electro-pneumatics seminar

Contents

Part A – Exercises Exercise 1: Realising a sorting device ____________________________________A-3 Exercise 2: Realising a shut-off device___________________________________A-15 Exercise 3: Realising a lid press ________________________________________A-25 Exercise 4: Realising the operation of a hinged lid _________________________A-35 Exercise 5: Realising a diverting device __________________________________A-43 Exercise 6: Actuation of a stacking magazine _____________________________A-53 Exercise 7: Sorting of packages ________________________________________A-65 Exercise 8: Actuation of a sliding platform _______________________________A-73 Exercise 9: Expanding a diverting device_________________________________A-81 Exercise 10: Designing a stamping device________________________________A-91 Exercise 11: Realising a pallet loading station __________________________ A-101 Exercise 12: Eliminating a fault on the pallet loading station_______________ A-107

© Festo Didactic GmbH & Co. KG • 541090 A-1

Contents

A-2 © Festo Didactic GmbH & Co. KG • 541090

Exercise 1: Realising a sorting device

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

Training aims

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

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

• To be able to explain and design an example of direct actuation. A sorting device is to be used to sort water samples according to the size of the sample bottle. Design a control system whereby this process can be carried out.

Problem definition

• A single-acting cylinder is to be used. Parameters • The control of the cylinder is to be effected by means of a pushbutton. • In the event of a power failure the cylinder piston rod is to return into the

retracted end position. 1. Answer the questions or carry out the exercises regarding the fundamentals of

the training contents listed. Project task

2. Draw the pneumatic and electrical circuit diagram. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile an equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.



Positional sketch

Sorting device

1. Pressing of a pushbutton causes the piston rod of a single-acting cylinder to

push the sample bottle off the conveyor. 2. When the pushbutton is released, the piston rod is to return into the retracted

end position.



Exercise 1: Realising the operation of a sorting device

Name: Date:

Fundamentals: Function of pneumatic working components Sheet 1 of 7

Pneumatic working components can be divided into two groups: • Working components using linear movement • Working components using rotary movement – Describe the function of the working components shown.

Symbol 1 Symbol 2 Symbol 3

Description of function

Symbol 1:

Symbol 2:

Symbol 3:




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Fundamentals: Completing solenoid valve symbols Sheet 2 of 7

– Complete the individual symbols with the help of the corresponding component

descriptions.

Description Symbol

Directly actuated 3/2-way

solenoid valve, normally open,

with manual override, with

spring return

2

31 Pilot actuated 3/2-way solenoid

valve, normally closed, with

manual override, with spring

return

2

31




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Fundamentals: Normal positions of directional control valves Sheet 3 of 7

An electrically actuated 3/2-way solenoid valve has two switching positions. It can be in the normal position (unactuated) or in the switching position (actuated). In the normal position the valve can be open or closed. – Describe the effects on the motion sequence of the following application arising

as a result of the different normal positions. The single-acting cylinder shown is controlled by an electrically actuated 3/2-way solenoid valve.

2

1M131

2

1M131

Description: Normal position closed Description: Normal position open




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Fundamentals: Direct and indirect actuation Sheet 4 of 7

An electrically actuated solenoid valve can be actuated either directly or indirectly. – Describe the difference with the help of the following application: Electrical

actuation of a spring-returned 3/2-way solenoid valve using a pushbutton.

Description: Direct actuation Description: Indirect actuation




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Design and function of an electrical switch Sheet 5 of 7

Switches are basically divided into pushbutton and control switch designs and perform the function of a normally open or normally closed contact or changeover switch. – Describe the design and function of the switches shown.

Symbol 1 Symbol 2 Symbol 3

3

4

2

1

42

1

Description: Design/Function




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Fundamentals: Mode of operation of different valve types Sheet 6 of 7

Electrically actuated directional control valves are switches with the help of solenoids. Basically, these can be divided into two groups: • Spring-return solenoid valves • Double solenoid valves – Describe the differences between the two groups with regard to function and

behaviour in the event of power failure.

Valve type Mode of operation

Spring-return valve

Double solenoid valve




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Fundamentals: Port designations of valves Sheet 7 of 7

In order to prevent incorrect tubing up of directional control valves, the valve ports (working and pilot lines) are identified in accordance with ISO 5599, both on the valve itself and in the circuit diagram. – Describe the meaning and function of the designations below.

Designation Meaning, function

3

12

10




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Completing the pneumatic and electrical circuit diagram Sheet 1 of 1

– Complete the pneumatic and electrical circuit diagram for the sorting device.

2

31

Pneumatic circuit diagram

1+24 V

0 V

Electrical circuit diagram




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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


Exercise 2: Realising a shut-off device

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

Training aims

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

Problem definition In a water treatment system numerous pipes need to be opened or and closed by means of shut-off devices. A test setup is to be used to find a possible means of actuating the shut-off valve. • A double-acting cylinder is to be used. Parameters • The cylinder control is to be effected by means of a pushbutton. • In the event of power failure the cylinder piston rod is to return into the retracted

end position. 1. Answer the questions or carry out the exercises regarding the fundamentals of


2. Design the pneumatic and electrical circuit diagrams. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile an equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.



