49408317-Neumatica-avanzada

Workbook TP 102

CD-ROM included

Festo Didactic

541089 en

PneumaticsAdvanced Level

2 Festo Didactic GmbH & Co. KG 541089

The Festo Didactic learning system has been developed and produced solely for

vocational and further training in the field of automation and technology. The

training company and / or instructor need to ensure that trainees observe the safety

precautions specified in this workbook.

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

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

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

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

Didactic.

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

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

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

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

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

Intended use

Festo Didactic GmbH & Co. KG 541089 3

Preface______________________________________________________________ 5

Introduction__________________________________________________________ 7

Notes on safety and operation ___________________________________________ 9

Technology package for pneumatics (TP100) ______________________________ 11

Training aims Advanced Level (TP102) __________________________________ 13

Allocation of training aims and exercises _________________________________ 15

Equipment set Advanced Level (TP102) _________________________________ 17

Allocation of equipment and exercises ___________________________________ 20

Methodological help for the trainer ______________________________________ 22

Methodological structure of the exercises_________________________________ 24

Designation of equipment _____________________________________________ 25

Equipment set Basic Level (TP101) _____________________________________ 26

Training aims Basic Level (TP101)______________________________________ 27

Part A Exercises

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

Exercise 2: Separating of drinks bottles __________________________________A-9

Exercise 3: Drilling of valve manifold blocks ______________________________A-17

Exercise 4: Filling of drinks bottles______________________________________A-25

Exercise 5: Cleaning of workpieces _____________________________________A-35

Exercise 6: Printing of mobile phone housings ____________________________A-43

Exercise 7: Packaging of spark plugs ____________________________________A-49

Exercise 8: Sealing of guide bushes_____________________________________A-55

Exercise 9: Hardening of material test specimens__________________________A-63

Exercise 10: Bending of sheet metal strips _______________________________A-69

Contents

Contents


Part B Fundamentals

Part C Solutions

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

Exercise 2: Separating of drinks bottles __________________________________C-7

Exercise 3: Drilling of valve manifold blocks ______________________________C-11

Exercise 4: Filling of drinks bottles______________________________________C-17

Exercise 5: Cleaning of workpieces _____________________________________C-27

Exercise 6: Printing of mobile phone housings ____________________________C-35

Exercise 7: Packaging of spark plugs ____________________________________C-41

Exercise 8: Sealing of guide bushes ____________________________________C-47

Exercise 9: Hardening of material test specimens__________________________C-53

Exercise 10: Bending of sheet metal strips _______________________________C-59

Part D Appendix

Organiser __________________________________________________________ D-2

Assembly technology ________________________________________________ D-3

Plastic tubing_______________________________________________________ D-4

Data sheets

Circuit diagrams


Festo Didactics Learning System for Automation and Technology is orientated

towards different training and vocational requirements and is therefore structured

into the following training packages:

Basic packages to provide technology-spanning basic knowledge

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

technology

Function packages to explain the basic functions of automated systems

Application packages to facilitate vocational and further training based on actual

industrial applications

The technology packages deal with the following technologies: Pneumatics,

electropneumatics, programmable logic controllers, automation using a personal

computer, hydraulics, electrohydraulics, proportional hydraulics and handling

technology.

Preface

Preface


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

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

hydraulic and electrical drives.

All the training packages are of identical structure:

Hardware

Teachware

Software

Seminars

The hardware consists of didactically designed industrial components and systems.

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

training hardware and comprises:

Textbooks (with exercises and examples)

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

sheets)

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

environment)

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

use both in the classroom and for self-tuition.

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

software for programmable logic controllers.

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

packages completes the range of vocational and further training available.


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

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

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

comprised exclusively of electropneumatic control systems.

Basic Level TP101 is suitable for basic training in pneumatic control technology and

provides knowledge regarding the physical fundamentals of pneumatics and the

function and use of pneumatic components. The equipment set enables you to

construct simple pneumatic control systems.

Advanced Level TP102 focuses on further training in pneumatic control technology.

The equipment set enables you to construct complex combinatorial circuits with

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

sequencer modules.

Prerequisite for the assembly of control systems is a fixed workstation using a Festo

Didactic profile plate, consisting of 14 parallel T slots spaced 50 mm apart. A mobile,

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

air supply.

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

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

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

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

systems for all of the 10 exercise definitions. The theoretical fundamentals to help

you understand this collection of exercises can be found in the textbook

Pneumatics Basic Level

Also available are data sheets in respect individual devices ( cylinders, valves,

measuring devices, etc.).

Introduction

Introduction



The following advice should be observed in the interest of your own safety:

Pressurised air lines that become detached can cause accidents. Switch off the

supply immediately.

Do not switch on compressed air until tubing is securely connected.

Caution!

Cylinders may advance automatically as soon as the compressed air is switched

on.

Do not operate roller lever valves manually during fault finding (use a tool).

Observe general safety regulations (DIN 58126).

Limit switches must always be mounted laterally to the trip cam (not to the

front).

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

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

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

fitting up to the stop, no additional securing required!

