Electropneumatics Basic Level

Festo worldwide

Austria Festo Gesellschaft m.b.H. Linzer Straße 227 1140 Wien Tel. ++43 (0)1/9 10 75-0, Fax 9 10 75-250 E-mail: [email protected] Belarus IP Festo Minsk, 220035 Mascherov Prospekt, 78 Belarus Tel. ++375 (0)17/204 85 58, Fax 204 85 59 E-mail: [email protected] Belgium Festo Belgium sa/nv Rue Colonel Bourg 101 1030 Bruxelles/Brussel Tel. ++32 (0)2/702 32 11, Fax 702 32 09 E-mail: [email protected] Brazil Festo Automação Ltda. Rua Guiseppe Crespi, 76 KM 12,5 - Via Anchieta 04183-080 São Paulo SP-Brazíl Tel. ++55 (0)11/50 13 16 00, Fax 50 13 18 68 E-mail: [email protected] Bulgaria Festo EOOD 1592 Sofia 9, Christophor Kolumb Blvd. Tel. ++359 (0)2/960 07 12, Fax 960 07 13 E-mail: [email protected] Canada Festo Inc. 5300 Explorer Drive Mississauga, Ontario L4W 5G4 Tel. ++1 (0)905/624 90 00, Fax 624 90 01 E-mail: [email protected] Chile Festo S.A. Mapocho 1901 6500151 Santiago de Chile Tel. ++56 (0)2/690 28 00, Fax 695 75 90 E-mail: [email protected] China Festo (China) Ltd. 1156 Yunqiao Road Jinqiao Export Processing Zone Pudong, 201206 Shanghai, PRC Tel. ++86 (0)21/58 54 90 01, Fax 58 54 03 00 E-mail: [email protected] Colombia Festo Ltda. Avenida El Dorado No. 98-43 Bogotá Tel. ++57 (0)1/404 80 88, Fax 404 81 01 E-mail: [email protected]

Japan Festo K.K. 1-26-10 Hayabuchi, Tsuzuki-ku Yokohama 224-0025 Tel. ++81 (0)45/593 56 10, Fax 593 56 78 E-mail: [email protected]

Singapore Festo Pte. Ltd. 6 Kian Teck Way Singapore 628754 Tel. ++65/62 64 01 52, Fax 62 61 10 26 E-mail: [email protected]

Finland Festo OY Mäkituvantie 9, P.O. Box 86 01511 Vantaa Tel. ++358 (09)/87 06 51, Fax 87 06 52 00 E-mail: [email protected]

Korea South Festo Korea Co., Ltd. 470-1 Gasan-dong, Geumcheon-gu Seoul #153-803 Tel. ++82 (0)2/850 71 14, Fax 864 70 40 E-mail: [email protected]

Slovakia Festo spol. s r.o. Gavlovicová ul. 1 83103 Bratislava 3 Tel. ++421 (0)2/49 10 49 10, Fax 49 10 49 11 E-mail: [email protected]

France Festo Eurl Numéro Indigo Tel. 0820/204640, Fax 204641 ZA des Maisons Rouges 8 rue du Clos Sainte Catherine 94367 Bry-sur-Marne cedex Tel. ++33 (0)1/48 82 64 00, Fax 48 82 64 01 E-mail: [email protected]

Latvia Festo SIA Deglava 60 1035 Riga Tel. ++371 67/57 78 64, Fax 57 79 46 E-mail: [email protected]

Slovenia Festo d.o.o. Ljubljana IC Trzin, Blatnica 8 1236 Trzin Tel. ++386 (0)1/530 21 00, Fax 530 21 25 E-mail: [email protected]

Lithuania Festo UAB Karaliaus Mindago pr. 22 3000 Kaunas Tel. ++370 (8)7/32 13 14, Fax 32 13 15 E-mail: [email protected]

South Africa Festo (Pty) Ltd. 22-26 Electron Avenue, P.O. Box 255 Isando 1600 Tel. ++27 (0)11/971 55 00, Fax 974 21 57 E-mail: [email protected]

Malaysia Festo Sdn.Berhad 10 Persiaran Industri Bandar Sri Damansara, Wilayah Persekutuan 52200 Kuala Lumpur Tel. ++60 (0)3/62 86 80 00, Fax 62 75 64 11 E-mail: [email protected]

Spain Festo Pneumatic, S.A. Tel. 901243660 Fax 902243660 Avenida Granvia, 159 Distrito económico Granvia L'H ES-08908 Hospitalet de Llobregat, Barcelona Tel. ++ 3493/261 64 00, Fax 261 64 20 E-mail: [email protected]