Positional sketch

Shut-off device

1. Pressing of a pushbutton is to cause the valve to open the slide 2. Releasing of the pushbutton is to cause the slide to close.




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Fundamentals: Comparison of directly actuated and pilot actuated valves Sheet 1 of 5

Differentiation is made between directly actuated and pilot actuated solenoid valves with regard to the type of actuation of the valve piston. – Compare these two valve types and describe the respective advantages and

disadvantages.

Directly actuated valve Pilot actuated valve




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Port designations of valves Sheet 2 of 5

In order to prevent incorrect tubing up of directional control valves, valve ports (working and pilot lines) are identified in accordance with ISO 5599-3, both on the valve itself and in the circuit diagram. – Describe the meaning and function of the designations below.

Designation Meaning, function

4

14

82/84




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Fundamentals: Mode of operation of a solenoid valve Sheet 3 of 5

A valve symbol provides information regarding the function of the valve, i.e. the number of ports, switching positions and type of actuation, but not about the constructional design. – Describe the mode of operation of the directional control valve shown.

1M1

24

351

Description: Mode of operation of a directional control valve




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Fundamentals: IP classification Sheet 4 of 5

Depending on the installation and ambient conditions, electrical equipment is protected by means of a housing or cover. The required protection class against dust, humidity and foreign objects is to be identified. The classification IP 65 is shown on a valve – Describe the meaning of this classification.

Description of IP 65 classification




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Fundamentals: Symbols of pneumatic cylinders Sheet 5 of 5

Piston rod cylinders with linear action can be divided into two groups: • Single-acting cylinders • Double-acting cylinders – Describe the meaning of the cylinder symbol shown.

Symbol 1 Symbol 2

Description of symbolic representation




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Completing the pneumatic and electrical circuit diagrams Sheet 1 of 1

– Complete the pneumatic and electrical circuit diagrams for the sorting device.

24

351


1+24 V

0 V





Name: Date:



below.


Equipment list


Exercise 3: Realising a lid press


Training aims

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

Problem definition In a filling plant, wall or ceiling paints are filled into plastic pots. Once filled, slip-lids are to be pressed onto the plastic pots. • A double-acting cylinder is to be used. Parameters • The cylinder control is to be effected indirectly and by means of a pushbutton. In

the event of power failure the cylinder piston rod is to return into the retracted end position.

1. Answer the questions or carry out the exercises regarding the fundamentals of





Positional sketch

Filling of pots of paint

1. Pressing of a pushbutton is to cause the pressing ram to advance and the slip-lid

to be pressed on. 2. Once the pushbutton is released, the pressing ram is to be returned into the

initial position.



Exercise 3: Realising of a lid press

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Fundamentals: Mode of operation of relays Sheet 1 of 4

A relay is a remotely controlled electromagnetically actuated switch with several contacts. The main components are: • Coil with core • Winding of coil • Contact set • Return spring • Armature • Terminal lugs The following illustration shows a sectional representation of a relay. – Allocate the component designations.

124A1 A2

2 3

1

5

67

4




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Fundamentals: Design and mode of operation of relays Sheet 2 of 4

– Describe the mode of operation of a relay.

Description of mode of operation of a relay




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One or several contacts can be switched by a relay coil. Relays with normally closed, normally open or changeover contact(s) are used depending on the function required. Additional designs of electromagnetically actuated switches are for instance a remanence relay, the time relay with switch-on delay, the time relay with switch-off delay and the contactor. – Describe the design and contact alignment of the relays shown.

Description of design/contact alignment Symbol

13 23 31 41

14 24 32 4

A1

A2 2

1412 2422 3432 4442

11 21 31 41

A1

A2




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– List the possible applications of relays in electrical or electropneumatic control

systems.

Description: Possible applications




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– Design the pneumatic and electrical circuit diagrams for the lid press.





Name: Date:


1+24 V

0 V

2

12

22

32

42

14

24

34

44

11

21

31

41





Name: Date:



below.


Equipment list


Exercise 4: Realising the operation of a hinged lid

• To be able to design an example of indirect actuation Training aims • To familiarise yourself with logic operations • To be able to select solenoid valve according to requirements Plastic granulate is to be filled from a storage silo. The silo is to be opened or closed using a hinged lid. The process is to be effected from two points.

Problem definition

• A single-acting cylinder is to be used. Parameters • The cylinder control is to be indirect and via hand levers.

In the event of power failure, the cylinder piston rod is to advance into the forward end position.

1. Answer the questions or carry out the exercises regarding the fundamentals of





Positional sketch

Filling of plastic granulate

1. Pressing of either one of the pushbuttons is to cause the hinged lid to open and

to empty the bulk material from the container. 2. Once the pusbutton is released, the hinged lid closes.




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Fundamentals: Converting solenoid valves Sheet 1 of 3

In industrial practice, there are numerous different requirements with regard to a valve. If a valve with all the required features is not available, it is often possible to use a valve with a different number of ports. The table below lists a selection of directional control valves frequently in use in industrial applications. – Describe the valve types shown. – Identify all solenoid valves that can be replaced by a 5/2-way solenoid valve of

the type shown.. – If measures are required to convert the valve, describe these. Note By „conversion measures“ we understand the simplest of conversions such as the sealing of working ports 2 or 4 using a blanking plug.

1M1

24

351

14

Symbol Description of valve type Replacement possible

Description of necessary conversions

2

1M11

12

2

1M131

12

2

1M131

10

4

1M131

14

2




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Fundamentals: Selecting solenoid valves Sheet 2 of 3

Valves are selected according to the following criteria: • Exercise definition, • Required behaviour in the event of power failure, • Minimum possible overall costs The following valves are available for selection for the actuation of a single-acting cylinder: • A pilot actuated, spring return 3/2way solenoid valve with manual override, • A pilot actuated, spring-return 5/2-way solenoid valve with manual override – Select a valve and explain the reasons for your decision. Note Apart from the cost of the valve, the above overall costs also include the cost of installation, maintenance and storage for replacement parts.

Valve type Reason




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Fundamentals: Logic operations: The OR function Sheet 3 of 3

Triggering the advancing of a cylinder piston rod is to be possible using two pushbuttons S1 and S2. If at least one of the two pushbuttons is actuated, the valve coil 1M1 is energised, the solenoid valve 1V1 switches into the actuated position and the piston rod advances. If both pushbuttons are released, the valve switches into the initial position and the piston rod retracts. – Create the appropriate function table and the logic symbol. Note 0 means: Pushbutton not actuated, i.e. piston rod does not advance 1 means: Pushbutton actuated, i.e. piston rod advances

S1 S2 1M1 1V1

Function table

Logic symbol




Name: Date:


– Design the pneumatic and electrical circuit diagrams for the operation of the

hinged lid.





Name: Date:


K1

1412

11

1

K1 1M1

+24 V 32

0 V

A1

A2

K1

12

22

32

42

14

24

34

44

11

21

31

41





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below.


Equipment list


Exercise 5: Realising a diverting device


Training aims

• To familiarise yourself with the design and mode of operation of a double solenoid valve.

Problem definition Packages are to be pushed from one conveyor to another via a diverting device.

• A double-acting cylinder is to be used. Parameters • The cylinder control is to be effected indirectly and via a pushbutton. In the event

of power failure the cylinder piston rod is to remain in the current position. 1. Answer the questions and carry out the exercises regarding the training contents

listed. Project task




Positional sketch

Diverting device

1. Pressing of a pushbutton is to cause the frame of the diverting device to be

advanced. The package is transferred and transported away. 2. Pressing of another pushbutton causes the frame to be moved into the initial

position.




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Fundamentals: Use of solenoid valves Sheet 1 of 4

Two factors are to be considered regarding the question as to which valve type is to be used for a particular application: • Duration, i.e. time frame, • Quantity or frequency of required switching operations. In order to utilise a directional control valve as efficiently as possible, you will need to decide in each case whether the use • of a double solenoid valve or • a spring-return directional control valve is more cost effective for the required application. – Decide whether a double solenoid or a spring-return solenoid valve seems more

cost effective for the applications listed and explain the reasons for your choice. Application 1 The clamping cylinder of a milling device is to firmly hold in position a workpiece for the duration of a milling operation (duration of approx. 10 min, 60 clamping operations per day).

Valve type Reason

Application 2 The ejecting cylinder of a sorting device is to push defective workpieces from a conveyor (duration of approx.1s, 600 ejecting operations per day).

Valve type Reason




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Fundamentals: Mode of operation of a solenoid valve Sheet 2 of 4

– Describe the mode of operation of the directional control valve shown.

1M1 1M2

24

351

Description of mode of operation of a directional control valve




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Fundamentals: Calculating the current consumption of a valve coil Sheet 3 of 4

A spring-return solenoid valve is to be switched via pushbutton S1. – Calculate the current consumption of the valve coil 1M1 at a voltage supply of

24 V DC and a coil resistance of 48 Ω (Ohm).

1M1

1

S1

13

14

+24 V

0 V

Current consumption in 1M1 Power rating of 1M1




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Fundamentals: Calculate the current consumption of a valve coil Sheet 4 of 4

– Would the current consumption in 1M1 be the same, higher or lower if the above

valve coil is connected to a 24V AC voltage? Explain the reasons for your answer.

Identical Higher Lower Reason




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– Design the pneumatic and electrical circuit diagrams for the diverting device.

1





Name: Date:


1 2+24 V

0 V

3 4

1212

2222

3232

4242

1414

2424

3434

4444

1111

2121

3131

4141





Name: Date:



below.


Equipment list


Exercise 6: Actuation of a stacking magazine

• To be able to use a double-acting cylinder. Training aims • To familiarise yourself with the design and mode of operation of a double

solenoid valve. • To familiarise yourself with the option of sensing the end positions of cylinders.

Problem definition Wooden boards are to be pushed from a stacking magazine into an assembly device. • The forward end position of the cylinder is to be sensed.

Parameters

1. Answer the questions or carry out the exercises regarding the fundamentals of the training contents listed.

Project task




Positional sketch

Stacking magazine

1. Pressing of a pushbutton causes a wooden board to be pushed out of the

stacking magazine. 2. Once the forward end position is reached, the slide is moved into the initial

position.




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Fundamentals: Components of an electropneumatic system Sheet 1 of 6

The components of an electropneumatic system are represented in a pneumatic circuit diagram and/or in an electrical circuit diagram. – Determine where the components below are to be represented.

Component Pneumatic circuit diagram


Manually operated pushbutton

Cylinder

Valves

Valve coils

Relay

Electromechanical limit switch

Electronic proximity sensor

Indicating devices




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Fundamentals: Components of an electropneumatic system Sheet 2 of 6

The function of sensors in electropneumatic control systems is to acquire information and to transmit this for signal processing. – What function(s) can an electromechanical limit switch fulfill in an

electropneumatic control system?

Description: Function(s) of electromechanical limit switches




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Fundamentals: Representation of limit switches Sheet 3 of 6

Limit switches can be actuated in different ways, via the function of a normally closed or normally open contact or changeover switch and, in the normal position of the system, can be either actuated or unactuated. – Describe the appropriate design or function of the symbols shown.

Description: Design/function Symbol

2

1

4

1




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Fundamentals: Creating a logic element table Sheet 4 of 6

One possibility of recording the allocated contacts of a relay is by means of listing these in a logic element table. – Create the logic element tables for relays K6 and K9.

K1

1412

11

K5

1412

11

K6 K7 K8 K9

10

A1 A1 A1 A1

A2 A2 A2 A2

K6 K7 K8 K9 K6 K7

14 14 14 14 34 3414 14 14

24 24 34 3424

12 12 12 12 32 3212 12 12

22 22 32 3222

11 11 11 11 31 3111 11 11

21 21 31 3121

1M1 2M1

12 14 16 18 1913 15 1711

K2 K4 K3

K6 K7 K9 K8K9

+24 V

...

...

0 V

2422

21

K8


Logic element table

Description: Logic element table

K6

K9




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Another method of recording the allocated contact sets of a relay can be seen in the electrical circuit diagram below.

NAEMERGENCY

STOP

K1

1412

11

K5

K11 K11 K11

14

14 24 34

12

12 22 32

11

11 21 31

K6 K7 K8 K9

11 25 27

A1 A1 A1 A1

A2 A2 A2 A2

12 12 12 12

22 22 22 22

32 32 32 32

42 42 42 42

.13 .15 .17 .19

.20

.26

.24

.14 .16 .18

.24

.23

.22 .23

.22

14 14 14 14

24 24 24 24

34 34 34 34

44 44 44 44

11 11 11 11

21 21 21 21

31 31 31 31

41 41 41 41

K6 K7 K8 K9

14 14 14 1414 14 14

2424 24 24

12 12 12 1212 12 12

2222 22 22

11 11 11 1111 11 11

2121 21 21

16 1817 191312

K4 K3

K6K10 K7 K8

S1Start

K1 K2 K3 K4 K5K11

+24 V 2 4 6 8 101 3 5 7 9

0 V

1B1 1B2 2B1 2B2

A1 A1 A1 A1 A1A1

A2 A2 A2 A2 A2A2

13

21

14

22

12 12 12 1212 12

22 22 22 2222 22

32 32 32 3232 32

42 42 42 4242 42

.12

.20

.14 .18

.27

.12.11

.25

.27

.1614 14 14 1414 14

24 24 24 2424 24

34 34 34 3434 34

44 44 44 4444 44

11 11 11 1111 11

21 21 21 2121 21

31 31 31 3131 31

41 41 41 4141 41

2M1

1A1+ 2A1-2A1+ 1A1-

K6 K8K7 K9 K3

34 3434 34 2432 3232 32 22

31 3131 31 21

22 2423 26

44 4444 3442 4242 32

41 4141 31

K7 K9K8 K10

K10A1

A2

12

22

32

42

.21

.12

.26

14

24

34

44

11

21

31

41

K10

1424

24

1222

22

1121

21

20 21

K1

K9

1M1 1M22M2





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– Complete the information regarding the relays shown by:

Indicating the current path in which the respective contact is used and specifying the function fulfilled by the contact set (normally open or normally closed contact).

Relay Current path Function:

Normally open contact

Function:

Normally

closed contact

Relay K9

Relay K10




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– Design the pneumatic and electrical circuit diagrams for the stacking magazine.

1A1

1V1 24

351

1V2 1V31 1

2 2





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K1 K2

14 1412 12

11 11

1 2+24 V

0 V

K1 K2

3 4

A1 A1

A2 A2

1212

2222

3232

4242

1414

2424

3434

4444

1111

2121

3131

4141





Name: Date:



below.


Equipment list


Exercise 7: Sorting of packages

• To be able to calculate piston forces according to specific values Training aims • To be able to calculate electrical characteristic values • To be able to explain and design an example of indirect actuation • To familiarise yourself with logic functions and to be able to design these

Problem definition Packages are to be transported on a conveyor past workstations. The packages can be diverted by means of deflectors. • A double-acting cylinder is to be used. Parameters • The cylinder control is to be effected indirectly via pushbuttons and

electromechanical limit switches. • Triggering of the advancing movement is to be possible only if the piston rod is in

the retracted end position. 1. Answer the questions or carry out the exercises regarding the fundamentals of





Positional sketch

Conveyor belt for packages

1. The piston rod of a cylinder is to advance automatically as soon as pushbutton

S1 is actuated. 2. If the pushbutton is no longer actuated, the piston rod is to assume the retracted

end position.




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Fundamentals: Calculation of piston force Sheet 1 of 3

The piston of a double-acting cylinder has a diameter of 16 mm and the piston rod a diameter of 8 mm. The frictional losses within the cylinder are 10 %. The following applies for double-acting cylinders: Advance stroke Feff = (A • p) – FF Return stroke Feff = (A' • p) – FF Feff = Effective piston force (N) A = Effective piston surface (m2)

= )4

D(

2 π•

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) – Calculate the effective piston force in the advance and return stroke at an

operating pressure of 6 bar (600 kPa).

To be calculated Solution approach

Advance stroke

Return stroke




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Fundamentals: Calculation of electrical characteristic values Sheet 2 of 3

A relay in an electropneumatic circuit is designated as follows: 580 Ω, 1 W. – Calculate the permissible operating voltage which ensures that no overload

occurs on the relay.

To be calculated Solution approach

Max. Operating

voltage




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Fundamentals: Sheet 3 of 3

Triggering of the advancing movement of the piston rod of a cylinder is to be achieved by means of two pushbuttons S1 and S2. The valve coil 1M1 is energised if both pushbuttons are actuated simultaneously and the solenoid valve 1V1 switches into the actuated position causing the piston rod to advance. If at least one of the two pushbuttons is released, the valve switches into the initial position and the piston rod retracts. – Create an appropriate function table and the logic symbol. Note 0 means: Pushbutton not actuated, i.e. piston rod not advancing 1 means: Pushbutton actuated, i.e. piston rod advances

S1 S2 1M1 1V1

Function table

Logic symbol




Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 vof 2

– Configure the pneumatic circuit diagram and design the electrical circuit diagram

for the feeding device.

1M1 1M2

1A1

1V1 24

351

1V2 1V3

1B1 1B2

1 1

2 2





Name: Date:


K3 1M2

1 2+24 V

0 V

K1 K2

3 4

A1 A1

A2 A2

12

22

32

42

14

24

34

44

11

21

31

41

12

22

32

42

14

24

34

44

11

21

31

41

12

22

32

42

14

24

34

44

11

21

31

41

5

1M1





Name: Date:



below.


Equipment list


Exercise 8: Actuation of a sliding platform

• To familiarise yourself with logic functions and to be able to design these Training aims • To be able to explain and design electrical latching circuits with dominant switch-

off signal

Problem definition Wooden boards are to be manually placed onto a sliding platform. The boards are to be pushed under a belt sanding machine by means of a pneumatic drive. • A double-acting cylinder is to be used. Parameters • The cylinder control is to be effected indirectly. 1. Answer the questions or carry out the exercises regarding the fundamentals of


2. Design the pneumatic and electrical circuit diagrams. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile the equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.



Positional sketch

Sliding platform

1. The piston rod of a cylinder is to advance if pushbutton S1 is actuated. 2. Actuation of pushbutton S2 is to cause the piston rod to retract.




Name: Date:

Fundamentals: Signal storage Sheet 1 of 3

The actuation of the pushbutton must be stored if the piston rod of a cylinder is to also advance if the pushbutton is only briefly actuated. This signal storage can be effected either in the power section or in the signal control section of a circuit. – Describe how signal storage is devised in the power section or in the signal

control section respectively.

Place of signal storage Description: Signal storage

Signal storage in the

power section

Signal storage in the

signal control section




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Fundamentals: Analysing circuits Sheet 2 of 3

– Describe the behaviour of the circuit specified (pilot actuated, spring-return

5/2-way solenoid valve with manual override, double-acting cylinder) in the event of – Power failure – Pressure failure.

Power failure Pressure failure




Name: Date:

Fundamentals: Logic functions Sheet 3 of 3

The lamp P1 is to be illuminated whenever pushbutton S1 is not actuated. – Draw up the appropriate function table and the logic symbol(s).

0 means: Pushbutton S1 not actuated, i.e. lamp P1 off 1 means: Pushbutton S1 actuated, i.e. P1 illuminated

S1 P1

Function table

Logic symbol




Name: Date:


– Design the pneumatic and electrical circuit diagrams for the sliding platform.

24

351





Name: Date:


12

22

32

42

14

24

34

44

11

21

31

41

1

K1 1M1

+24 V 32

0 V

A1

A2




Exercise 8: Actuation of a diverting device

Name: Date:



below.


Equipment list


Exercise 9: Expanding a diverting device

• To familiarise yourself with different types of end position control and to be able to select a suitable type.

Training aims

• To familiarise yourself with latching circuits of different characteristics.

Problem definition Packages are to be transferred from one conveyor belt to another via a diverting device using reciprocating strokes. Once switched on, the device is to run continuously and only be switched off via a stop signal. • The latching circuit used is to exhibit a dominant „Off“ behaviour.

Parameters


Project task

2. Design the pneumatic and electrical circuit diagram. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile the equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.



Positional sketch

Diverting device for packages

1. Actuation of the pushbutton is to cause a reciprocating movement of the cylinder

piston rod to drive the diverting device via a latching drive. 2. The packages are to be deflected and transported in the opposite direction. 3. Pressing of a second pushbutton is to switch off the drive.




Name: Date:

Fundamentals: Latching circuits Sheet 1 of 4

A latching relay circuit is required in order to store a signal in the signal control section. – The relay K1 is energised by actuating pushbutton S1. Complete the electrical

circuit diagram below so that the relay latches after the pushbutton S1 is released.

12

22

32

42

14

24

34

44

11

21

31

41

1

S1

K1

+24 V

0 V

A1

A2

13

14





Name: Date:


An additional normally closed contact is required in order to cancel a set self-latching loop. Differentiation is made between two groups depending on the configuration of this normally closed contact: • Dominant setting self-latching loop • Dominant resetting self-latching loop – Complete the electrical circuit diagram below so that the self-latching loop is

reliably cancelled via the actuation of a pushbutton S2.

12

22

32

42

14

24

34

44

11

21

31

41

1

S1

K1

+24 V

0 V

A1

A2

13

14





Name: Date:


The various circuits for signal storage exhibit different behaviour: • with simultaneously applicable set and reset conditions • in the event of power failure or cable fracture – Complete the table and enter the behaviour of the respective valve.

Valve position unchanged/valve is actuated/valve switches to normal position

Signal storage via electrical latching circuit combined with spring-return valve

Signal storage via

double solenoid valve

Dominant setting Dominant resetting

Set and reset signal shared

Power failure




Name: Date:

Fundamentals: Limit switches and proximity sensors Sheet 4 of 4

The function of limit switches and proximity sensors is to acquire information and to transmit this for signal processing. These include: Mechanical position switches (limit switches), magnetic proximity sensors (reed switches), optical proximity sensors, capacitive proximity sensors, inductive proximity sensors – Allocate the designations to the corresponding symbols in the table.

Designation Symbol

BN

BU

BK

BN

BU

BK

BN

BU

BK

42

1

BN

BU

BK




Name: Date:


– Design the pneumatic and electrical circuit diagram for the diverting device.

1M1 1M2

1V1 24

351

1V2 1V3

1A1

1 1

2 2





Name: Date:


12

22

32

42

14

24

34

44

11

21

31

41

K1

1412

11

1

S1

K1 1M1 1M2

+24 V 3 5 7 82 4 6

0 V

A1

A2

S2

31

13

32

14





Name: Date:



below.


Equipment list


Exercise 10: Designing a stamping device

• To be able to design a pressure-dependent reversal control. Training aims • To familiarise yourself with the design and mode of operation of magnetic

proximity sensors.

Problem definition Small mounting blocks are to be stamped during the production of door frames. These blocks are to be stamped by means of a stamping device. • The stamping pressure is to be 5.5 bar (550 kPa).

Parameters


Project task




Positional sketch

Stamping device

1. The pressing of a pushbutton is to cause the stamping device to advance and the

workpiece to be stamped. 2. The stamping tool is to return into the initial position once the stamping pressure

is obtained.




Name: Date:

Fundamentals: Magnetic proximity sensor Sheet 1 of 5

In contrast with limit switches proximity sensors are switched contactlessly and without an external mechanical actuating force. – Describe the design and function of a magnetic proximity sensor (reed switch).

Description: Design and function Symbol Schematic representation

BN

BU

BK




Name: Date:

Fundamentals: Magnetic proximity sensors Sheet 2 of 5

As regards polarity there are two different designs of electronic proximity sensors, i.e. PNP or NPN. – Describe the differences between these two types.

PNP NPN




Name: Date:

Fundamentals: Pressure switches Sheet 3 of 5

Pressure sensitive sensors, so-called PE converters, are used to monitor the pressure in a system. – Describe the mode of operation of PE converter.

Description of mode of operation




Name: Date:

Fundamentals: Pressure sensors Sheet 4 of 5

Pressure sensors can be divided into two groups whereby differentiation is made between: • Pressure sensors with mechanical contact (mechanical principle of action) • Pressure sensors with electronic switching

(electronic principle of action) – Describe the purpose and function of the pressure sensor shown below.

Description: Purpose and function Symbol Schematic representation




Name: Date:

Fundamentals: Choice of proximity sensors Sheet 5 of 5

The end positions of a drive cylinder are to be sensed by means of proximity sensors. The following requirements apply regarding the proximity sensors: • The end positions of the piston rod are to be sensed contactlessly • The proximity sensors are to be insensitive to dust • The piston rod and trip cam of the cylinder are made of metal – Choose which proximity sensors meet the specified requirements and explain

your reasons for this.

Proximity sensor Reason




Name: Date:


– Design the pneumatic and electrical circuit diagrams for the stamping device.

1M1 1M2

1V1 24

351

1V2 1V3

1A1

1 1

2 2





Name: Date:


7

K2 K3K1 1M1 1M2

+24 V 1 3 5 82 4 6

0 V

1B1 1B2 1B3

A1 A1A1

A2 A2 A2

p

12 1212

22 2222

32 3232

42 4242

14 1414

24 2424

34 3434

44 4444

11 1111

21 2121

31 3131

41 4141





Name: Date:



below.


Equipment list


Exercise 11: Realising a pallet loading station

• To familiarise yourself with displacement-step diagrams and to be able to design these for specified problem definitions.

Training aims

• To be able to realise a sequence control using two cylinders.

Problem definition Stacks of roof tiles are to be strapped with a band and then transported to a pallet loading station, where they are to be transferred onto Euro pallets. • Adjust the one-way flow control valve so that both cylinders retract at identical

speed.

Parameters

1. Design the displacement-step diagram. Project task 2. Draw up the corresponding function diagram and function chart. 3. Design the pneumatic and electrical circuit diagrams. 4. Simulate the electropneumatic circuit diagram and check its correct functioning. 5. Compile an equipment list. 6. Carry out the pneumatic and electrical circuit assembly. 7. Check the circuit operation.



Positional sketch

Pallet loading station

1. Cylinder 1A1 is to advance when pushbutton S1 is pressed, whereby a single

package arrives at the loading point and sensor 1B2 is actuated. 2. Cylinder 2A1 advances, actuates sensor 2B2, and pushes the package onto the

pallet. 3. If 2B2 is actuated and S1 is unactuated, cylinder 1A1 retracts. 1B2 is therefore no

longer actuated and cylinder 2A1 retracts. Consequently, the overall sequence is: 1A1+ 2A1+ 1A1– 2A1–




Name: Date:

Fundamentals: Designing the displacement-step diagram Sheet 1 of 3

If pushbutton S1 is actuated, cylinder 1A1 advances whereby the package reaches its loading point and sensor 1B2 is actuated. Cylinder 2A1 advances, actuates sensor 2B2 and pushes the package onto the pallet. If 2B2 is actuated and S1 unactuated, cylinder 1A1 retracts. 1B2 is no longer actuated and cylinder 2A1 retracts. Consequently the overall sequence is: 1A1+ 2A1+ 1A1– 2A1– – Design the displacement-step diagram for the problem definition described.

1A10

1

2A10

1

1 2 3 4=1

Displacement-step diagram




Name: Date:


– Design the pneumatic and electrical circuit diagrams for the pallet loading

station.

1V1 24

351

1V2 1V3

1A1

2V2

2

31

2A1

2V1

1 1

2 2

2

1





Name: Date:


1M1 1M2 2M1

+24 V 1 3 5 6 7 82 4

0 V

1B2 2B2

A1A1 A1

A2 A2 A2

12 12 12

22 22 22

32 32 32

42 42 42

14 14 14

24 24 24

34 34 34

44 44 44

11 11 11

21 21 21

31 31 31

41 41 41

BN

BU

BK

BN

BU

BK





Name: Date:



below.


Equipment list


Exercise 12: Eliminating a fault on the pallet loading station

• To be able to identify and eliminate faults in simple electropneumatic control systems.

Training aims

Problem definition The pallet loading station stops during continuous operation. A fault has occurred and must be eliminated. Thereafter the pallet loading station is to be re-started. • Only one fault has occurred.

Parameters

1. Describe the behaviour of the control system. Compare this with the correct control system behaviour. Use the displacement-step diagram to assist you.

Project task

2. Localise potential causes of the fault with the help of the pneumatic and electrical circuit diagrams.

3. Find the fault in the control system and eliminate it. 4. Re-start the control system.



Pallet loading station 1. Cylinder 1A1 is to advance if pushbutton S1 is pressed. This causes a single

package to reach its loading point thereby actuating sensor 1B2. 2. Cylinder 2A1 advances, actuates sensor 2B2 and pushes the package onto the

pallet. 3. If 2B2 is actuated and S1 unactuated, cylinder 1A1 retracts, 1B2 is no longer

actuated and cylinder 2A1 retracts. Consequently the overall sequence is: 1A1+ 2A1+ 1A1– 2A1–

Positional sketch




Name: Date:

Fault finding in simple electropneumatic circuits Sheet 1 of 4

The following fault occurs in the circuit shown below: The piston rod of cylinder 1A1 and the piston rod of cylinder 2A1 advance and remain in the forward end position. – Describe what the potential causes of the fault could be.

1M1 1M2

1V1 24

351

1V2 1V3

1A11B2 2B2

2V2

2

2M131

2A1

2V1

1 1

2 2

2

1





Name: Date:


K3

1412

11

K2

1412

11

K1

1412

11

K2K1 K3 1M1 1M2 2M1

+24 V 1 3 5 6 7 82 4

0 V

1B2 2B2

A1A1 A1

A2 A2 A2

S1

13

14

12 12 12

22 22 22

32 32 32

42 42 42

.8 .7 .614 14 14

24 24 24

34 34 34

44 44 44

11 11 11

21 21 21

31 31 31

41 41 41

BN

BU

BK

BN

BU

BK


List of potential causes of faults




Name: Date:


A cable break occurs at the areas marked in the circuit shown below. – Describe what the effects of a cable break at these respective points are on the

functioning of the circuit.

K3

1412

11

K2

1412

11

K1

1412

11

K2K1 K3 1M1 1M2 2M1

+24 V 1 3 5 6 7 82 4

0 V

1B2 2B2

A1A1 A1

A2 A2 A2

S1

13

14

12 12 12

22 22 22

32 32 32

42 42 42

.8 .7 .614 14 14

24 24 24

34 34 34

44 44 44

11 11 11

21 21 21

31 31 31

41 41 41

BN

BU

BK

BN

BU

BK





Name: Date:


Fault Effect of fault

Break in earthing wire of

relay K1 (current path 2)

Break in signal line of

sensor 2B2 (current path 4)

Break in supply line of relay

K3 (current path 5)

Break in supply line of relay

contact 14 at K2 (current

path 7)

Break in earthing wire 2M1

(current path 8)




Name: Date:

Fault finding: Determining the required status Sheet 1 of 9

– Create the displacement-step diagram with the help of the documentation given

out.

Time

Designation SignalIdentification

Components

Step

1 2 3 4 5 6 7 8 9 10




Exercise 12: Eliminating a fault in the pallet loading station

Name: Date:

Fault finding: Setpoint/actual comparison Sheet 2 of 9

Determine the ACTUAL status of the system with the help of the following documentation: • Positional sketch with problem description • Graphic representation – If the correct function is not given (REFERENCE/ACTUAL comparison), clearly

mark the area in the diagram where the fault occurs.

Time

Designation SignalIdentification

Components

Step

1 2 3 4 5 6 7 8 9 10





Name: Date:

Fault finding: Description of faults Sheet 3 of 9

You have marked the area where a fault occurs in the diagram of the worksheet ‘REFERENCE/ACTUAL comparison. – Describe the process up the point where the station or system stops. _____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




Name: Date:

Fault finding: Definition of faults - pneumatics Sheet 4 of 9

Once you have established the ACTUAL status of the system, consider what the causes of the faults could be. In which pneumatic tubing connections could the fault occur? – Enter all the possibilities and indicate components at the start and end of the

tubing connection in order to ensure clear identification.

Potential fault No.

Tubing connection Start

End

Potential faults




Name: Date:

Fault finding: Definition of faults – electrics Sheet 5 of 9

Once you have established the ACTUAL status of the system, consider what the causes of the faults could be. • In which current paths could the fault be located? • What is the function of the current path? – Enter all the possibilities.

Potential fault No.

Current path No. Function of current path

Potential faults




Name: Date:

Fault finding: Localisation of faults - pneumatics Sheet 6 of 9

Investigate the potential causes of errors you have found in the pneumatics. • Use the same fault numbering that you have used for the worksheet ‘Definition

of faults – pneumatic. • Document the procedure used to investigate the tubing connections. – Enter the results of your investigation.

Measuring and test protocol

Potential fault No.

Tubing connection Start

End

Inspection Result





Name: Date:

Fault finding: Localisation of faults Sheet 7 of 9

Investigate the potential error causes you have found. • Use the same fault numbering that you have used in the worksheet ‘Definition of

faults - electrics’. • Document the procedure you have used to check the line connection. – Enter the result of the investigation.


Potential fault No.

Current path No.

Measuring points

Inspection Result





Name: Date:

Fault finding: Elimination of fault Sheet 8 of 9

Once you have localised the failure location, your procedure for the elimination of the fault must be documented on this worksheet. – Describe each of the steps carried out in detail. _____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

Note In the event of the system not fulfilling the intended function return to the first worksheet and repeat the fault finding. Ask for new worksheet s to do so.




Name: Date:

Fault finding: Re-starting Sheet 9 of 9

Once you have identified, localised and eliminated the fault, re-start the system in accordance with the required status. Reset the specified required times. – Briefly document the procedure followed in note form. _____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________


electro-pneumatics seminar

Documents

sorting device exercise

exercises exercise

sorting device n

diverting device

stamping device

sorting of packages

circuit operation

festo didactic gmbh