Releasing of push-in fitting: The tubing can be released by pressing down the

releasing ring (disconnection under pressure is not possible!)

Switch off compressed air supply prior to dismantling the circuit.

The mounting plates of the devices are in the form of mounting variants A, B or C:

Variant A, latching system

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

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

the blue lever.

Variant B, rotary system

For medium weight loadable devices (e.g. actuators). These devices are clamped

onto the profile plate by means of T-head bolts. Clamping and releasing is

achieved by means of the blue knurled nut.

Variant C, screw system

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

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

socket head screws and T-head bolts.

The data for the individual devices, as specified in the data sheets in Part D, must

be observed.

Notes on safety and operation

Notes on safety and operation


A stop watch is required for the evaluation of the assembled control systems, i.e.:

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

with the specified values,

To adjust time delay valves.


The technology package TP100 consists of numerous individual training media as

well as seminars. The subject matter of this package is exclusively pneumatic control

systems. Individual components from the technology package TP100 may also form

a component part of other packages.

Fixed workstation with Festo Didactic profile plate

Compressor (230 V, 0.55 kW, maximum 8 bar = 800 kPa)

Equipment set or individual components (e.g. cylinders, directional control

valves, predetermining counters, stepper modules, logic elements, pneumatic

proximity sensors)

Optional training aids (e.g. visual displays, 5/3-way valve, pulling/pushing load)

Practical training models

Complete laboratory set-ups

Training documentation

Textbooks Basic Level TP101

Fundamentals of pneumatic control technology

Maintenance of pneumatic devices and systems

Workbooks Basic Level TP101

Advanced Level TP102

Optional teachware Sets of overhead transparencies

Magnetic symbols, drawing template

Simulation software FluidSIM

Pneumatics

WBT Fluid Studio Pneumatics

Cutaway model sets 1 + 2 with storage case

Technology package for pneumatics (TP100)

Important elements of

TP100

Technology package for pneumatics (TP100)


Seminars

P111 Fundamentals of pneumatics and electropneumatics

P121 Maintenance of and fault finding on pneumatic and electropneumatic systems

IW-PEP Maintenance and servicing in control technology pneumatic and electropneumatic

control systems

P-AL Pneumatics for vocational training

Details of venues, dates and prices can be found in the current seminar planner.

Information regarding further training media is available in our catalogues and on

the Internet. The Learning System for Automation and Technology is continually

updated and expanded. The sets of overhead transparencies, films, CD-ROMs and

DVDs as well as technical books are available in several languages.


To familiarise yourself with different types of end position sensing.

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

memory function.

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

open).

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

these for a specified circuit.

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

To be able to use pneumatic decrementing counters.

To be able to design indirect cylinder actuation.

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

sensors.

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

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

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

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

To be able to set time delays according to specifications.

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

To be able to realise the following input commands:

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

CYCLE END and AUTOMATIC/MANUAL.

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

To familiarise yourself with the option of facilitating variable step repetitions

within a motion sequence and to assemble this circuit.

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

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

and to be able to assemble this circuit.

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

movement in the partial stroke range.

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

air.

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

To understand how valve output signals can be inverted.

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

a sequence control in stepper design.

Training aims of Advanced Level (TP102)

Training aims of Advanced Level (TP102)



Exercise 1 2 3 4 5 6 7 8 9 10

Training aims

To familiarise yourself with different types of end position

sensing.

To familiarise yourself with the options of designing

control systems with a memory function.

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

(normally closed/normally open).

To familiarise yourself with displacement-step diagrams

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

To be able to realise circuits with parallel movements in

push-pull mode.



To be able to select appropriate sensors for applications

and adjust such sensors.

To familiarise yourself with the design and function of

stepper modules.

To be able to design the basic continuous cycle stepper

control system.

To be able to install one-way flow control valves

dependent on given parameters.

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


To familiarise yourself with circuits in order to cancel time

delays via signal input.

To be able to design a stepper control with the input

commands AUTOMATIC/MANUAL, START and RESET.


EMERGENCY-STOP, acknowledge EMERGENCY-STOP,

START, RESET, STOP at CYCLE END and

AUTOMATIC/MANUAL.

Allocation of training aims and exercises

Allocation of training aims and exercises


Exercise 1 2 3 4 5 6 7 8 9 10

Training aims

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

loop, that enables the following inputs:

AUTOMATIC/MANUAL, START, STOP at CYCLE END and

RESET.

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

To familiarise yourself with the option of facilitating a

variable motion sequence and to be able to design this

circuit.

To familiarise yourself with the option of realising the

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

circuit.

To familiarise yourself with circuits in order to realise the

reversal of a cylinder movement in the partial stroke

range.

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

with protected pilot air with the inputs START,

AUTOMATIC/MANUAL and RESET.

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

stroke range.

To be able to adjust proximity sensors in the end positions

and in the partial stroke range.

To understand how valve output signals can be inverted.

To be able to realise a control system with control

behaviour in combination with a sequence control in

stepper design.


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

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

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

expanded as desired with other equipment sets of the Learning System for

Automation and Technology.