Germany Festo Didactic GmbH & Co. KG Postfach 10 07 10 73707 Esslingen Rechbergstraße 3 73734 Esslingen Tel. ++49 (0)711/3467-0 Fax ++49 (0)711/347-54 88500 E-mail: [email protected] Greece Festo Ltd. 40 Hamosternas Ave. 11853 Athens Tel. ++30 210/341 29 00, Fax 341 29 05 E-mail: [email protected] Hong Kong Festo Ltd. Unit C&D, 7/F, Leroy Plaza 15 Cheung Shun Street Cheung Sha Wan, Kowloon Hong Kong Tel. ++ 852/27 43 83 79, Fax 27 86 21 73 E-mail: [email protected] Hungary Festo Kft. Csillaghegyi út 32-34. 1037 Budapest Tel. ++36 1/436 51 11, Fax 436 51 01 E-mail: [email protected] India Festo Controls Private Ltd. 237B, Bommasandra Industrial Area, Bangalore Hosur Highway, Bangalore 560 099 Tel. ++91 (0)80/22 89 41 00, Fax 783 20 58 E-mail: [email protected] Indonesia PT. Festo JL. Sultan Iskandar Muda No.68 Arteri Pondok Indah Jakarta 12240 Tel. ++62 (0)21/27 50 79 00, Fax 27 50 79 98 E-mail: [email protected] Iran Festo Pneumatic S.K. # 2, 6th street, 16th avenue, Tehran 1581975411 Km 8, Special Karaj Road, P.O.Box 15815-1485 Tehran 1389793761 Tel. ++98 (0)21 44 52 24 09, Fax ++98 (0)21 44 52 24 08 E-mail: [email protected]

Mexico Festo Pneumatic, S.A. Av. Ceylán 3 Col. Tequesquinahuac 54020 Tlalnepantla, Edo. de México Tel. ++52 (01)55/53 21 66 00, Fax 53 21 66 55 E-mail: [email protected]

Sweden Festo AB Stillmansgatan 1, P.O. Box 21038 20021 Malmö Tel. ++46 (0)40/38 38 40, Fax 38 38 10 E-mail: [email protected]

Netherlands Festo B.V. Schieweg 62 2627 AN Delft Tel. ++31 (0)15/251 88 99, Fax 261 10 20 E-mail: [email protected]

Switzerland Festo AG Moosmattstrasse 24 8953 Dietikon ZH Tel. ++41 (0)44/744 55 44, Fax 744 55 00 E-mail: [email protected]

New Zealand Festo Limited MT. Wellington Auckland NZ Tel. ++64 (0)9/574 10 94, Fax 574 10 99 E-mail: [email protected]

Taiwan Festo Co., Ltd. Head Office 24450, No. 9, Kung 8th Road Linkou 2nd Industrial Zone Linkou 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]

Nigeria Festo Automation Ltd. Motorways Centre, First Floor, Block C Alausa, Ikeja, Lagos, NIGERIA Tel. ++234 (0)1/794 78 20, Fax 555 78 94 E-mail: [email protected] Norway Festo AS Ole Deviks vei 2 0666 Oslo, Norway Tel. ++47 22 72 89 50, Fax ++47 22 72 89 51 E-mail: [email protected] Peru Festo S.R.L. Calle Amador Merino Reyna #480, San Isidro Lima, Perú Tel. ++51 (0)1/222 15 84, Fax 222 15 95 Philippines Festo Inc. KM 18, West Service Road South Superhighway 1700 Paranaque City, Metro Manila Tel. ++63 (0)2/776 68 88, Fax 823 42 19 E-mail: [email protected]

With CD-ROM

+24 V

Turkey Festo San. ve Tic. A.S. Tuzla Mermerciler Organize Sanayi Bölgesi, 6/18 TR 34956 Tuzla - Istanbul/TR Tel. ++90 (0)216/585 00 85, Fax 585 00 50 E-mail: [email protected] Ukraine Festo Ukraina Borisoglebskaja 11 Kiev 04070 Tel. ++380 (0)44/239 24 33, Fax 463 70 96 E-mail: [email protected] United Kingdom Festo Limited Applied Automation Centre, Caswell Road Brackmills Trading Estate Northampton NN4 7PY Tel. ++44 (0)1604/66 70 00, Fax 66 70 01 E-mail: [email protected]

Croatia Festo d.o.o. Nova Cesta 181 10000 Zagreb Tel. ++385 (0)1/619 19 69, Fax 619 18 18 E-mail: [email protected] Czech Republic Festo, s.r.o. Modøanská 543/76 147 00 Praha 4 Tel. ++420 261 09 96 11, Fax 241 77 33 84 E-mail: [email protected]

Israel Festo Pneumatic Israel Ltd. P.O. Box 1076, Ha'atzma'ut Road 48 Yehud 56100 Tel. ++972 (0)3/632 22 66, Fax 632 22 77 E-mail: [email protected]

Romania Festo S.R.L. St. Constantin 17 010217 Bucuresti Tel. ++40 (0)21/310 29 83, Fax 310 24 09 E-mail: [email protected]

United States Festo Corporation (New York) Call Toll-free 800/993 3786 Fax Toll-free 800/963 3786 395 Moreland Road, P.O.Box 18023 Hauppauge, N.Y. 11788 Tel. ++ 1(0)314/770 01 12, Fax 770 16 84 E-mail: [email protected]

Denmark Festo A/S Islevdalvej 180 2610 Rødovre Tel. ++45 70 21 10 90, Fax ++45 44 88 81 10 E-mail: [email protected]

Italy Festo S.p.A Via Enrico Fermi 36/38 20090 Assago (MI) Tel. ++39 02/45 78 81, Fax 488 06 20 E-mail: [email protected]

Russia Festo-RF OOO Michurinskiy prosp., 49 119607 Moskow Tel. ++7 495/737 34 00, Fax 737 34 01 E-mail: [email protected]

Venezuela Festo C.A. Av. 23, Esquina calle 71, No. 22-62 Maracaibo, Edo. Zulia Tel. ++58 (0)261/759 09 44, Fax 759 04 55 E-mail: [email protected]

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13 S1

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K1 11

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A1

K1

A2

0V 11

12 14 .2

21

22 24

31

32 34

41

42 44

1M1

1A1

Thailand Festo Ltd. 67/1 Moo 6 Phaholyothin Road Klong 1, Klong Luang, Pathumthani 12120 Tel. ++66 29 01 88 00, Fax ++66 29 01 88 33 E-mail: [email protected]

Ireland Festo Limited Unit 5 Sandyford Park Sandyford Industrial Estate Dublin 18 Tel. ++ 353(0)1/295 49 55, Fax 295 56 80 E-mail: [email protected]

Poland Festo Sp. z o.o. Janki k/Warszawy, ul. Mszczonowska 7 05090 Raszyn Tel. ++48 (0)22/711 41 00, Fax 711 41 02 E-mail: [email protected]

Workbook TP 201

1V2

Workbook TP 201

Australia Festo Pty. Ltd. Head Office (Melbourne) 179-187 Browns Road, P.O. Box 261 Noble Park Vic. 3174 Call Toll Free 1300 88 96 96 Fax Toll Free 1300 88 95 95 Tel. ++ 61(0)3/97 95 95 55, Fax 97 95 97 87 E-mail: [email protected]

Estonia Festo OY AB Eesti Filiaal Laki 11B 12915 Tallinn Tel. ++372 666 15 60, Fax ++372 666 15 61 E-mail: [email protected]

Electropneumatics, Basic level

Argentina Festo S.A. Edison 2392 (B1640 HRV) Martinez Prov. Buenos Aires Tel. ++54 (0)11/47 17 82 00, Fax 47 17 82 82 E-mail: [email protected]

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Festo Didactic 541090 EN

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. Status: Authors: Editor: Graphics: Layout:

541090 06/2009 M. Pany, S. Scharf Frank Ebel Doris Schwarzenberger 01/2010

© Festo Didactic GmbH & Co. KG, D-73770 Denkendorf, 2010 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.

Table of Contents Preface _________________________________________________________________________________ V Introduction ____________________________________________________________________________ VII Safety precautions and work instructions ____________________________________________________ VIII Technology module for electro-pneumatics (TP200) ______________________________________________X Learning objectives for the basic level (TP201) _________________________________________________ XI Overview of learning objectives per exercise __________________________________________________ XII Equipment set for the basic level (TP201) ____________________________________________________ XIII Allocation of equipment per exercise _______________________________________________________ XVII Practical tools for the trainer ______________________________________________________________ XVIII Structure of the exercises ________________________________________________________________ XVIII Designations of the components___________________________________________________________ XVIII CD ROM contents ________________________________________________________________________ XIX Equipment set for the advanced level (TP202) _________________________________________________ XXI Learning objectives for the advanced level (TP202)____________________________________________ XXII

Solutions Exercise 1: Inspecting beverage cases _________________________________________________________1 Exercise 2: Opening and closing a supply pipe ________________________________________________ 13 Exercise 3: Sealing plastic cans _____________________________________________________________ 23 Exercise 4: Packing plastic pellets___________________________________________________________ 33 Exercise 5: Diverting packages _____________________________________________________________ 41 Exercise 6: Pushing wooden boards out of a stacking magazine __________________________________ 51 Exercise 7: Sorting packages _______________________________________________________________ 61 Exercise 8: Sanding wooden boards _________________________________________________________ 69 Exercise 9: Diverting bottles _______________________________________________________________ 77 Exercise 10: Stamping taper keys ___________________________________________________________ 87 Exercise 11: Palletising roof tiles ___________________________________________________________ 99 Exercise12: Eliminating a malfunction at a pallet loading station _________________________________ 107

© Festo Didactic GmbH & Co. KG 541090

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IV

© Festo Didactic GmbH & Co. KG 541090

Preface Festo Didactic’s training system for automation and technology is geared towards various educational backgrounds and vocational requirements. The training packages are therefore broken down as follows: Basic modules impart basic, interdisciplinary, technological knowledge. Technology modules address the important topics of open and closed-loop control technology. Function modules explain the fundamental functions of automated systems. Application modules enable training and further education that is aligned to real-life practice. The technology modules deal with various technologies including pneumatics, electro-pneumatics, programmable logic controllers, automation using a personal computer, hydraulics, electro-hydraulics, proportional hydraulics and applications technology (handling).

The modular design of the training system makes it possible to focus on applications above and beyond those covered in the individual modules, such as, for example, PLC actuation of pneumatic, hydraulic and electric drives.

© Festo Didactic GmbH & Co. KG 541090

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All training modules have the same structure: • Hardware • Courseware • Software • Seminars The hardware is comprised of industrial components and systems that are specially designed for training purposes. The structure of the courseware corresponds to that of the training hardware. It includes: • Textbooks (with exercises and examples) • Workbooks (with practical exercises, supplementary instructions and solutions) • Transparencies and videos (for dynamic instruction) The working materials for TP201 consist of 19 exercises and a workbook. Each exercise has its own set of ready-to-use worksheets. The solutions are included in the workbook, which also has the worksheets and a CD ROM. The exercises can be purchased without the workbook and are used as consumables. They can thus be easily made available to trainees. Data sheets for the hardware components are made available along with the training module and on the CD ROM. The teaching and learning media are available in several languages. They’re intended for use in classroom instruction, but are also suitable for self-study. Where software is concerned, computer training programs and programming software are made available for programmable logic controllers. A wide range of seminars covering the contents of the technology module round off the programme for training and further education.

VI

© Festo Didactic GmbH & Co. KG 540671

Introduction This workbook is part of the training system for automation and technology from Festo Didactic GmbH & Co. KG. The system provides a solid basis for practical training and further education. The TP200 technology module only includes electro-pneumatic control systems. The TP201 basic level is suitable for basic training in the field of electro-pneumatic control technology. It covers the fundamentals of electro-pneumatics as well as the function and use of electro-pneumatic equipment. Simple electro-pneumatic control systems can be set up with the equipment set. The TP202 advanced level is targeted at vocational training in the field of electro-pneumatic control technology. The two equipment sets can be used to set up extensive combinatory circuits with linking of the input and output signals, as well as programme control systems. A permanent workstation equipped with a Festo Didactic profile plate is a prerequisite for setting up the control systems. The profile plate has 14 parallel T-slots at 50 mm intervals. A power supply with shortcircuit protection is used as a direct voltage source (input: 230 V, 50 Hz, output: 24 V, max. 5 A). A portable compressor with silencer (230 V, max. 8 bar = 800 kPa) can be used for compressed air supply. Working pressure should not exceed 6 bar (600 kPa).

Ideal reliability can be achieved by operating the control system at a working pressure of 5 bar (500 kPa) without oil. All the control systems for the 12 exercises are set up using the equipment set for the TP201 basic level. The theoretical fundamentals for understanding this collection of exercises are included in the textbook: •

Electro-pneumatics

Data sheets for the individual components are also available (cylinders, valves, measuring instruments etc.).

© Festo Didactic GmbH & Co. KG 541090

VII

Safety precautions and work instructions

General Trainees should only work with the control systems under the supervision of a trainer. Observe specifications included in the data sheets for the individual components and in particular all safety instructions!

Mechanical • Mount all of the components securely onto the profile plate. • Limit switches may not be actuated frontally. • Danger of injury during troubleshooting! • Use a tool to actuate the limit switches, for example a screwdriver. • Only reach into the set-up when it’s at a complete standstill.

Electrical • Electrical connections must only be established and interrupted in the absence of voltage! • Use connector cables with safety plugs only for electrical connections. • Use low-voltage only (max. 24 V DC).

Pneumatics • Do not exceed the maximum permissible pressure of 6 bar (600 kPa). • Do not switch on the compressed air until all the tubing connections have been completed and secured. • Do not disconnect tubing while under pressure. • Danger of injury when switching compressed air on! Cylinders may advance and retract automatically. • Danger of accident due to tubing slipping off! Use shortest possible tubing connections. Wear safety glasses. In the event that tubing slips off: Switch compressed air supply off immediately. • Pneumatic circuit set-up: Connect the components using plastic tubing with an outside diameter of 4 or 6 mm. Push the tubing into the push-in connector as far as it will go. Switch compressed air supply off before dismantling the circuit. • Dismantling pneumatic circuits: Press the blue release ring down, after which the tubing can be pulled out.

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© Festo Didactic GmbH & Co. KG 540671

The mounting boards for the components are equipped with mounting variants A through D: Variant A, snap-in system Lightweight components that are not load-bearing (e.g. directional control valves). Simply clip the component into the slot on the profile plate. Release the component from the slot by actuating the blue lever. Variant B, bolt system Components with medium load capacity (e.g. drives). These components are clamped to the profile plate using T-head bolts. The blue, knurled nut is used for clamping and loosening. Variant C, screw system For components with high load capacity and components which are seldom removed from the profile plate (for example on-off valve with filter regulator). These components are secured with socket head screws and T-head bolts. Variant D, plug-in system Lightweight components with locking pins that are not load-bearing (e.g. indicators). These are secured using plug adapters. Observe specifications in the data sheets regarding the individual components.

© Festo Didactic GmbH & Co. KG 540671

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Technology module for electro-pneumatics (TP200) The TP200 technology packet consists of a multitude of training materials and seminars. The subject matter is entirely focused on electro-pneumatic control systems. Individual components included in the TP200 technology module can also be included in any of the other modules. Important elements of the TP200: • Permanent workstation with Festo Didactic profile plate • Compressor (230 V, 0.55 kW, max. 8 bar = 800 kPa) • Equipment sets or individual components • Optional training materials • Practical training models • Complete laboratory set-ups Training documentation Textbooks

TP201 basic level Fundamentals of pneumatic control technology Maintenance of pneumatic equipment and systems

Workbooks

Optional courseware

TP201 basic level TP202 advanced level Set of transparencies and overhead projector Magnetic symbols, drawing template Electro-pneumatics WBT, pneumatics WBT Electrical engineering WBTs 1 and 2, electronics WBTs 1 and 2 Set of cutaway models with storage case FluidSIM® pneumatic simulation software

Seminars P100

Basic pneumatics knowledge for machine operators

P111

Fundamentals of pneumatics and electro-pneumatics

P121

Maintenance and troubleshooting for pneumatic and electro-pneumatic systems

P-OP

Tracking down waste – economic use of pneumatics

P-NEU

Pneumatics refresher and update

IW-PEP

Repair and maintenance in the field of control technology – pneumatic and electro-pneumatic systems

P-AL

Pneumatics for further education

P-AZUBI

Pneumatics and electro-pneumatics for trainees

Please refer to the current seminar planner for locations, dates and prices. You’ll find further training materials in our catalogue and on the Internet. The training system for automation and technology is continuously updated and expanded. Transparencies, videos, CD ROMs and DVDs, as well as textbooks, are offered in several languages.

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© Festo Didactic GmbH & Co. KG 540671

Learning objectives for the basic level (TP201) • • • • • • • • • • • • • • • • • • • •

Become familiar with the set-up and mode of operation of a single-acting cylinder. Become familiar with the set-up and mode of operation of a double-acting cylinder. Be able to calculate piston forces based on specified values. Become familiar with the set-up and mode of operation of a 3/2-way solenoid valve. Become familiar with the set-up and mode of operation of a double solenoid valve. Be able to select solenoid valves based on the specified requirements. Be able to recognise and sketch the various types of actuation for directional control valves. Be able to convert solenoid valves. Be able to explain and set up direct actuation. Be able to explain and set up indirect actuation. Become familiar with logic operations and be able to set them up. Become familiar with various types of end-position control and learn to select the appropriate type. Be able to calculate characteristic electrical values. Become familiar with latching circuits with varying performance features. Be able to explain and set up an electrical latching circuit with dominant shutdown signal. Be able to set up a pressure-dependent control system. Become familiar with the set-up and mode of operation of magnetic proximity switches. Become familiar with displacement-step diagrams and learn to create them for specific problems. Be able to implement sequence control with two cylinders. Be able to detect and eliminate errors in simple electro-pneumatic control systems.

© Festo Didactic GmbH & Co. KG 541090

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Overview of learning objectives per exercise Exercise

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11

12

Learning objectives Become familiar with the set-up and mode of operation of a single-acting cylinder.

•

Become familiar with the set-up and mode of operation of a double-acting cylinder.

•

Learn to calculate piston forces based on specified values. Become familiar with the set-up and mode of operation of a 3/2-way valve.

• •

Become familiar with the set-up and mode of operation of a double solenoid valve.

•

Be able to select solenoid valves based on the specified requirements. Be able to recognise and sketch the various types of actuation for directional control valves.

• • •

Be able to convert solenoid valves. Be able to explain and set up direct actuation. Be able to explain and set up indirect actuation.

•

• •

•

Become familiar with various types of end-position control and learn to select the appropriate type. Become familiar with logic operations and be able to set them up. Be able to calculate characteristic electrical values.

• •

•

• • •

Become familiar with latching circuits with varying performance features.

•

Be able to explain and set up an electrical latching circuit with dominant breaking signal.

•

Be able to set up a pressure-dependent control

•

system.

•

Become familiar with the set-up and mode of operation of magnetic proximity switches.

•

Become familiar with displacement-step diagrams and learn to create them for specific problems.

•

Be able to implement sequence control with two

•

cylinders. Be able to detect and eliminate errors in simple electro-pneumatic control systems.

XII

•

•

© Festo Didactic GmbH & Co. KG 541090

Equipment set for the basic level (TP201) The equipment set has been put together for basic training in the field of electro-pneumatic control technology. It includes all the elements that are necessary for mastering the specific learning objectives and can be supplemented with any other equipment sets. A profile plate, an electrical power supply unit and a source of compressed air are also required in order to set up functional control systems. Equipment set for the basic level (TP201) Designation

Order no.

Quantity

2 x 3/2-way solenoid valve, normally closed

539776

1

5/2-way double solenoid valve

539778

2

5/2-way solenoid valve

539777

1

Blanking plug

153267

10

Double-acting cylinder

152888

2

One-way flow control valve

193967

4

Pressure sensor

539757

1

Single-acting cylinder

152887

1

On-off valve with filter regulator

540691

1

Limit switch, electrical, actuated from left

183322

1

Limit switch, electrical, actuated from right

183322

1

Plastic tubing, 4 x 0.75, 10 m

151496

2

Proximity switch, electronic

540695

2

Proximity switch, optical

178577

1

Relay, 3-way

162241

2

Signal input, electrical

162242

1

Push-in sleeve

153251

10

Push-in T-connector

153128

20

Distributor block

152896

1

© Festo Didactic GmbH & Co. KG 541090

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Equipment set symbols Designation

Symbol

Relay, 3-way

A1

12 14

22 24

32 34

42 44

11

21

31

41

12 14

22 24

32 34

42 44

11

21

31

41

12 14

22 24

32 34

42 44

11

21

31

41

A2 A1

A2 A1

A2

Signal input, electrical

13

21

14

22

13

21

14

22

3/2-way solenoid valve, normally closed

13

21

14

22

13

21

14

22

12 1M1

2

1

3

1M1

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© Festo Didactic GmbH & Co. KG 541090

Designation

Symbol

5/2-way double solenoid valve

5/2-way solenoid valve

Proximity switch, electronic

Pressure sensor p

Proximity switch, optical

Electrical limit switch 2

4 1

One-way flow control valve

1

© Festo Didactic GmbH & Co. KG 541090

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Designation

Symbol

Single-acting cylinder

Double-acting cylinder

On-off valve with filter regulator

1 2

3

Distributor block

Connectors

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© Festo Didactic GmbH & Co. KG 541090

Allocation of equipment per exercise Exercise

1

2

3

4

5

6

7

8

9

10

11

12

1

1

Components Cylinder, single-acting

1

Cylinder, double-acting One-way flow control valve

1

3/2-way solenoid valve, normally closed

1

5/2-way solenoid valve

1 1

1

2

2

1

1

1

1

1

1

1

1

1

2

2

2

2

2

2

3

3

1

1

1

1

1

2

1

1

1

1

1

(1) 1

1

1

5/2-way double solenoid valve

1 1

1

1

1

Pressure sensor

1 1

Limit switch, electrical

1

2

Proximity switch, normally open

2

2

Proximity switch, optical Pushbutton, electrical, normally open

1

1

1

2

2

1

1

Pushbutton, electrical, normally closed Relay

1

1

1

1

1

1

2

2

3

1

3

3

3

3

Distributor block

1

1

1

1

1

1

1

1

1

1

1

1

On-off valve with filter regulator

1

1

1

1

1

1

1

1

1

1

1

1

Power supply unit, 24 V DC

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

5/2-way solenoid valve

© Festo Didactic GmbH & Co. KG 541090

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Practical tools for the trainer Learning objectives The basic learning objectives for the exercises in this module are the systematic sketching of circuit diagrams as well as the practical set-up of a control system on the profile plate. This direct interaction involving both theory and practice ensures faster, long-term learning. Each exercise has its own individual learning objectives; the specific learning objectives are documented in the matrix. Required time The time required for the exercises depends on the trainee’s previous knowledge of the subject matter. For training a skilled labourer in metalworking or electrical installation: approx. 2 weeks. For training a technician or engineer: approx. 1 week. Equipment sets The exercises and the equipment sets match each other. For all the exercises you’ll only need the components included in the equipment set for the TP201 basic level. Each exercise in the basic level can be set up on a profile plate.

Structure of the exercises All 12 exercises in part A have the same structure and are broken down into: • Title • Learning objectives • Presentation of the problem • Layout • Parameters • Project assignment • Worksheets The solutions for all the 12 exercises are included in the trainer’s manual.

Designations of the components Pneumatic components are designated in circuit diagrams to DIN ISO 1219 2. All the components included in any given circuit have the same primary identifying number. Letters are assigned depending on each respective type of component. Consecutive numbers are assigned if several components of the same type are included within a single circuit. Pressure lines are designated with a P and are numbered separately. Drives: Valves: Sensors: Signal input: Accessories: Pressure lines:

XVIII

1A1, 2A1, 2A2 ... 1V1, 1V2, 1V3, 2V1, 2V2, 3V1 ... 1B1, 1B2 ... 1S1, 1S2 ... 0Z1, 0Z2, 1Z1 ... P1, P2 ...

© Festo Didactic GmbH & Co. KG 540671

CD ROM contents The CD ROM provides you with additional media. The contents of parts A (exercises) and C (solutions) have been saved as PDF files. The CD ROM has the following structure: • Operating instructions • Data sheets • Demo • Festo catalogue • FluidSIM® circuit diagrams • Industrial applications • Presentations • Product information • Videos Operating instructions Operating instructions for various components included in the technology module are available. These instructions are helpful when using and commissioning the equipment. Data sheets The data sheets for the components included in the technology module are available as PDF files. Demo A demo version of the FluidSIM® pneumatics software package is included on the CD ROM. Even this demo version is suitable for testing control systems developed by the user. Festo catalogue The relevant pages from the Festo catalogue will be provided with selected components. The representations and descriptions of the components are intended to demonstrate how the components are presented in an industrial catalogue. Additional information regarding the components is also included. FluidSIM® circuit diagrams The FluidSIM® circuit diagrams for all 12 exercises included in the technology module are contained in this directory. Industrial applications Photos and graphics representing industrial applications are made available. These can be used to illustrate individual tasks. Project presentations can also be supplemented with these illustrations. Presentations Contains short presentations of the components included in the technology module. These can be used, for example, to create project presentations.

© Festo Didactic GmbH & Co. KG 541090

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Product information This directory contains product information and data sheets from Festo AG & Co. KG for the components included in this technology module. This is intended to demonstrate which information and data are available for industrial components. Videos Several videos of industrial applications complete the media provided with the technology module. Short clips demonstrate the applications in their actual industrial environments.

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© Festo Didactic GmbH & Co. KG 540671

Equipment set for the advanced level (TP202) The equipment set for the advanced level has been put together for vocational training in the field of electropneumatic control technology. The two equipment sets (TP201 and TP202) include components that are necessary for mastering the predefined learning objectives and can be supplemented as required with other equipment sets from the training system for automation and technology. Equipment set for the advanced level (TP202, order no. 540713) Quantity

Designation

Order no.

2

Relay, 3-way

162241

1

Signal input, electrical

162242

1

Time relay, 2-way

162243

1

Preset counter, electrical

162355

1

Proximity switch, inductive

178574

1

Proximity switch, capacitive

178575

1

Emergency-stop button

183347

1

Valve terminal with 4 valve slices (MMJJ)

540696

2

Non-return valve, piloted

540715

© Festo Didactic GmbH & Co. KG 541090

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Learning objectives for the advanced level (TP202) • • • • • • • • • • •

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Describe the structure and application of valve terminals Implement sequence controls with overlapping signals – solution according to group method Implement sequence controls with overlapping signals – solution with step sequence using spring return valves Implement sequence controls with overlapping signals – solution with step sequence using double pilot valve (with control step) Describe and set up modes of operation (single/continuous cycle) Describe the function and application of a preset counter Explain and implement the emergency stop function with spring return valves Implement special emergency stop conditions: actuators must come to a standstill during an emergency stop Explain function and use of a 5/3-way solenoid valve Describe and set up the “Set” operating mode Execute troubleshooting in complex electro-pneumatic circuits

© Festo Didactic GmbH & Co. KG 540671

Exercise 1: Inspecting beverage cases Learning objectives After completing this exercise: • You’ll be familiar with the set-up and mode of operation of a single-acting cylinder. • You’ll be familiar with the set-up and mode of operation of a 3/2-way solenoid valve. • You’ll be able to recognise and sketch the various types of actuation for directional control valves. • You’ll be able to explain and set up direct actuation.

Presentation of the problem Beverage cases are inspected for completeness with a test device. Incomplete cases are pushed off of the roller conveyor by pressing a pushbutton. Develop a control system with which this process can be executed.

Layout

Test device

© Festo Didactic GmbH & Co. KG 541090

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Exercise 1: Inspecting beverage cases

• • •

2

Control sequence After pressing a pushbutton, the piston rod of a single-acting cylinder pushes the beverage case from the conveyor. When the pushbutton is released, the piston rod moves to its retracted end position.

1 2 3 4 5

Project assignment Answer the questions and complete the tasks for the learning topics. Draw the pneumatic and electrical circuit diagrams. Create an equipment list. Set up the pneumatic and electrical circuits. Check the circuit sequence.

1

2

Parameters A single-acting cylinder is to be used. The cylinder will be actuated using a pushbutton. In the event of a power failure, the cylinder’s piston rod should move to the retracted end position.

© Festo Didactic GmbH & Co. KG 540671

Exercise 1: Inspecting beverage cases

Function of pneumatic power components Pneumatic power components can be subdivided into two groups: • Power components with straight motion • Power components with rotary motion –

Describe the power components shown below, as well as their functions.

Symbol

Function Single-acting cylinder, reset spring in piston chamber, return stroke by means of compressed air, forward stroke by means of reset spring. Function The piston rod of this single-acting cylinder moves to its retracted end position by activating the compressed air. After deactivating the compressed air, the piston moves to its advanced end position by a reset spring in the piston chamber (2 operating positions). Single-acting cylinder, reset spring in piston chamber, forward stroke by means of compressed air, return stroke by means of reset spring. Function The piston rod of the single-acting cylinder moves to its advanced end position when the compressed air has been activated. After deactivating the compressed air, the piston moves to its retracted end position by a reset spring (2 operating positions). Pneumatic quarter turn actuator (rotary drive) with limited swivel angle Function This swivel cylinder is double-acting and reverses by alternately activating the compressed air at either end (2 operating positions).

© Festo Didactic GmbH & Co. KG 541090

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Exercise 1: Inspecting beverage cases

Complete the symbols for solenoid valves –

Complete the individual symbols with the help of the descriptions of the respective components.

Description

Symbol

Directly actuated 3/2-way solenoid valve, normally open,

2

with manual override, spring return

10 1M1

1

3

Pilot actuated 3/2-way solenoid valve, normally closed,

2

with manual override, spring return

12 1M1

4

1

3

© Festo Didactic GmbH & Co. KG 540671

Exercise 1: Inspecting beverage cases

Normal positions of directional control valves An electrically actuated 3/2-way solenoid valve has two switching positions. It can be in the normal position (unactuated) or the switched position (actuated). The valve can be either closed or open in its normal position. The single-acting cylinder depicted below is controlled by an electrically actuated 3/2-way solenoid valve. –

Describe how the two different normal positions affect the motion sequence of the cylinder shown below:

3/2-way solenoid valve, normally closed

3/2-way solenoid valve, normally open

The solenoid valve used is reversed by applying voltage to the

The solenoid valve used is reversed by applying voltage to the

solenoid coil; flow is enabled from supply port 1 to working port

solenoid coil; supply port 1 is closed, thus stopping flow. After

2. After the signal has been stopped, the valve returns to its

stopping the signal, the valve returns to its normal position by a

normal position by a reset spring and supply port 1 is closed, thus reset spring and flow from supply port 1 to working port 2 is stopping flow. If the directional control valve’s solenoid coil is de- enabled. If the directional control valve’s solenoid coil is deenergised, the cylinder chamber is vented via exhaust port 3 at

energised, the cylinder chamber is pressurised via the directional

the directional control valve. The piston rod is retracted. When

control valve. The piston rod is advanced. When the solenoid coil is

the solenoid coil is energised, the directional control valve

energised the directional control valve switches and the cylinder

switches and the cylinder chamber is pressurised. The piston rod

chamber is exhausted via exhaust port 3 at the directional control

advances. When the solenoid coil is de-energised, the valve

valve. The piston rod is retracted. When the solenoid coil is de-

switches back again. The cylinder chamber is exhausted and the

energised, the valve switches back again. The cylinder chamber is

piston rod is retracted. The motion sequence is thus as follows: 1A1+ 1A1-.

pressurised and the piston rod is advanced. The motion sequence is thus as follows: 1A1- 1A1+.

© Festo Didactic GmbH & Co. KG 541090

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Exercise 1: Inspecting beverage cases

Direct and indirect actuation An electrically actuated solenoid valve can be directly or indirectly actuated. –

Describe the difference on the basis of the following example: electrical actuation of a 3/2-way solenoid valve with spring return using a pushbutton.

Direct actuation

Indirect actuation

When the pushbutton is activated, current flows through the

In the case of indirect actuation, current flows through a relay coil

valve’s solenoid coil. The solenoid is energised and the valve

when a pushbutton is activated. The relay’s contacts are closed

switches to the actuated position.

and the valve switches. The valve remains in this switching

The flow of electrical current is interrupted when the pushbutton

position as long as electrical current flows through the solenoid

is released. The solenoid is de-energised and the valve switches to the normal position.

coil or the relay coil. The relay drops out when the flow of electrical current through the relay coil is interrupted and the valve switches to its normal position. More complicated indirect actuation is used when the control circuit and the primary circuit use different voltages, when current flowing through the directional control valve’s solenoid coil is greater than permissible current for the pushbutton, when several valves are switched with a single pushbutton or pressure switch or if extensive logic operations are required amongst the signals from various pushbuttons.

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© Festo Didactic GmbH & Co. KG 540671

Exercise 1: Inspecting beverage cases

Design and function of electrical switches In principle, switches are subdivided into two types, namely pushbuttons and control switches and function as NC contacts, NO contacts or change-over contacts. –

Describe the design and function of the switches depicted below.

Symbol

Design / function Design: Pushbutton with normally open contacts

3 4

Function: In the case of a pushbutton, the selected switching position is only retained as long as the pushbutton is activated. The pushbutton shown here has a normally open function. With normally open contacts, the electrical circuit is interrupted when the pushbutton is in its normal position, i.e. in the unactivated state. When the control stem is actuated, the electrical circuit is closed and current flows to the consuming device. When the control stem is released, the pushbutton is returned to its normal position by means of spring force and the electrical circuit is interrupted. Design: Control switch with normally closed contacts Function: Control switches are mechanically locked into the two switching positions. The respective switching position is retained until the switch is once again activated. The control switch shown here has a normally closed function. In the case of normally closed contacts, the electrical circuit is closed when the control switch is held in its normal position by means of spring force. When the control switch is activated, the electrical circuit is interrupted and reactivation closes the circuit again. Design: Pushbutton with change-over contacts

2

4 1

Function: In the case of a pushbutton, the selected switching position is only retained as long as the pushbutton is activated. The pushbutton shown here has a change-over function. In the case of change-over contacts, NC and NO functions are combined into a single component. An electrical circuit is closed and another is interrupted with a single switching operation. Both circuits are briefly interrupted during switching.

© Festo Didactic GmbH & Co. KG 541090

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Exercise 1: Inspecting beverage cases

Mode of operation of various valve types Electrically actuated directional control valves are switched by means of solenoids. In principle, they can be subdivided into two groups: • Solenoid valves with spring return • Double solenoid valves –

Explain the difference between the two groups with regard to function and performance in the event of a power failure.

Valve type

Mode of operation

Solenoid valve with spring return

The actuated switching position is only retained as long as electrical current flows through the solenoid coil. The normal position is clearly defined by the reset spring. If there is no electrical power, the valve returns to its normal position by the spring. This may cause dangerous machine motion. For example, the piston rod of a pneumatic cylinder could be returned to its normal position, thus releasing a previously clamped workpiece.

Double solenoid valve

Only a brief signal is required in order to reverse the valve and the last switching position is retained even in the de-energised state as the result of static friction. All solenoid coils are de-energised in the normal position and the normal position cannot be clearly defined. The valve stays in its last switching position in the event of a power failure. No dangerous machine motion can be triggered as a result. For example, the piston rod of a pneumatic cylinder is kept in its operating position and workpiece clamping is thus retained.

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© Festo Didactic GmbH & Co. KG 540671

Exercise 1: Inspecting beverage cases

Identifying valve ports In order to prevent incorrect tubing connections at directional control valves, the valve ports (working and pilot lines) are identified in accordance with ISO 5599-3 on the valves themselves, as well as in the circuit diagram. –

Explain the meanings and functions of the port designations listed below.

Port identification

Meaning and function

3

Exhaust port

12

Pilot line, function for pilot actuated or pneumatically actuated directional control valves when actuated: supply port 1 and working port 2 are connected

10

Pilot line, function for pilot actuated or pneumatically actuated directional control valves when actuated: supply port 1 is closed

© Festo Didactic GmbH & Co. KG 541090

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Exercise 1: Inspecting beverage cases

Complete the pneumatic and electrical circuit diagrams –

Complete the pneumatic and electrical circuit diagrams for the sorting system. 1A1 +24 V

1V2

1

13

2 S1

14

1 1V1 1M1

2

1

3 1M1

0V Pneumatic circuit diagram

10

Electrical circuit diagram

© Festo Didactic GmbH & Co. KG 540671

Exercise 1: Inspecting beverage cases

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 in the table below.

Quantity

Designation

1

Cylinder, single-acting

1

One-way flow control valve

1

3/2-way solenoid valve, normally closed

1

Pushbutton (normally open)

1

Distributor block

1

On-off valve with filter regulator

1

Compressed air source

1

Power supply unit, 24 V DC

Equipment list

© Festo Didactic GmbH & Co. KG 541090

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Exercise 1: Inspecting beverage cases

12

© Festo Didactic GmbH & Co. KG 540671