/87 06 51, Fax 87 06 52 00 E-mail: [email protected]
FranceFesto EurlNuméro Indigo Tel. 0820/204640, Fax 204641ZA des Maisons Rouges8 rue du Clos Sainte Catherine94367 Bry-sur-Marne cedexTel. ++33 (0)1/48 82 64 00, Fax 48 82 64 01 E-mail: [email protected]
GermanyFesto Didactic GmbH & Co. KGPostfach 10 07 1073707 EsslingenRechbergstraße 373734 EsslingenTel. ++49 (0)711/3467-0Fax ++49 (0)711/347-54 88500E-mail: [email protected]
GreeceFesto Ltd.40 Hamosternas Ave.11853 AthensTel. ++30 210/341 29 00, Fax 341 29 05 E-mail: [email protected]
Hong KongFesto Ltd.Unit C&D, 7/F, Leroy Plaza15 Cheung Shun StreetCheung Sha Wan, KowloonHong KongTel. ++ 852/27 43 83 79, Fax 27 86 21 73 E-mail: [email protected]
HungaryFesto Kft.Csillaghegyi út 32-34.1037 BudapestTel. ++36 1/436 51 11, Fax 436 51 01E-mail: [email protected]
IndiaFesto Controls Private Ltd.237B,Bommasandra Industrial Area,Bangalore Hosur Highway,Bangalore 560 099Tel. ++91 (0)80/22 89 41 00, Fax 783 20 58 E-mail: [email protected]
IndonesiaPT. FestoJL. Sultan Iskandar Muda No.68Arteri Pondok IndahJakarta 12240Tel. ++62 (0)21/27 50 79 00, Fax 27 50 79 98 E-mail: [email protected]
IranFesto Pneumatic S.K.# 2, 6th street, 16th avenue,Tehran 1581975411Km 8, Special Karaj Road, P.O.Box 15815-1485Tehran 1389793761Tel. ++98 (0)21 44 52 24 09, Fax ++98 (0)21 44 52 24 08E-mail: [email protected]
IrelandFesto LimitedUnit 5 Sandyford ParkSandyford Industrial EstateDublin 18Tel. ++ 353(0)1/295 49 55, Fax 295 56 80 E-mail: [email protected]
IsraelFesto Pneumatic Israel Ltd.P.O. Box 1076, Ha'atzma'ut Road 48Yehud 56100Tel. ++972 (0)3/632 22 66, Fax 632 22 77 E-mail: [email protected]
ItalyFesto S.p.AVia Enrico Fermi 36/3820090 Assago (MI)Tel. ++39 02/45 78 81, Fax 488 06 20 E-mail: [email protected]
JapanFesto K.K.1-26-10 Hayabuchi, Tsuzuki-kuYokohama 224-0025Tel. ++81 (0)45/593 56 10, Fax 593 56 78 E-mail: [email protected]
Korea SouthFesto Korea Co., Ltd.470-1 Gasan-dong, Geumcheon-guSeoul #153-803Tel. ++82 (0)2/850 71 14, Fax 864 70 40 E-mail: [email protected]
LatviaFesto SIADeglava 601035 RigaTel. ++371 67/57 78 64, Fax 57 79 46 E-mail: [email protected]
LithuaniaFesto UABKaraliaus Mindago pr. 223000 KaunasTel. ++370 (8)7/32 13 14, Fax 32 13 15 E-mail: [email protected]
MalaysiaFesto Sdn.Berhad10 Persiaran IndustriBandar Sri Damansara, Wilayah Persekutuan52200 Kuala LumpurTel. ++60 (0)3/62 86 80 00, Fax 62 75 64 11 E-mail: [email protected]
MexicoFesto Pneumatic, S.A.Av. Ceylán 3Col. Tequesquinahuac54020 Tlalnepantla, Edo. de MéxicoTel. ++52 (01)55/53 21 66 00, Fax 53 21 66 55 E-mail: [email protected]
NetherlandsFesto B.V.Schieweg 622627 AN DelftTel. ++31 (0)15/251 88 99, Fax 261 10 20 E-mail: [email protected]
New ZealandFesto LimitedMT. WellingtonAuckland NZTel. ++64 (0)9/574 10 94, Fax 574 10 99 E-mail: [email protected]
NigeriaFesto Automation Ltd.Motorways Centre, First Floor, Block CAlausa, Ikeja,Lagos, NIGERIATel. ++234 (0)1/794 78 20, Fax 555 78 94 E-mail: [email protected]
NorwayFesto ASOle Deviks vei 20666 Oslo, NorwayTel. ++47 22 72 89 50, Fax ++47 22 72 89 51 E-mail: [email protected]
PeruFesto S.R.L.Calle Amador Merino Reyna #480, San IsidroLima, PerúTel. ++51 (0)1/222 15 84, Fax 222 15 95
PhilippinesFesto Inc.KM 18, West Service RoadSouth Superhighway1700 Paranaque City, Metro ManilaTel. ++63 (0)2/776 68 88, Fax 823 42 19 E-mail: [email protected]
PolandFesto Sp. z o.o.Janki k/Warszawy, ul. Mszczonowska 705090 RaszynTel. ++48 (0)22/711 41 00, Fax 711 41 02 E-mail: [email protected]
RomaniaFesto S.R.L.St. Constantin 17010217 BucurestiTel. ++40 (0)21/310 29 83, Fax 310 24 09 E-mail: [email protected]
RussiaFesto-RF OOOMichurinskiy prosp., 49119607 MoskowTel. ++7 495/737 34 00, Fax 737 34 01 E-mail: [email protected]
SingaporeFesto Pte. Ltd.6 Kian Teck WaySingapore 628754Tel. ++65/62 64 01 52, Fax 62 61 10 26 E-mail: [email protected]
SlovakiaFesto spol. s r.o.Gavlovicová ul. 183103 Bratislava 3Tel. ++421 (0)2/49 10 49 10, Fax 49 10 49 11 E-mail: [email protected]
SloveniaFesto d.o.o. LjubljanaIC Trzin, Blatnica 81236 TrzinTel. ++386 (0)1/530 21 00, Fax 530 21 25 E-mail: [email protected]
South AfricaFesto (Pty) Ltd.22-26 Electron Avenue, P.O. Box 255Isando 1600Tel. ++27 (0)11/971 55 00, Fax 974 21 57 E-mail: [email protected]
SpainFesto Pneumatic, S.A.Tel. 901243660 Fax 902243660Avenida Granvia, 159Distrito económico Granvia L'HES-08908 Hospitalet de Llobregat, BarcelonaTel. ++ 3493/261 64 00, Fax 261 64 20 E-mail: [email protected]
SwedenFesto ABStillmansgatan 1, P.O. Box 2103820021 MalmöTel. ++46 (0)40/38 38 40, Fax 38 38 10 E-mail: [email protected]
SwitzerlandFesto AGMoosmattstrasse 248953 Dietikon ZHTel. ++41 (0)44/744 55 44, Fax 744 55 00 E-mail: [email protected]
TaiwanFesto Co., Ltd.Head Office24450, No. 9, Kung 8th RoadLinkou 2nd Industrial ZoneLinkou Hsiang, Taipei Hsien, Taiwan, R.O.C.Tel. ++886 (0)2 26 01 92 81, Fax ++886 (0)2 26 01 92 86-7 E-mail: [email protected]
ThailandFesto Ltd.67/1 Moo 6 Phaholyothin RoadKlong 1, Klong Luang,Pathumthani 12120Tel. ++66 29 01 88 00, Fax ++66 29 01 88 33 E-mail: [email protected]
TurkeyFesto San. ve Tic. A.S.Tuzla Mermerciler OrganizeSanayi Bölgesi, 6/18 TR34956 Tuzla - Istanbul/TRTel. ++90 (0)216/585 00 85, Fax 585 00 50 E-mail: [email protected]
UkraineFesto UkrainaBorisoglebskaja 11Kiev 04070Tel. ++380 (0)44/239 24 33, Fax 463 70 96 E-mail: [email protected]
United KingdomFesto LimitedApplied Automation Centre, Caswell RoadBrackmills Trading EstateNorthampton NN4 7PYTel. ++44 (0)1604/66 70 00, Fax 66 70 01 E-mail: [email protected]
United StatesFesto Corporation (New York)Call Toll-free 800/993 3786Fax Toll-free 800/963 3786395 Moreland Road, P.O.Box 18023Hauppauge, N.Y. 11788Tel. ++ 1(0)314/770 01 12, Fax 770 16 84 E-mail: [email protected]
VenezuelaFesto C.A.Av. 23, Esquina calle 71, No. 22-62Maracaibo, Edo. ZuliaTel. ++58 (0)261/759 09 44, Fax 759 04 55 E-mail: [email protected]
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Use for intended purpose
The training system from Festo Didactic has been developed and produced exclusively for training and
further education in the field of automation and technology. The respective training companies and/or
trainers must ensure that all trainees observe the safety precautions which are described in this workbook.
Festo Didactic hereby excludes any and all liability for damages suffered by trainees, the training company
and/or any third parties, which occur during use of the equipment in situations which serve any purpose
other than training and/or further education, unless such damages have been caused by Festo Didactic due
to malicious intent or gross negligence.
Order no. 570691
Status: 10/2009
Authors: W. Haring, M. Metzger, R.-C. Weber
Editor: Frank Ebel
Graphics: Doris Schwarzenberger
Layout: 12/2009
© Festo Didactic GmbH & Co. KG, D-73770 Denkendorf, 2009
Internet: www.festo-didactic.com
E-mail: [email protected]
The reproduction, distribution and utilisation of this document, as well as the communication of its contents
to others without explicit authorisation, is prohibited. Offenders will be held liable for compensation of
damages. All rights reserved, in particular the right to file patent, utility model and registered design
applications. Portions of this documentation may be duplicated by an authorised user exclusively for
training purposes.
© Festo Didactic GmbH & Co. KG 570691 III
Table of contents
Exercises
Exercise 1: Pressing cheeses _________________________________________________________________ 1
Exercise 2: Opening a fodder silo _____________________________________________________________ 9
Exercise 3: Clamping boards to a saw bench __________________________________________________ 15
Exercise 4: Sorting packages _______________________________________________________________ 21
Exercise 5: Stopping milk bottles ___________________________________________________________ 31
Exercise 6: Opening and closing a pipeline ___________________________________________________ 37
Exercise 7: Shutting off a pipeline ___________________________________________________________ 45
Exercise 8: Actuating a shut-off device _______________________________________________________ 51
Exercise 9: Expanding the control system for pressing cheeses ___________________________________ 59
Exercise 10: Clamping a workpiece __________________________________________________________ 65
Exercise 11: Loading wire baskets __________________________________________________________ 73
Exercise 12: Actuating a sliding door ________________________________________________________ 79
Exercise 13: Feeding wooden boards ________________________________________________________ 87
Exercise 14: Compacting beverage cans ______________________________________________________ 93
Exercise 15: Packaging of brochures ________________________________________________________ 99
Exercise 16: Mounting locking pins _________________________________________________________ 105
Exercise 17: Labelling paint pots ___________________________________________________________ 111
Exercise 18: Cleaning workpieces __________________________________________________________ 117
Exercise 19: Pressing labels into place ______________________________________________________ 123
IV © Festo Didactic GmbH & Co. KG 570691
© Festo Didactic GmbH & Co. KG 570691 1
Exercise 1: Pressing cheeses
Learning objectives
After completing this exercise you’ll:
• Be familiar with the set-up and mode of operation of a single-acting cylinder.
• Be able to calculate the piston force of a single-acting cylinder.
• Be familiar with the set-up and mode of operation of a normally closed 3/2-way valve.
• Be able to recognise and sketch the various types of actuation for directional control valves.
• Be able to explain and set up direct actuation.
Presentation of the problem
Presses are used to press cheeses into moulds during the production process. Develop a control system
with which this process can be executed
Layout
Cheese production
Exercise 1: Pressing cheeses
2 Name: __________________________________ Date: ____________ © Festo Didactic GmbH & Co. KG 570691
Parameters
• Use a double-acting cylinder.
• Pneumatically control the cylinder using a manually actuated valve.
Project assignment
1. Describe the mode of operation of a single-acting cylinder.
2. Describe the mode of operation of a normally closed 3/2-way valve.
3. Complete the pneumatic circuit diagram for the pressing tool.
4. Set up the control system.
5. Double-check the control system configuration.
6. Describe the mode of operation of the control system.
7. Create an equipment list.
Procedure
1. The cheeses are placed into the tool manually.
2. When the pushbutton is activated, the cylinder advances and presses the cover onto the tool.
3. The pushbutton is pressed and held until the pressing operation has been completed.
4. When the pushbutton is released, the cylinder is retracted and the tool can be accessed.
5. The cheese can be removed.
Safety note
Limit pressure at the service unit for this exercise to a maximum of3.5 bar (350 kPa). Immediately
deactivate compressed air supply if the tubing slips off.
Exercise 1: Pressing cheeses
© Festo Didactic GmbH & Co. KG 570691 Name: __________________________________ Date: ____________ 3
Set-up and mode of operation of a single-acting cylinder
1 2 3 4 5
678
Circuit symbol and schematic diagram of a single-acting cylinder
– Compare the circuit symbol shown above with the schematic diagram of the single-acting cylinder.
Determine whether or not the two representations coincide with each other.
_________________________________________________________________________________________
– Describe the set-up and mode of operation of a single-acting cylinder.
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
– Match up each component with the corresponding number from the above drawing.
Component Designation
Cylinder barrel
End cap
Bearing cap
Piston rod
Piston
Spring return
Supply port
Exhaust port
Table of component designations
Exercise 1: Pressing cheeses
4 Name: __________________________________ Date: ____________ © Festo Didactic GmbH & Co. KG 570691
Calculate the piston force of a single-acting cylinder
Theoretical piston force is calculated using the following formula:
Fth = A • p
Fth = theoretical piston force (N)
A = effective piston surface (sq. metres)
= )
4
D(
2π•
p = working pressure (Pa)
D = cylinder diameter (m)
Piston force Feff is important in actual practice. Frictional resistance has to be taken into consideration when
calculating piston force. Under normal operating conditions (pressure range of 4 to 8 bar or 400 to 800 kPa),
it is assumed that friction forces (FR) amount to roughly 10% of the theoretical piston force.
The following applies to the effective piston force of single-acting cylinders:
Feff = A • p – (FR + FF)
Feff = effective piston force (N)
FR = friction force (approx. 10% of Fth ) (N)
FF = return spring force (N)
– Calculate the effective piston force for the advance stroke of the used cylinder with a working pressure
of 6 bar (600 kPa).
Note
The required data is included in the data sheet for the cylinder.
Exercise 1: Pressing cheeses
© Festo Didactic GmbH & Co. KG 570691 Name: __________________________________ Date: ____________ 5
Mode of operation of a normally closed 3/2-way valve
– Complete the circuit symbol of a manually actuated, normally closed 3/2-way valve with spring return.
2
31
1
2
3
Circuit symbol and schematic representation of a normally closed 3/2-way valve
– Describe the mode of operation of the 3/2-way valve.
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
Exercise 1: Pressing cheeses
6 Name: __________________________________ Date: ____________ © Festo Didactic GmbH & Co. KG 570691
Complete the pneumatic circuit diagram
– Complete the pneumatic circuit diagram for the control system and enter the port designations.
Pneumatic circuit diagram
Note
The on-off valve with filter regulator and the distributor block are not shown. These components are
required in order to set up the control system.
Exercise 1: Pressing cheeses
© Festo Didactic GmbH & Co. KG 570691 Name: __________________________________ Date: ____________ 7
Sequence description
– Set up the control system and describe its working sequence.
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
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_________________________________________________________________________________________
_________________________________________________________________________________________
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_________________________________________________________________________________________
Exercise 1: Pressing cheeses
8 Name: __________________________________ Date: ____________ © Festo Didactic GmbH & Co. KG 570691
Create an equipment list
In addition to the circuit diagram, complete project documentation also includes an equipment list.
– Create an equipment list by entering the required components and their quantities in the table below.
Quantity Designation
Equipment list