Description Order No. Quantity

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

3/2-way pneumatic valve, convertible 539768 4

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

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

(EMERGENCY-STOP)

152864 1

5/2-way pneumatic double pilot valve 539769 2

Back pressure valve 152868 1

Double-acting cylinder 152888 2

Dual pressure valve, 3-fold 152883 1

Non-return valve, piloted 540715 2

One-way flow control valve 539773 2

Plastic tubing 4 x 0.75, 10 m 151496 2

Predetermining counter, pneumatic 152877 1

Push-in sleeve 153251 10

Push-in T-connector 153128 20

Shuttle valve 539771 1

Shuttle valve, 3-fold 152882 1

Stepper module 152886 1

Time delay valve, normally open 539759 1

Equipment set Advanced Level (TP102)

Equipment set Advanced

Level (TP102

Order No.: 540711)



Desccription Symbol

3/2-way valve with pushbutton,

normally closed

2

31

3/2-way valve with mushroom

actuator,

normally open (EMERGENCY-STOP)

2

31

3/2-way roller lever valve with idle

return

2

31

Back pressure valve

31

2

3/2-way pneumatic valve,

normally closed

2

31

12

5/2-way double pilot valve 24

35 1

14 12

Predetermining counter, pneumatic 2

1

12 10

Time delay valve,

normally open 10

2

31

One-way flow control valve 21

Equipment set symbols



Description Symbol

Shuttle valve, 3-fold 2 2 2

1 1/31/31/3 1 1

Shuttle valve 2

1/31

Dual pressure valve, 3-fold 2 2 2

1 1/31/31/3 1 1

Double-acting cylinder

Non-return valve, piloted 2

1 21

Description Symbol

Stepper module

L L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

A1

X1

YnY Yn+1 Yn+1Yn

Zn Zn Zn+1Z Z

L LLL

P PP P PP

Y

TABTAATAATAA

Zn+1


Exercise 1 2 3 4 5 6 7 8 9 10

Equipment

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

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

Non-return valve, piloted 2

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

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

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

Back pressure valve 1 1 1

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

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

(EMERGENCY-STOP)

1 1

Stepper module 1 1 1 1 1 1

Time delay valve, normallyopen 1 1

Predetermining counter, pneumatic 1 1

Shuttle valve 1 1 1

Shuttle valve, 3-fold 3 3 3 3 2

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

Allocation of equipment and exercises

Equipment set TP102

Allocation of equipment and exercises


Exercise 1 2 3 4 5 6 7 8 9 10

Equipment

Cylinder, double-acting 1

Cylinder, single-acting 1

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

3/2-way pneumatic valve 1

5/2-way pneumatic valve 1*

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

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

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

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

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

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

Time delay valve, normally closed 1 1

Shuttle valve 1 1

Dual pressure valve 1

Manifold 1 1 1 1 1 1 1 1 1 1

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

* Convert the available valve into the required valve.

Equipment set TP101


Training

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

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

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

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

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

training aims addressed at the time.

Variations in training aims

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

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

importance.

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

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

commissioning of the control system.

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

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

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

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

theoretical part of training.

The preparation of complete solution descriptions or sections thereof based on

the circuit documentation or the assembled control system also facilitates

interdisciplinary tuition.

Time required

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

knowledge of the trainees:

Trainees who have undergone vocational training in the engineering and

electrical field:

Just under 160 hours,

Trainees with technicians or engineering training:

up to 80 hours.

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

diagrams or sections of circuit diagrams.

Methodological help for the trainer

Methodological help for the trainer


Components of the equipment set

The collection of exercises in TP102 is didactically and methodologically

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

Advanced Level TP102).

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

Representation

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

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


All 10 exercises in Part A are of the same methodological structure.

The exercises are divided into:

Title

Training aims

Problem definition

Parameters

as well as

Project task

Positional sketch

Worksheets

The proposed solutions in Part C are divided into:

Circuit diagram

Solution description

as well as

Circuit design

Equipment list

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

Methodological structure of exercises


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

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

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

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

and these are consecutively numbered separately.

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

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

Sensors: 1B1, 1B2, ...

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

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

Designation of equipment


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

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

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

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

control system.

Description Order No. Quantity

3/2-way pneumatic valve, convertible 539768 1

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

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

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

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

5/2-way double solenoid valve 539769 3

5/2-way pneumatic valve 538694 1

5/2-way valve with selector switch 152862 1

Double-acting cylinder 152888 1

Dual pressure valve 539770 2

Manifold 152896 1

One-way flow control valve 539773 2

On-off valve with filter regulating valve 540691 1

Plastic tubing 4 x 0.75, 10 m 151496 2

Pneumatic proximity sensor 539775 2

Pressure gauge 152865 2

Pressure regulating valve with pressure gauge 539756 1

Pressure sequence valve 152884 1

Push-in sleeve 153251 10

Push-in T-connector 153128 10

Quick exhaust valve 539772 1

Shuttle valve 539771 1

Single-acting cylinder 152887 1

Time delay valve, normally closed 540694 1

Equipment set Basic Level (TP101)

Equipment set Basic Level

(TP101

Order No.: 540710)


To familiarise yourself with the design and function of a single-acting cylinder.

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

To be able to identify and draw types of directional control valve actuation.

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

To be able to analyse and evaluate circuits.

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

cylinder.

To familiarise yourself with the design and mode of operation of a 5/2-way valve.

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

To familiarise yourself with the mode of operation of a 5/2-way valve with

pneumatic actuation.

To familiarise yourself with the difference between a signalling element and a

control element.

To be able to measure pressure in pneumatic control circuits.

To be able to differentiate between and utilise types of flow control according to

specifications.

To be able to set cylinder advancing and retracting speeds.

To familiarise yourself with one type of signal storage in pneumatic circuits.

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

To be able to explain and configure latching circuits.

To familiarise yourself with one option of cylinder end position sensing.

To be able to combine logic operations.

To familiarise yourself with the design and mode of operation of magnetic

proximity sensors.

To be able to differentiate between and select and use 5/2-way valves according

to specifications.

To be able to further develop existing circuits.

To familiarise yourself with the design and mode of operation of a pressure

regulating valve.

To be able to analyse circuits and optimise these according to specifications.

To familiarise yourself with the design and mode of operation of a pressure

regulating valve.

To be able to analyse circuits and optimise these according to specifications.

To familiarise yourself with the design and mode of operation of a time delay

valve.

To be able to design circuits with oscillating movements.

To be able to use time delay valves dependent on parameters.

To be able to analyse and design circuits using two cylinders.

Training aims Basic Level (TP101)

Festo Didactic GmbH & Co. KG 541089 A-1

Part A Exercises

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

Exercise 2: Separating of drinks bottles __________________________________A-9

Exercise 3: Drilling of valve manifold blocks ______________________________A-17

Exercise 4: Filling of drinks bottles______________________________________A-25

Exercise 5: Cleaning of workpieces _____________________________________A-35

Exercise 6: Printing of mobile phone housings ____________________________A-43

Exercise 7: Packaging spark plugs ______________________________________A-49

Exercise 8: Sealing of guide bushes_____________________________________A-55

Exercise 9: Hardening of material test specimens__________________________A-63

Exercise 10: Bending of sheet metal strips _______________________________A-69

Contents

Contents

A-2 Festo Didactic GmbH & Co. KG 541089


To familiarise yourself with different types of end position sensing.

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

memory function.

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

open).

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

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

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

closed and opened using double-acting cylinders.

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

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

1. Complete the pneumatic circuit diagram.

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

3. Carry out the assembly.

4. Check the assembled circuit.

5. Describe the mode of operation of the circuit.

6. Compile the equipment list.

Exercise 1: Opening and closing of an oven door

Training aims

Problem definition

Parameters

Project task



Hardening oven

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

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

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

one of the two end positions.

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

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

3. The cylinder movement in abbreviated annotation is

1A1+ 1A1

What faults may occur when tubing up the circuit?

What are the effects of such faults? Describe these.

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

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

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

function?

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

converted?

How does the circuit react after a pressure loss?

What is a binary reducing stage?

Positional sketch

Additional exercises




Name: Date:

Completing the pneumatic circuit diagram Sheet 1 of 1

Complete the pneumatic circuit diagram and enter the port designations.

1V4

1V3

2

1 1

2 2

2

4

4

3

3

5

5

1

1

1V5

14

14

12

12

1V6

1A1

2

31

1S1

10

10

2

2

3

3

1

1

1V2

1V1

Pneumatic circuit diagram




Name: Date:

Compiling the equipment list Sheet 1 of 1

Apart from the circuit diagram, comprehensive project documentation also requires

an equipment list.

Compile the equipment list by entering the required equipment in the table

below.

Quantity Description

Equipment list




Name: Date:

Carrying out additional exercises Sheet 1 of 2

What faults can occur when tubing up the circuit?

What are the effects of such faults? Describe these.

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

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

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

function?

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________



Exercise 1: Opening and closing of an over door

Name: Date:


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

to be converted?

How does the circuit react after a loss of pressure?

What is a binary reducing stage?

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________


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

these for a specified circuit.

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


In a bottling plant, bottles are to be filled with drinks. The bottles are to be

separated immediately after the filling station. Three bottles at a time are to be

pushed on to a conveyor via an ejecting cylinder. In a subsequent station, these

bottles are to be placed into a drinks crate/box?.

It is essential to ensure that only one single start signal is emitted even if the

start button is actuated for a longer period.






Exercise 2: Separating of drinks bottles

Training aims

Problem definition

Parameters

Project task



Filling system

1. If the 5/2-way pneumatic valve with selector switch 0S1 is actuated, cylinder 1A1

is to advance and cylinder 2A1 to retract.

2. The output signal of the pneumatic proximity sensor 2B1 is to decrement the

numeric value by one at the predetermining counter 0Z1 with each actuation.

3. If the numeric value of the pneumatic predetermining counter 0Z1 is 0, the

compressed air supply of pilot port 14 of the 5/2-way double pilot valve 0V2 is to

be switched off via the 3/2-way pneumatic valve 0V1.

4. Resetting of the 5/2-way pneumatic valve with selector switch 0S1 is to reset the

pneumatic predetermining counter.

5. The cylinder movement in abbreviated notation is

1A+ 1A

2A 2A+

3 double strokes

Positional sketch



What happens if both limit switches on the cylinder are moved?

Notes

You will need to mount one of the two magnetic limit switches of the double-

acting cylinder from TP101 on the double-acting cylinder from TP102.

The pneumatic predetermining counter 0Z1 is set by pressing the wide key

adjacent to the counter and entering the units (one, ten, .. ) (see data sheet).

Additional exercise




Name: Date:

Designing the displacement-step diagram Sheet 1 of 1

Design the displacement-step diagram for the process described.

1A1

0

1

2A1

0

1

1 2 3=1

Displacement-step diagram




Name: Date:


Complete the pneumatic circuit diagram.

1V1

0V2 0Z1

2V1

2

224

4

4

3

3

35

5

51

1

1

14

14

1412 12

12

31

2B1 2

1V2 2V21V3 2V3

1A1 2A1

1B1 2B1

2

1

12 10

1 11 1

2 22 2

2

31

1B1 2

10

2

31

0V1

0S1 24

35

1





Name: Date:



an equipment list.


below.


Equipment list




Name: Date:


What happens if both limit switches on the cylinder are moved?

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________


To be able to design indirect circuit actuation.

To be able to compare different sensors and select appropriate sensors for an

application.

Valve manifold blocks are to be drilled horizontally and vertically by two

pneumatically actuated feed units. The two drilling axes are to intersect.

The start is to be effected via a valve with pushbutton.

Since the drilling axes are intersecting, you need to ensure that the first drilling

operation is completed before the second one starts.






Exercise 3: Drilling of valve manifold blocks

Training aims

Problem definition

Parameters

Project task



Automatic drilling machine

1. The double-acting cylinders 1A1 and 2A1 are to be monitored in the end position

by a roller lever valve with idle return 1B1, a back pressure valve 1B2, pneumatic

proximity sensor 2B1 and a roller lever valve 2B2.

2. The start is to be effected via a 3/2-way valve with pushbutton 1S1.

3. Cylinder1A1 is to advance and simulate the first drilling operation. In the

forward end position, the cylinder is to actuate a back pressure valve 1B2, which

is to switch the final control element 1V1. Cylinder 1A1 is to retract.

4. If cylinder 1A1 is back in the retracted end position, the roller lever valve with

idle return 1B1 is to switch in the direction of flow and actuate the final control

element 2V1.

5. Cylinder 2A1 is to advance and simulate the second drilling operation. Once it

reaches the forward end position, it is to actuate the roller lever valve 2B2. The

final control element 2V1 is to reverse and cylinder 2A1 is to return into the

retracted end position where it is to actuate the pneumatic proximity sensor 2B1.


1A1+ 1A1 2A1+ 2A1

Positional sketch



If the cylinder impacts on the back pressure valve, this may be damaged.

How does the circuit react if a limit switch is moved?

What must be observed when mounting the back pressure end stop?

Compare the function and response of the various sensors.





Name: Date:


Design the displacement-step diagram.

1A1

0

1

2A1

0

1

1 2 3 4 5=1





Name: Date:



2

2

3

3

1

1

1S1

1B1

3 3 31 1 1

2B1 1B2 2B22 2 2

1B1 1B2 2B21A1

2A1

2B1





Name: Date:



an equipment list.


below.


Equipment list




Name: Date:


How does the circuit react if a limit switch is moved?

What needs to be observed when mounting the back pressure end stop?

Compare the function and response of the various sensors.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________



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

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

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

A drinks producer requires bottles to be filled automatically. During the filling

operation, the bottles are to be pressed against the extended piston rod of the

separating cylinder by a continuously running conveyor. The storage container is

located above this and is to be opened and closed by a cylinder. The cylinder is to

close the container opening in the retracted state.

The flow control of the separating cylinder is to be set such that only the filled

bottle is released and a new, empty drinks bottle is positioned underneath the

filling valve.

1. First of all, process the introductory exercises for the stepper module.






Exercise 4: Filling of drinks bottles

Training aims

Problem definition

Parameters

Project task



Filling device

1. If a valve is actuated using selector switch 0S1, the closing cylinder 1A1 is to

advance and retract again with restricted exhaust air. Both cylinder end positions

are to be monitored via the roller lever valves 1B1 and 1B2.

2. The separating cylinder 2A1 is then to retract with restricted exhaust air and

immediately advance again with restricted exhaust air. The cylinder end

positions are to be monitored via the pneumatic proximity sensors 2B1 and 2B2.

3. Both proximity sensors and the roller lever valves are to signal the cylinder

positions to the sequencer.

4. The motion sequence is to end if the valve is reset via selector switch 0S1.


1A+ 1A 2A 2A+

How does the circuit react if the roller lever valve 1B2 or the proximity sensor

2B2 are moved?

Design the displacement-step diagram for this circuit.

Positional sketch





Name: Date:

Stepper module Sheet 1 of 3

Introductory exercise using a stepper module

(without drives and sensors)

Connect the correct connections of the stepper so that it runs automatically.

Which connections do you need to connect together?

Connection Connection

Yn Yn+1

P P

Zn Zn+1

L L

X1 A1

X2 A2

X3 A3

X4 A4

What are the effects of the interruption in the tubing connections?

Draw up an evaluation table.

Connection Effect

A1 X1

A2 X2

A3 X3

A4 X4

Zn Zn+1

Yn Yn+1




Name: Date:


Mode of operation of a stepper sequencer

A signal is input into the stepper module 1 via input, thereby triggering the output

command, e.g. 1A1+. Step 2 is prepared simultaneously and the last step in the

chain (in this case step 4) is cancelled via the output connection Z.

Step 2 is reset and an output signal, e.g. 2A1, is triggered if step 1 receives the

acknowledgement step executed" via the limit switch 1B2. Step 3 is prepared

simultaneously and step 1 is cancelled.

The next steps are executed correspondingly.

L L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

A1

X1

YnY Yn+1 Yn+1Yn

Zn Zn Zn+1Z Z

L LLL

P PP P PP

Y

TABTAATAATAA

Zn+1

Resetting a sequencer

If the sequencer stops in any step, the currently activated step can be cancelled via a

central reset signal at connection "L". The central reset signal is transmitted to one

of the two OR inputs.




Name: Date:


What are the advantages of the stepper module compared to reversing valve

technology?

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

Which exercises can the individual stepper module undertake?

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




Name: Date:


Design the displacement-step diagram.

1A1

0

1

2A1

0

1

1 2 3 4 5=1





Name: Date:



Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

1V1 2V1 2 24 4

3 35 51 1

1V2 2V2

14 1412 12

1V3 2V3

1B1 1B21A1

s1

s2

s3

s4

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

1B2 2B1 2B22 2 2

3 3 31 1 1

1B1 2

31

2B1

2A1

2B2

Y

TABTAATAATAA

0S1 2

31

1 11 1

2 22 2





Name: Date:



an equipment list.


below.


Equipment list




Name: Date:


How does the circuit react if the roller lever valve 1B2 or the proximity sensor

2B2 are moved?

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________


To be able to design a stepper sequencer control with the input commands

AUTOMATIC/MANUAL, START and RESET.

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


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

A cleaning bath is to be fed automatically. A wire cage with material is to be moved

above the bath via a double-acting cylinder. A second double-acting cylinder is to

lower the wire cage into the cleaning bath, where it is to remain for an adjustable

time period, until it is raised again for draining. The draining time must also be

adjustable, after which the first cylinder is to return into the initial position.

It must be possible for the drives and sequencer to be reset via a pushbutton

0S3, if a valve with selector switch 0S1 is reset from AUTOMATIC to MANUAL.

The bath dwell time t1 is to be cancelled if pushbutton 0S4 is pressed and the

dipping cylinder 2A1 is to move into the retracted end position.

Actuation of a valve with pushbutton 0S5 is to terminate the draining time t2 and

the horizontal cylinder 1A1 is to return into the initial position.

1. First of all, design a simplified ciruit diagram without taking into account the

parameters and time delay.

2. Assemble this circuit and check its functioning.

3. Expand the pneumatic circuit diagram in accordance with the parameters.

4. Carry out the circuit assembly.



7. Complete the equipment list.

Exercise 5: Cleaning of workpieces

Training aims

Problem definition

Parameters

Project task



Cleaning bath

1. A horizontally built-in double-acting cylinder 1A1 is to move the wire cage to the

right underneath the extractor hood, i.e. the cleaning bath, if a valve is actuated

using pushbutton 0S2.

2. The cage is to remain in the bath for t1 = 3 seconds after the double-acting

cylinder 2A1 has advanced.

3. Once the cage is raised again, it is to pause for t2 = 2 seconds to drain before the

horizontal cylinder 1A1 moves into the retracted end position again.

4. The cylinder movements are to be with exhaust air restriction at both ends.

5. The cylinder movements in abbreviated notation are

1A+ 2A+ 2A 1A

Design the displacement-step diagram with signal lines.

Positional sketch





Name: Date:



1A1

0

1

2A1

0

1

1 2 3 4 5=1





Name: Date:


Complete the pneumatic circuit diagram without realising the parameters.

s1

s2

s3

s4

Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

1V1 2V1 2

1 11 1

2 22 2

24 4

3 35 51 1

1V2 2V21V3 2V3

14 1412 12

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

Y

TABTAATAATAA

1A1

1B1 1B2

2 2

3 31 1

0S2 0S3

0S1 24

351

2B1 2B22A1





Name: Date:


Complete the pneumatic circuit diagram including the parameters.

s1

s2

s3

s4

Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

1V1 2V1 2

1 11 1

2 22 2

24 4

3 35 51 1

1V2 2V21V3 2V3

14 1412 12

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

2B2

2B1

2

2

3

3

1

1

Y

TABTAATAATAA

0V7 0V8 2 2

1/3 1/31 1

1A1

1B1 1B2

2 2 2 2

3 3 3 31 1 1 1

0S2 0S3

0S1

0S4 0S5

24

351

2B1 2B22A1

1B2 1B12 2

3 31 1

0V4 0V52 2

1/3 1/31 1

0V1 2

31

31

0V32

10

10

2

31

0V2





Name: Date:


Modify the circuit diagram such that, during the reset function, cylinder 2A1

advances first and then cylinder 1A1.

s1

s2

s3

s4

Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

1V1 2V1 2

1 11 1

2 22 2

24 4

3 35 51 1

1V2 2V21V3 2V3

14 1412 12

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

2B1 2

31

Y

TABTAATAATAA

0V7

0V8

2 2

1/3

1/3

1

1

1A1

1B1 1B2

2 2 2

3 3 31 1 1

0S2 0S3

0S1

0S5

24

351

2B1 2B22A1

1B2 1B12 2

3 31 1

0V5 2

1/3

2

31

0S4

0V4 2

1/31 1

0V1 2

31

31

0V32

10

10

2

31

0V22B2 2

31





Name: Date:

Completing the equipment list Sheet 1 of 1


an equipment list.

Complete the equipment list by entering the required equipment in the table

below.


2 Cylinder, double-acting

4 One-way flow control valve

2 5/2-way pneumatic double pilot valve

5/2-way valve with selector switch

3/2-way valve with pushbutton, normally closed

3/2-way pneumatic valve, normally open

3/2-way roller lever valve, normally closed

Proximity sensor, pneumatic

Shuttle valve (OR)

Dual pressure valve (AND)

Time delay valve, normally closed

Time delay valve, normally open

1 Stepper module Type 3TAA/1TAB

1 Manifold

1 On/off valve with filter regulating valve

1 Compressed air supply

Equipment list



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

CYCLE END and AUTOMATIC/MANUAL.

Mobile phone faceplates are to be printed using a tampon-printing machine. The

faceplates are to be fed in pairs via a conveyor.

The tampon printing machine sequence is to be realised via a feed unit.

Pre-selection between MANUAL and AUTOMATIC mode is to be facilitated via a

valve with selector switch.

In AUTOMATIC mode, two valves with pushbuttons (START, STOP at CYCLE END),

that influence a memory, are to be pressurised.

Two further valves with mushroom actuator or pushbutton (EMERGENCY-STOP,

acknowledge EMERGENCY-STOP) also influence a memory.

In MANUAL mode, the sequencer and the drives must be resettable via a fifth

valve with pushbutton.

1. Extend the pneumatic circuit diagram in accordance with the parameters.





Exercise 6: Printing of mobile phone housings

Training aims

Problem definition

Parameters

Project task



Tampon printing machine

1. Continuous operation is to be started by pressing the START button 0S6. The

sequence is to stop at the end of a cycle by pressing the STOP at CYCLE END

button 0S5.

2. In MANUAL mode, the cylinders and sequencer are to be resettable by pressing

the RESET button 0S4.

3. The retracting movements of the cylinders are to be exhaust air restricted.

4. The cylinder movements in abbreviated annotation are:

1A+ 3A+ 1A 3A

2A 2A+

Positional sketch



Exercise 6: Printing of mobile phone casings

Name: Date:



1A1

0

1

2A1

0

1

3A1

0

1

1 2 3 4 5=1





Name: Date:



2B1

31

1B2 2 2

31

Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

1V1 3V1 2V1 2 224 4 4

3 335 551 11

1V2 2V2 3V2

14 1414

14

12 1212

12

1B1 3B11B2 3 B21A1 3A1

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

2B2

31

3B1

1B1

2

2 2

3

3

1

1

Y

TABTAATAATAA

2

31

3B2

0V9 0V10

0V12

2 2

2

1/3 1/3

1/3

1 0V8 2

1/31

1

1

2A12B1 2B2

10

10

2

23

3

1

1

0V13

0V11

0V6 24

351

14 12

0V5 2

1/31

2

2

2

2

3

3

3

3

1

1

1

1

0S6

Start

0S4

0S3

Reset

0S2

0S5

Stop at cycle end

AcknowledgeEMERGENCY-STOP

Manual/Automatic

0V2

2

2

4

4

3

3

5

5

1

1

2

31

0S1

EMERGENCY-STOP

1 1 1

2 2 2

0V1 2

31

10

s1

s2

s3

s4





Name: Date:



an equipment list.

Complete the equipment list by entering the required equipment in the table

below.




5/2-way pneumatic double pilot valve



3/2-way valve with mushroom actuator, normally open (EMERGENCY-STOP)


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

3/2-way back pressure valve, normally closed



Shuttle valve (OR)



1 Manifold



Equipment list


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

To familiarise yourself with the option of facilitating variable step repetitions

within a motion sequence and to assemble this circuit.

To be able to develop an input circuit with self-latching loop, that enables the

following inputs: AUTOMATIC/MANUAL, START, STOP at CYCLE END AND RESET.

To be able to select suitable sensors for an application and adjust these sensors

(use of a sensor to detect cardboard boxes in a magazine).

Two double-acting cylinders 1A1 and 2A1 are to operate two magazines. One flat

magazine is to contain the spark plugs and the other the cardboard boxes for the

packaging. Four spark plugs each are to be fed from the flat magazine to a

cardboard box. The number of spark plugs to be packed is to be adjustable.

A cardboard box is to be pushed out of the gravity feed magazine with the advancing

of cylinder 1A1, to be ready for filling. Then, cylinder 2A1 is to execute four double

strokes, thereby separating the spark plugs from the flat magazine. The cycle is to

be completed with the retraction of cylinder 1A1 (gravity feed magazine).

Switching between MANUAL and AUTOMATIC mode is to be possible by actuating

the valve with selector switch 0S1.

Actuation of the STOP at CYCLE END pushbutton 0S4 is to start the cycle through

to the end and stop the control system.

In AUTOMATIC mode, the control system is to operate in continuous cycle.

When switching to MANUAL, both cylinders are to retract if the RESET

pushbutton 0S2 is actuated and the sequencer is to be returned into the initial

position.

It must not be possible to start unless cardboard boxes are present. A 3/2-way

valve with selector switch 0S5 is to simulate the conditions magazine empty

and magazine loaded.

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


3. Check the circuit assembly.



Exercise 7: Packaging of spark plugs

Training aims

Problem definition

Parameters

Project task



2A1

1A1

0S5

Packaging device

1. Actuation of the START button 0S3 is to set up a self-holding circuit with the

control system operating in a continuous cycle. Actuation of the STOP at CYCLE

END button 0S4 is to interrupt the self-latching loop and cancel the stored START

signal. The self-latching loop is to be interrupted also, i.e. it cannot be set up, if

the selector switch 0S5 simulates the condition magazine empty, i.e. in the

absence of any packaging material in the stacking magazine.

2. In AUTOMATIC mode, the self-holding circuit and sequencer are to be supplied

with compressed air. If operation is switched to MANUAL via a 5/2-way valve

with selector switch 0S1, the RESET button 0S2 is to be supplied with

compressed air. Its actuation is to cause the two cylinders to retract and the

sequencer to assume the initial position.

3. A pneumatic predetermining counter is to count the advance movements of

cylinder 2A1 and emit a signal to the stepper sequencer when reaching a preset

value.

4. The end positions of cylinder 1A1 are to be monitored using pneumatic proximity

sensors. Two roller lever valves are to monitor the end positions of cylinder 2A1.

5. The cylinder movement in abbreviated notation is:

1A1+ 2A1+ 2A1 1A1

4x

Design the displacement-step diagram for this circuit.

Positional sketch




Notes

In practice, a roller lever valve is used to monitor whether the stacking magazine

is full. This is not suitable in this case, since continuous actuation of the valve is

not intended. The use of a 3/2-way valve with selector switch 0S5 is suggested

instead.

According to the circuit diagram, the stepper sequencer 0Z1 consists of three

modules. The Festo Didactic stepper module is equipped with four modules. You

should therefore bridge the second step by tubing up output A2 and input X2.

The following applies for the bridging of steps:

The last step must not be an idle step.

Two idle steps must not be consecutively switched.

The valves for input are:

STOP at CYCLE END 0S4,

START 0S3,

RESET 0S2,

AUTOMATIC/MANUAL 0S1.

Trial run

Proceed as follows:

1. Reset: "MAN" and "RESET"

2. Start: "AUTO" and "START"

3. Interrupt: "STOP at CYCLE END"




Name: Date:



1 2 3 4 5 6 7 8 9 10 11=1

2A1

0

1

1A1

0

1





Name: Date:



s1

s2

s3

s4

Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

1V1 2V1 2

1 11 1

2 22 2

24 4

3 35 51 1

1V2 2V21V3 2V3

14 1412 12

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

Y

TABTAATAATAA

0V1

2

1/3

1

1A1

1B1 1B2

2

2

22

2

2

2B1 2B22A1

1B2 1B12 2

3 31 1

0Z3 2

1

12 10

2B2 2

31

2B1 2

31

10

10

12

3

3

3

33

3

3

1

1

1

11

1

1

0V7

0V4

0V2

0S50S4

0S3

0S2

0S1 24

351





Name: Date:



an equipment list.

Complete the equipment list by entering the number of required components in

the table below.




2 5/2-way pneumatic double pilot valve


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


3/2-way pneumatic valve, normally closed




Pneumatic predetermining counter

Shuttle valve (OR)



1 Manifold



Equipment list


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

and to be able to assemble this circuit.

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

movement in the partial stroke range.

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

with the inputs START, AUTOMATIC/MANUAL and RESET.

Guide bushes with lapped through holes are to be sealed on both sides using a

plastic plug. The guide bushes are to be manually inserted into the device and the

plugs are to be fed via a gravity magazine.

The START signal 0S4 is to first of all trigger the advancing of the piston rod of the

exhaust air restricted double-acting cylinder 1A1. A plug is to be pressed through

the hole and close the rear righthand opening of the bush. