541088 Workbook Pneumatics Basic Level

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Workbook TP 101 With CD-ROM

Pneumatics

Basic level

1 2 3 1A1 1V2 ₄ ₂ 3 5 1 1V3 1V4 1Z1 1Z2 14 1V1 2 3 1 1S1 1B1 1 1 2 2 2 3 1 1B1 12 2 3 1 1S2 2 1 1

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Use for intended purpose

The training system from Festo Didactic has been developed and manufactured for training and vocational education in the field of automation 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 sets in situations which serve any purpose other than training and/or vocational education, unless such damages have been caused by Festo Didactic due to malicious intent or gross negligence.

Order no. 541088 Status: 03/2012

Authors: W. Haring, M. Metzger, R.-C. Weber Editor: Frank Ebel

Graphics: Doris Schwarzenberger Layout: 03/2012

E-mail: [email protected]

The purchaser shall receive a single right of use which is non-exclusive, non-time-limited and limited geographically to use at the purchaser's site/location as follows.

The purchaser shall be entitled to use the work to train his/her staff at the purchaser's site/location and shall also be entitled to use parts of the copyright material as the basis for the production of his/her own training documentation for the training of his/her staff at the purchaser's site/location with

acknowledgement of source and to make copies for this purpose. In the case of schools/technical colleges and training centres, the right of use shall also include use by school and college students and trainees at the purchaser's site/location for teaching purposes.

The right of use shall in all cases exclude the right to publish the copyright material or to make this available for use on intranet, Internet and LMS platforms and databases such as Moodle, which allow access by a wide variety of users, including those outside of the purchaser's site/location.

Entitlement to other rights relating to reproductions, copies, adaptations, translations, microfilming and transfer to and storage and processing in electronic systems, no matter whether in whole or in part, shall require the prior consent of Festo Didactic GmbH & Co. KG.

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Preface _________________________________________________________________________________ V Introduction ____________________________________________________________________________ VII Technology module for pneumatics (TP100) ____________________________________________________X Learning objectives for the basic level (TP101) _________________________________________________ XI Overview of learning objectives per exercise __________________________________________________ XII Equipment set for the basic level (TP101) ____________________________________________________ XIV Allocation of equipment per exercise _______________________________________________________ XVIII Practical tools for the trainer _______________________________________________________________ XIX Structure of the exercises _________________________________________________________________ XIX Designations of the components ____________________________________________________________ XIX CD ROM contents ________________________________________________________________________ XX Equipment set for the advanced level (TP102) ________________________________________________ XXII Learning objectives for the advanced level (TP102) ____________________________________________ XXIII

Solutions

Exercise 1: Pressing cheeses _________________________________________________________________ 1 Exercise 2: Opening a fodder silo _____________________________________________________________ 9 Exercise 3: Clamping boards to a saw bench __________________________________________________ 15 Exercise 4: Sorting packages _______________________________________________________________ 21 Exercise 5: Stopping milk bottles ___________________________________________________________ 31 Exercise 6: Opening and closing a pipeline ___________________________________________________ 37 Exercise 7: Shutting off a pipeline ___________________________________________________________ 45 Exercise 8: Actuating a shut-off device _______________________________________________________ 51 Exercise 9: Expanding the control system for pressing cheeses ___________________________________ 59 Exercise 10: Clamping a workpiece __________________________________________________________ 65 Exercise 11: Loading wire baskets __________________________________________________________ 73 Exercise 12: Actuating a sliding door ________________________________________________________ 79 Exercise 13: Feeding wooden boards ________________________________________________________ 87 Exercise 14: Compacting beverage cans ______________________________________________________ 93 Exercise 15: Packaging of brochures ________________________________________________________ 99 Exercise 16: Mounting locking pins _________________________________________________________ 105 Exercise 17: Labelling paint pots ___________________________________________________________ 111 Exercise 18: Cleaning workpieces __________________________________________________________ 117 Exercise 19: Pressing labels into place ______________________________________________________ 123

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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 with real-life practice. The technology modules deal with various technologies including pneumatics, electro-pneumatics,

programmable logic control systems, automation using a personal computer, hydraulics, electrohydraulics, proportional hydraulics, sensor technology, electric drives and applications technology (handling).

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VI © Festo Didactic GmbH & Co. KG 541088 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.

All training modules have the same structure:  Hardware

 Teachware  Software  Seminars

The hardware is comprised of industrial components and systems that are specially designed for training purposes.

The structure of the teachware 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 TP101 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.

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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 TP100 technology module only includes pneumatic control systems.

The TP101 basic level is suitable for basic training in the field of pneumatic control technology. It covers the fundamentals of pneumatics as well as the function and use of pneumatic equipment. The equipment can be used to set up simple pneumatic control systems.

The TP102 advanced level comprises vocational training in the field of pneumatic control technology. The equipment can be used to set up extensive combinatory circuits with linking of the input and output signals as well as control systems with stepper modules.

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 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 control sequence 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 19 exercises are set up using the equipment set for the TP101 basic level. The theoretical fundamentals for understanding this series of exercises are included in the textbook:

 Pneumatics, basic level

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VIII © Festo Didactic GmbH & Co. KG 541088

Work instructions and safety precautions

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 the components securely onto the profile plate.  Limit switches must 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!  Only use connector cables with safety plugs for electrical connections.

 Only use low-voltage (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 of 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 the pneumatic circuit:

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The mounting boards for the components are equipped with mounting variant A, B or C: Variant A, snap-in system

Lightweight components that are not load-bearing (e.g. directional control valves). Simply clip the components into the slot on the profile plate. Release the component from the slot by actuating the blue lever.

Variant B, bolt-on system

Components with medium load capacity (e.g. actuators). These are clamped onto 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 that 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.

Observe specifications in the data sheets regarding the individual components.

A stopwatch is required in order to evaluate the control systems once they have been set up. The stopwatch is used to:

 Adjust the one-way flow control valves so that the cylinder stroke times comply with the specified values

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X © Festo Didactic GmbH & Co. KG 541088

Technology module for pneumatics (TP100)

The TP100 technology module consists of a multitude of training materials and seminars. The subject matter is focused entirely on pneumatic control systems. Individual components included in the TP100 technology packet can also be included in any of the other modules.

Important components of the TP100

 Permanent workstation with Festo Didactic profile plate  Compressor (230 V, 0.55 kW, max. 8 bar = 800 kPa)

 Equipment sets or individual components (e.g. cylinders, directional control valves, preset counters, stepper modules, logic components, pneumatic proximity switches)

 Optional training materials (e.g. optical displays, 5/3-way valve, pulling/pushing load)  Practical training models

 Complete laboratory set-ups

Training documentation

Textbooks TP101 basic level

Fundamentals of pneumatic control technology Maintenance of pneumatic equipment and systems Pneumatics/electropneumatics

Workbooks TP101 basic level

TP102 advanced level Optional teachware Set of transparencies

Magnetic symbols, drawing template FluidSIM®_{pneumatic simulation software} WBT Pneumatics

Set of cutaway models with storage case

Seminars

P100 Basic pneumatics for machine operators

P111 Fundamentals of pneumatics and electropneumatics

P121 Maintenance and troubleshooting for pneumatic and electropneumatic systems P-OP Tracking down wastage – economic use of pneumatics

P-NEU Pneumatic refresher and update

IW-PEP Repair and maintenance in the field of control technology – pneumatic and electropneumatic systems P-AL Pneumatics for further education

P-AZUBI Pneumatics and electropneumatics 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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Learning objectives for the basic level (TP101)

 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 3/2-way valve.

 Be able to recognise and sketch the various types of actuation for directional control valves.  Be able to explain and set up direct actuation.

 Be able to analyse and evaluate circuits.

 Become familiar with the set-up and mode of operation of a double-acting cylinder.  Become familiar with the set-up and mode of operation of a 5/2-way valve.

 Be able to explain and set up indirect actuation.

 Become familiar with the mode of operation of a 5/2-way valve with pneumatic actuation.  Become familiar with the difference between a signalling element and a control element.  Be able to measure pressure in pneumatic control systems.

 Be able to differentiate between the various types of flow control and use them in accordance with specifications.

 Be able to adjust cylinder advancing and retracting speeds.

 Become familiar with one type of signal storage in pneumatic control systems.  Be able to explain and implement AND/OR/NOT logic operations.

 Be able to explain and set up latching circuits.

 Become familiar with one option for end-position sensing in cylinders.  Be able to combine logic operations.

 Become familiar with the set-up and mode of operation of a magnetic proximity switch.  Be able to differentiate between 5/2-way valves and to select and use them in accordance with

specifications.

 Be able to further develop existing circuits.

 Become familiar with the set-up and mode of operation of a pressure sequence valve.  Be able to set up pressure-dependent control systems.

 Become familiar with the set-up and mode of operation of a pressure regulator.

 Be able to analyse existing circuits and optimise them in accordance with specifications.  Become familiar with the set-up and mode of operation of a time delay valve.

 Be able to set up circuits with oscillating motion.

 Be able to use time delay valves in accordance with specific constraints.  Be able to analyse and set up circuits with two cylinders.

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XII © Festo Didactic GmbH & Co. KG 541088

Overview of learning objectives per exercise

Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Learning Objective

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 3/2-way valve.

• • •

Be able to recognise and sketch the various types of actuation for directional control valves.

• • •

Be able to explain and set up

direct actuation. • • • • Be able to analyse and evaluate

circuits. • •

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

•

Become familiar with the set-up and mode of operation of a 5/2-way valve.

• •

indirect actuation. • •

Become familiar with the difference between a signalling element and a control element.

•

Be able to measure pressure in

pneumatic control systems. •

Be able to differentiate between the various types of flow control and use them in accordance with specifications.

• •

Be able to adjust cylinder

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Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Learning Objective

Become familiar with one type of signal storage in pneumatic control systems.

•

Be able to explain and implement

AND/OR/NOT logic operations. • • • • •

latching circuits. •

Become familiar with one option for end-position sensing in cylinders.

•

Be able to combine logic

operations. • •

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

•

Be able to differentiate between 5/2-way valves and to select and use them in accordance with specifications.

•

Be able to further develop

existing circuits. • •

Become familiar with the set-up and mode of operation of a pressure sequence valve.

•

Be able to set up

pressure-dependent control systems. • • • •

Become familiar with the set-up and mode of operation of a pressure regulator.

•

Become familiar with the set-up and mode of operation of a time delay valve.

•

Be able to set up circuits with

oscillating motion. •

Be able to use time delay valves in accordance with specific constraints.

•

Be able to analyse and set up

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XIV © Festo Didactic GmbH & Co. KG 541088

Equipment set for the basic level (TP101)

The equipment set has been put together for basic training in the field of pneumatic control technology. It includes all the components that are necessary for mastering the specific learning objectives and can be supplemented with any other equipment sets. A profile plate and a source of compressed air are also required in order to set up functional control systems.

Equipment set for the basic level (TP101)

Quantity Designation Order no.

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

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

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

1 3/2-way valve with selector switch, normally closed 152863 1 3/2-way valve, pneumatically actuated at one end 576302 3 5/2-way double pilot valve, pneumatically actuated at both ends 576303

1 5/2-way valve with selector switch 152862

1 5/2-way valve, pneumatically actuated at one end 576307

1 Double-acting cylinder 152888

2 One-way flow control valve 193967

2 Pressure gauge 152865

1 Pressure regulator with pressure gauge 539756

1 Pressure sequence valve 152884

1 Single-acting cylinder 152887

1 On-off valve with filter regulator 540691

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

2 Pneumatic proximity switch with cylinder mounting 539775

1 Pneumatic timer, normally closed 540694

1 Quick exhaust valve 539772

10 Push-in sleeve 153251

10 Push-in T-connector 153128

1 Distributor block 152896

1 Shuttle valve (OR) 539771

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Equipment set symbols

Designation Symbol

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

3 1

3/2-way valve with pushbutton, normally open

5/2-way valve with selector switch 4 2

3 5

1 3/2-way valve with selector switch

Pressure gauge

3/2-way roller lever valve, normally closed

3 1

2

Pneumatic proximity switch

3 1

2

3/2-way valve, pneumatically actuated at one end ₂

3 1 12

5/2-way valve, pneumatically actuated at one end ₄ ₂

1 5 14

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

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XVI © Festo Didactic GmbH & Co. KG 541088 Designation Symbol Shuttle valve 2 1 1 Dual-pressure valve 2 1 1

Pneumatic timer, normally closed

2

3 1

t

Quick exhaust valve

2

3 1

One-way flow control valve

2 1

Pressure sequence valve

2 3 1 12 Single-acting cylinder Double-acting cylinder

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Designation Symbol

On-off valve with filter regulator

2

3

1

Pressure regulator with pressure gauge

2

3 1

Distributor block

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XVIII © Festo Didactic GmbH & Co. KG 541088

Allocation of equipment per exercise

Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Equipment

Cylinder, single-acting 1 1 1 1 1 1

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

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

Quick exhaust valve 1 1

Pressure gauge 2 2 1 2 1

3/2-way valve, pushbutton, normally closed

1 2 2 1 2 1 2 2 1 1 1 1

3/2-way valve, pushbutton, normally open

1 1

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

1 1 2 1

3/2-way roller lever valve, normally closed

1 1 1

Pneumatic proximity switch 2 2 2 1 2 2 2 2

3/2-way pneumatic valve 1 1

3/2-way pneumatic double pilot valve

1 1

5/2-way valve, selector switch

1 1 1

5/2-way pneumatic valve 1 1 1 1

5/2-way pneumatic double pilot valve

1 1 1 1 1 1 1 1

Shuttle valve 1 1 1 1 1

Dual-pressure valve 1 2 2 1 1 2 1 1

Pressure sequence valve 1 1 1

Pressure regulator with pressure gauge

1 2 1 1

Time delay valve, normally closed

1 1

Distributor block 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

On-off valve with filter regulator

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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 learner’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 matched each other. For all 19 exercises you’ll only need the components included in the equipment set for TP101 basic level.

Each exercise in the basic level can be set up on a profile plate.

Structure of the exercises

All 19 exercises have the same structure and are broken down into:  Title

 Learning objectives

 Presentation of the problem  Parameters

 Project assignment  Layout

 Worksheets

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XX © Festo Didactic GmbH & Co. KG 541088

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

Valves: 1V1, 1V2, 1V3, 2V1, 2V2, 3V1 ... Sensors: 1B1, 1B2 ...

Signal inputs: 1S1, 1S2 ... Accessories: 0Z1, 0Z2, 1Z1 ...

CD ROM contents

The CD ROM provides you with additional media. The worksheets and solutions have been saved as PDF files on the CD ROM that is included with the trainer’s manual.

The CD ROM contains the following folders:  Operating instructions

 Demo

 Festo catalogue

 FluidSIM®_{circuit diagrams}

 Industrial applications  Presentations

 Product information  Videos

Operating instructions

Operating instructions for the various components included in the technology module are available. These instructions are helpful when using and commissioning the equipment.

FluidSIM®_{demo version}

A demo version of the FluidSIM®_{pneumatics software package is included on the CD ROM. Even this demo}

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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 19 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.

Product information

This directory contains product information and data sheets from Festo for the components included in the 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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XXII © Festo Didactic GmbH & Co. KG 541088

Equipment set for the advanced level (TP102)

The equipment set for the advanced level has been put together for further training in the field of pneumatic control technology. The two equipment sets (TP101 and TP102) 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 (TP102)

Quantity Designation Order no.

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

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

1 3/2-way valve with mushroom actuator (red), normally open 152864 4 3/2-way valve, pneumatically actuated at one end 576302 2 5/2-way double pilot valve, pneumatically actuated at both ends 576303

2 Double-acting cylinder 152888

2 One-way flow control valve 193967

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

1 Pneumatic timer, normally open 539759

2 Non-return valve, piloted non-return function 540715

1 Back pressure limit valve 152868

10 Push-in sleeve 153251

1 Stepper module 152886

20 Push-in T-connector 153128

1 Pneumatic preset counter 152877

1 Shuttle valve (OR) 539771

1 Shuttle valve, 3-way (OR) 152882

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Learning objectives for the advanced level (TP102)

 Detect end-positions without limit switches

 Understand and set up flip-flop circuits (flip-flop, double pilot valve)  Convert a 3/2 and/or a 5/2-way valve

 Evaluate, use and adjust various sensors  Explain the function of a back pressure end stop  Explain the function of stepper modules

 Develop basic sequence control systems (continuous cycle)

 Implement a sequence control system with the following operating modes: automatic/manual, start and reset

 Implement an OR operation for feedback signals  Set and coordinate delays

 Be able to abort delay times with an OR operation

 Implement a sequence control system with idle step (3 steps)

 Describe and set up variable step repetition within a motion sequence using a preset counter  Develop an input circuit with self-latching loop including the following functions: automatic/manual,

start, stop (at end of cycle) and reset

 Evaluate and use sensors for material sensing

 Actuate the final control element with two steps via a shuttle valve (double cylinder stroke)  Use a proximity switch within the stroke sub-range in order to reverse cylinder motion

 Development of an input circuit for a sequence control system with secure pilot air, as well as start, emergency stop and reset functions

 Stop the cylinder within the sub-stroke range (positioning) by pressurising at both ends (preloading)  Adjust proximity switches in the end positions and within the sub-stroke range

 Combined use of quick exhaust valve and pressure regulator with pressure gauge  Set up an inverted timer signal

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Exercise 1: Pressing cheeses

After completing this exercise you’ll:

 Be familiar with the set-up and mode of operation of a single-acting cylinder.  You’ll be able to calculate the piston force of a single-acting cylinder.

 Be familiar with the set-up and mode of operation of a normally closed 3/2-way valve.  Be able to recognise and sketch the various types of actuation for directional control valves.  Be able to explain and set up direct actuation.

Presentation of the problem

Presses are used to press cheeses into moulds during the production process. Develop a control system with which this process can be executed

Layout

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Exercise 1: Pressing cheeses

2 © Festo Didactic GmbH & Co. KG 541088

Parameters

 Use a double-acting cylinder.

 Pneumatically control the cylinder using a manually actuated valve.

Project assignment

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

2. Describe the mode of operation of a normally closed 3/2-way valve. 3. Complete the pneumatic circuit diagram for the pressing tool. 4. Set up the control system.

5. Double-check the control system configuration. 6. Describe the mode of operation of the control system. 7. Create an equipment list.

Procedure

1. The cheeses are placed into the tool manually.

2. When the pushbutton is activated, the cylinder advances and presses the cover onto the tool. 3. The pushbutton is pressed and held until the pressing operation has been completed. 4. When the pushbutton is released, the cylinder is retracted and the tool can be accessed. 5. The cheese can be removed.

Safety note

Limit pressure at the service unit for this exercise to a maximum of3.5 bar (350 kPa). Immediately deactivate compressed air supply if the tubing slips off.

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Set-up and mode of operation of a single-acting cylinder

1 2 3 4 5

6 7

8 Circuit symbol and schematic diagram of a single-acting cylinder

– Compare the circuit symbol shown above with the schematic diagram of the single-acting cylinder. Determine whether or not the two representations coincide with each other.

The two representations coincide with each other.

– Describe the set-up and mode of operation of a single-acting cylinder.

The compressed air flows into the cylinder’s piston chamber. Pressure is built up in the chamber and force is applied to the surface of the piston as a result. If this force exceeds static friction, the piston is advanced. Pressure is not built up to full operating pressure until the piston is fully advanced.

When this pressure drops, the integrated return spring forces the piston back into its initial position. Spring force is not great enough to move heavy loads attached to the piston rod. Hence single-acting cylinders only perform work in a single direction.

– Match up each component with the corresponding number from the above drawing.

Component Designation 3 Cylinder barrel 1 End cap 6 Bearing cap 5 Piston rod 8 Piston 7 Spring return 2 Supply port 4 Exhaust port

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Calculate the piston force of a single-acting cylinder Theoretical piston force is calculated using the following formula: Fth = A  p

Fth = theoretical piston force (N)

A = effective piston surface (sq. metres)

= ( )

4 D2

p = working pressure (Pa) D = cylinder diameter (m)

Piston force Feff is important in actual practice. Frictional resistance has to be taken into consideration when

calculating piston force. Under normal operating conditions (pressure range of 4 to 8 bar or 400 to 800 kPa), it is assumed that friction forces (FR) amount to roughly 10% of the theoretical piston force.

The following applies to the effective piston force of single-acting cylinders: Feff = A  p – (FR + FF)

Feff = effective piston force (N)

FR = friction force (approx. 10% of Fth ) (N)

FF = return spring force (N)

– Calculate the effective piston force for the advance stroke of the used cylinder with a working pressure of 6 bar (600 kPa). A = ( ) 4 3.14 0.022 = 0.000314 Feff = 0.9  A  p – FF Feff = 0.9  (0.000314)  600,000 – 13.6 Feff = 169.56 – 13.6 = 155.96 N Note

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Mode of operation of a normally closed 3/2-way valve

– Complete the circuit symbol of a manually actuated, normally closed 3/2-way valve with spring return.

2 3 1 1 2 3

Circuit symbol and schematic representation of a normally closed 3/2-way valve

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

A 3/2-way valve has 3 ports and 2 switching positions. It’s represented in the normal position. Normally closed means that compressed air cannot flow through the valve. When the pushbutton is actuated the valve is opened, thus allowing air to flow and the piston of a connected cylinder is advanced.

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Complete the pneumatic circuit diagram

– Complete the pneumatic circuit diagram for the control system and enter the port designations.

2 3 1 0Z1 0Z2 2 3 1 1A1 1S1

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Sequence description

– Set up the control system and describe its working sequence. Initial position

Valve 1S1 is closed in its initial position. The piston rod of cylinder 1A1 is retracted.

Step 1-2

When the pushbutton on 3/2-way valve 1S1 is pressed, compressed air flows into the piston chamber of cylinder 1A1 and the piston rod is advanced.

Step 2-3

When the pushbutton is released, valve 1S1 is exhausted and cylinder 1A1 returns to its initial position due to force applied by the return spring.

(32)

Create an equipment list

In addition to the circuit diagram, complete project documentation also includes an equipment list. – Create an equipment list by entering the required components and their quantities in the table below.

Quantity Designation

1 Cylinder, single-acting

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

1 Distributor block

1 On-off valve with filter regulator

1 Compressed air source

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Exercise 2: Opening a fodder silo

 Be familiar with the set-up and mode of operation of a normally open 3/2-way valve.  Be able to recognise and sketch the various types of actuation for directional control valves.  Be able to explain and set up direct actuation.

The slide of a fodder silo is to be opened by pressing a pushbutton. When the pushbutton is released, the slide is once again closed.

Layout

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Exercise 2: Opening a fodder silo

Parameters

 A single-acting cylinder is to be used.

 The cylinder will be pneumatically controlled using a pushbutton.

1. Answer the questions on the normally open 3/2-way valve. 2. Create the pneumatic circuit diagram for controlling the slide. 3. Set up the control system.

4. Double-check the control system configuration. 5. Describe the mode of operation of the control system. 6. Create the equipment list.

Procedure

1. When the pushbutton is activated, the cylinder is retracted to the retracted end position. 2. The pushbutton is pressed and held for as long as the slide is to remain open.

3. When the pushbutton is released, the cylinder is advanced and the slide closes the opening in the silo.

Safety note

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Mode of operation of a 3/2 way valve

– Complete the circuit symbol of the 3/2-way valve. It needs to include the following functions: manual actuation, spring return, normally open.

2

3 1

Circuit symbol, 3/2-way valve, normally open

3 2

1

Schematic representation of a 3/2-way valve, normally open

– Explain the mode of operation of a 3/2-way valve, normally open.

A normally open 3/2-way valve has 3 controlled ports and 2 switching positions. It’s represented in the normal position.

This is a normally open variant of the valve. This means that compressed air flows through the valve to the cylinder and holds the cylinder’s piston in the advanced end position. When the pushbutton is activated, the valve stops the flow of compressed air, the cylinder is exhausted via the valve and the piston is retracted.

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Change the pneumatic circuit diagram

– Change the pneumatic circuit diagram for the control system and enter the port designations.

2 3 1 0Z1 0Z2 2 3 1 1A1 1S1 Circuit diagram Note

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The 3/2-way valve is open in the free-flow direction and the piston chamber is pressurised. The piston at cylinder 1A1 is advanced.

Step 1-2

If pushbutton 1S1 is activated, the piston is exhausted via the 3/2-way valve and cylinder 1A1 is retracted.

Step 2-3

When the pushbutton is released, the spring forces the 3/2-way valve into its initial position, the piston chamber is once again pressurised and cylinder 1A1 advances again.

Safety note

(38)

Change the equipment list

– Change the equipment list shown below such that it corresponds with the requirements for this control system.

1 Distributor block

Tubing material

1 Single-acting cylinder

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

Equipment list

1 Distributor block

Tubing material

1 Single-acting cylinder

1 3/2-way valve, manually actuated, normally open

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Exercise 3: Clamping boards to a saw bench

 Be able to recognise and sketch the various types of actuation for directional control valves.  Be able to explain and set up direct actuation.

 Be able to analyse and optimise control systems.

Boards are manually laid on the saw bench where they are cut to length with a circular saw. The sawing operation is controlled from a separate control panel and thus the boards are pneumatically clamped to the saw bench. The control system is implemented with only one cylinder for the test set-up.

Layout

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Exercise 3: Clamping boards to a saw bench

Parameters

 Use one of the control systems from the previous exercises and modify it for this task.  Use, by way of example, only one single-acting cylinder to design the control system.

1. Complete the pneumatic circuit diagram for the clamping tool. 2. Set up the control system.

3. Double-check the control system configuration. 4. Describe the mode of operation of the control system. 5. Change the equipment list.

Procedure

1. A board is manually laid on the saw bench.

2. After activating a switch, the cylinder advances and clamps the board.

3. The cylinder remains in the advanced position, even when the switch has been released.

4. After turning the switch back to its initial position, the cylinder is retracted to the retracted end position, where it remains until the switch is activated again.

Safety note

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– Complete the circuit diagrams shown below by entering the required type of actuation.

a) b)

Circuit diagram

– Select the best control system and justify your answer. The correct solution is a).

Reason:

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The valve’s free-flow direction is closed. The cylinder’s piston rod is retracted.

Step 1-2

When selector switch 1S1 is activated, compressed air flows into the piston chamber and the cylinder is advanced.

Step 2-3

When the selector switch is reset, the valve is exhausted and the cylinder returns to its initial position due to force applied by the return spring.

Safety note

(43)

Change the equipment list

In addition to the circuit diagram, complete project documentation also includes an equipment list. – Change the equipment list by entering the required components in the table below.

1 Cylinder, single-acting

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

1 Distributor block

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Exercise 4: Sorting packages

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

 Be able to calculate the piston force of a double-acting cylinder for both the advance and the return strokes.

 Be familiar with the set-up and mode of operation of a 5/2-way valve.

Packages are sorted manually from a roller conveyor into large containers at a sorting station. When the containers are full, they’re removed and new containers are provided. At this point the material flow should be interrupted, but the roller conveyor continues to run. The material flow is interrupted by mechanical blocking (slide). The slide has to be operated at the sorting station.

Layout

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Exercise 4: Sorting packages

Parameters

 A double-acting cylinder will be used, because work is carried out during both the advance and the return strokes.

1. Describe the set-up of a double-acting cylinder. 2. Describe the mode of operation of a 5/2-way valve.

3. Create a pneumatic circuit diagram for the package blocking slide. 4. Set up the control system.

Procedure

1. When the selector switch is activated, the cylinder advances and pushes the slide into the flow of material.

2. The cylinder remains in this position after releasing the selector switch and the material flow remains interrupted.

3. After turning the selector switch to its initial position, the cylinder moves to its retracted end position and the material flow is resumed. The cylinder remains in this position until the selector switch is activated again.

Safety note

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Set-up of a double-acting cylinder

2 3 4 5

6 1

7

Circuit symbol and schematic diagram of a double-acting cylinder

– Compare the circuit symbol shown above with the schematic diagram of the double-acting cylinder. Determine whether or not the two illustrations are the same.

The two illustrations are the same.

– Make a note of the characteristics of a single-acting and a double-acting cylinder designs that are the same as well as those that are different.

Both cylinder designs include cylinder barrel, piston and piston rod. The double-acting cylinder doesn’t have a return spring.

The double-acting cylinder has 2 supply ports.

– Match the numbers from the schematic drawing with the individual components of the double-acting cylinder.

Component Designation

1 Supply port, piston chamber 2 Piston

3 Cylinder barrel

4 Supply port, piston rod chamber

5 Piston rod

6 Bearing cap

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Mode of operation of a double-acting cylinder

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

As opposed to a single-acting cylinder, more air is consumed. As the piston surfaces differ in size, the forces vary with identical pressure.

Forward stroke

Compressed air flows into the cylinder through the piston chamber supply port. Pressure is built up in the chamber and force is applied to the surface of the piston as a result. If this force exceeds static friction, the piston is advanced. Air in the piston rod chamber escapes through the port at the piston rod end. Pressure is not built up to full force until the piston is fully advanced.

Return stroke

After reversing, air flows through the supply port at the piston rod chamber where it builds up pressure until the piston rod is retracted. Air escapes from the piston chamber through the piston chamber port.

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Calculate the piston force for the advance and return strokes Theoretical piston force is calculated using the following formula: Fth = A  p

The following applies to double-acting cylinders: Advance stroke Feff = (A  p) – FR

Return stroke Feff = (A'  p) – FR

Feff = effective piston force (N)

A = effective piston surface (m2₎

= ( )

4 D2

A' = effective piston ring surface (m2₎

= (D d )4

2 2_ 

p = working pressure (Pa)

FR = friction force (approx. 10% of Fth ) (N)

D = cylinder diameter (m) d = piston rod diameter (m)

– Calculate the effective piston force for the advance and return strokes of the cylinder with a working pressure of 6 bar (600 kPa).

Forward stroke Feff = (A  p) – FR Feff = 0.9  A  p Feff = 0.9  0.000314  600,000 Feff = 169.66 N Return stroke Feff = (A'  p) – FR Feff = 0.9  (0.000314 – 0.00005024)  600,000 Feff = 0.9  0.00026376  600,000 Feff = 142.4 N Note

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Determine the requirements for the directional control valve – Write down the requirements for the directional control valve.

Compressed air must be available in both switching positions, because the double-acting cylinder cannot be retracted without compressed air. Venting of the other cylinder chamber must be ensured in each case.

– Indicate why the directional control valve has to be actuated with a switch.

A switch has to be used because a pushbutton cannot be held in the activated position for as long as it takes to replace the containers.

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Mode of operation of a 5/2 way valve

– Complete the circuit symbol of a manually actuated, 5/2-way valve with spring return and locking function, and enter the port designations.

2 4

3 5

1 ₅ ₄ ₁ ₂ ₃

Circuit symbol and schematic representation of a 5/2-way valve

– Describe the mode of operation of a 5/2-way valve when valve port 2 is connected to the piston rod end of a double-acting cylinder.

Mode of operation of a 5/2 way valve, unactuated

When the 5/2-way valve is not actuated, the return spring holds the valve in its initial position. The piston rod end of the cylinder is pressurised and the piston rod is retracted.

Mode of operation of a 5/2 way valve, actuated

When the 5/2-way valve is actuated, the force of the valve return spring is overcome and the valve is reversed. In this state, the supply port is connected to the piston end of the cylinder via the valve while the piston rod end is exhausted via the valve. Pressure which is built up at the piston end causes the piston rod to advance. As soon as the piston rod has reached its advanced end position, maximum operating pressure is built up at the piston end of the cylinder.

Actuation with a switch

If the valve is actuated with a switch, the valve remains in either of its positions until the switch is reversed again.

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Complete the circuit diagram

– Complete the circuit diagram shown below.

2 3 1 1A1 1S1 0Z2 0Z1 2 4 3 5 1

(53)

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.

1 Cylinder, double-acting

1 Distributor block

(54)

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Exercise 5: Stopping milk bottles

 Be able to explain and set up indirect actuation.

 Be familiar with the mode of operation of a 5/2-way valve with pneumatic actuation.  Be familiar with the difference between a signalling element and a control element.

A filling system fills bottles with milk. The bottles are fed to the system on a conveyor belt and are stopped underneath the filler using a pneumatic cylinder. The positioning accuracy of the stopping operation will be checked during a test set-up. The stopping operation will be activated at the system’s control panel.

Layout

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Exercise 5: Stopping milk bottles

Parameters

 Stopping of the material flow will be carried out at a central control panel.

 As compressed air is available at the control panel, a pneumatic solution will be used.  The control valve for the cylinder will be pneumatically actuated.

1. Determine the requirements for the control system with regard to actuating components and the control element.

2. Complete the pneumatic circuit diagram for stopping the material flow. 3. Set up the control system.

Procedure

1. When the selector switch is activated, the cylinder advances and pushes the slide into the flow of material, thus stopping the bottles.

2. After setting the selector switch back to its initial position, the cylinder is in its retracted end position and once again enables material flow.

3. The cylinder remains in this position until the selector switch is activated again.

Additional task

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– Complete the circuit diagram shown below and enter the missing connection and component designations. 2 3 1 1A1 1V1 0Z2 0Z1 2 3 1 1S1 4 2 1 5 14 3

Pneumatic circuit diagram

Note

The on-off valve with filter regulator and the distributor block are not shown. These components are required in order to set up the control system.

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– Explain the mode of operation of the control system by describing its operating sequence. Initial position

The signalling element and the control element are in the position generated by the return spring.

Step 1-2

When the selector switch at the 3/2-way valve 1S1 is actuated, pneumatic control port 14 at 5/2-way valve 1V1 is pressurised with compressed air. The 5/2-way valve is reversed as a result. The left-hand port (piston end) of the double-acting cylinder is pressurised with compressed air, and the right-hand port (piston rod end) is exhausted. The cylinder advances.

Step 2-3

When the selector switch is returned to its initial position, the compressed air supply to the 3/2-way valve is blocked, the 5/2-way valve looses pressure at control port 14 and the valve piston is returned to its initial position by the return spring. The piston end of the cylinder is thus exhausted and the piston rod end is pressurised with compressed air. The cylinder travels to its retracted end position.

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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.

1 Pneumatic 5/2-way valve with spring return 1 Normally closed 3/2-way valve with selector switch

1 Distributor block

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Additional task

– Explain the term “indirect control”. Indirect control

Cylinders with large piston diameters have high air consumption rates. Control elements with high nominal flow rates must be used to actuate them. If the force is too great for manual actuation of the valve, indirect actuation must be set up. In doing so, a signal is generated by a second, smaller valve, which then provides the force required in order to switch the control element.

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Exercise 6: Opening and closing a pipeline

 Be able to measure pressure in pneumatic control systems.

 Be able to differentiate between the various types of flow control and use them in accordance with specifications.

The gate in a pipeline needs to be opened and closed. Actuation is via a valve with selector switch. A double-acting cylinder will be used as an actuator.

Layout

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Exercise 6: Opening and closing a pipeline

Parameters

 The gate must be opened and closed slowly because the pipeline would otherwise be overloaded (the forming of waves should be avoided).

 The speed of the opening and closing strokes should be steady.

Project assignment 1. Create a pneumatic circuit. 2. Set up the control system.

6. Observe pressure conditions upstream and downstream of the flow control and document them.

Procedure

1. When the selector switch is activated, the cylinder is advanced and opens the gate.

2. When the selector switch is returned to its initial position, the cylinder is retracted to its initial position and the gate is closed.

Additional tasks

 At which pressure level do you observe jerking motion?  Explain how jerking motion occurs.

Safety note

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Mode of operation of a one-way flow control valve

1

2

1 2

Circuit symbol and schematic diagram of a one-way flow control valve

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

Air is restricted in one direction only with a one-way flow control valve. The non-return valve inhibits the flow of air in one direction and air can only flow through the selected cross-section. Air flows freely in the other direction through the open non-return valve. These valves are used primarily for controlling the speed of the pneumatic cylinders. The speed of the piston rod can be controlled with one-way flow control valves by adjusting the volumetric flow rate.

– Describe two types of flow control used with double-acting cylinders. Supply air flow control

In the case of supply air flow control, the one-way flow control valves are installed such that air being fed to the cylinder is restricted. Exhaust air can escape freely on the downstream side via the non-return valve. Feed speed irregularities occur as the result of even the smallest load fluctuations at the piston rod, for example in the case of limit switch overtravel. A load in the direction of cylinder motion accelerates the cylinder beyond the selected value.

Exhaust air flow control

In the case of exhaust air flow control, supply air flows freely to the cylinder and the flow control in the exhaust line resists the escaping air. The piston is held between two air cushions, which are generated as a result of supply air pressure and resistance caused by the flow control. This one-way flow control valve arrangement contributes significantly to improved feed characteristics. Exhaust air flow control should be used with double-acting cylinders.

– Explain how a one-way flow control valve is tested for correct functioning.

A one-way flow control valve is tested for correct functioning by means of two pressure gauges. The pressure gauges are connected directly upstream and downstream from the valve under test.

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Create the pneumatic circuit diagram

– Complete the circuit diagram shown below. Complete the symbols for the one-way flow control valves.. Observe the specified basic conditions when doing so.

1A1 1S1 2 1 1 2 2 4 3 5 1 1V1 1V2 1Z2 1Z1

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In addition to the circuit diagram, complete project documentation also includes an equipment list. – Create an equipment list by entering the required components and their quantities in the table below.

2 One-way flow control valve

2 Pressure gauge

1 Distributor block

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– Set up the control system and describe its operating sequence. Initial position

In the initial position, the piston is in the retracted end position. The piston chamber is exhausted via 5/2-way valve 1S1.

Step 1-2

When the 5/2-way valve is reversed, the piston chamber in the cylinder is pressurised via the one-way flow control valve. The cylinder travels to its advanced end position.

Step 2-3

After resetting the switch, the cylinder’s piston rod chamber is pressurised via the one-way flow control valve and the 5/2-way valve. The cylinder travels to its retracted end position.

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Additional tasks

– At which pressure level do you observe jerking motion?

Jerking motion occurs in the case of very low operating pressure or excessive restriction.

– Explain how jerking motion occurs.

It’s caused by pressure building up and working against static friction and sliding friction. Pressure builds up at the stationary piston and works against static friction. If force due to pressure exceeds the friction coefficient, the piston is advanced and minimal sliding friction comes into play. But then the air increases again and pressure drops, because it can’t be built back up quickly enough; the piston stops. This sequence is repeated. The piston “stammers”.

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Exercise 7: Shutting off a pipeline

 Be able to adjust cylinder advancing and retracting speeds.

 Be able to differentiate between the various types of flow control and use them appropriately.

A filling system fills bottles with milk. The pipes through which the milk flows are opened and closed using a gate. The gate should be opened slowly in order to prevent any spillage at the beginning of the filling process. Closing, on the other hand, should take place as quickly as possible.

Layout

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Exercise 7: Shutting off a pipeline

Basic condition

 Speed control should enable a smooth opening process.

1. Select the appropriate type of flow control.

2. Create a pneumatic circuit diagram for the shut-off mechanism. 3. Set up the control system.

Procedure

1. A gate valve is opened slowly after activating a selector switch.

2. The gate valve is closed quickly when the selector switch is returned to its initial position.

Safety note

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Select the type of flow control

Determine whether supply air or exhaust air flow control is required for the application. – Justify your selection and write your reasons down.

Exhaust air flow control is the right selection for the application. Load-independent, uniform feed speed is ensured by means of exhaust air flow control.

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Create the pneumatic circuit diagram

– Complete the circuit diagram shown below. Observe the specific constraints when doing so.

1A1 1S1 2 1 2 4 3 5 1 1V1

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– Create an equipment list by entering the required components and their quantities in the table below.

1 One-way flow control valve

1 Distributor block

541088 Workbook Pneumatics Basic Level

Pneumatics

Basic level

Use for intended purpose

Table of contents

Preface

Introduction

Work instructions and safety precautions

Technology module for pneumatics (TP100)

Learning objectives for the basic level (TP101)

Overview of learning objectives per exercise

Equipment set for the basic level (TP101)

Allocation of equipment per exercise

Practical tools for the trainer

Structure of the exercises

Designations of the components

CD ROM contents

Equipment set for the advanced level (TP102)

Learning objectives for the advanced level (TP102)

Exercise 1: Pressing cheeses

Exercise 2: Opening a fodder silo

Exercise 3: Clamping boards to a saw bench

Exercise 4: Sorting packages

Exercise 5: Stopping milk bottles

Exercise 6: Opening and closing a pipeline

Exercise 7: Shutting off a pipeline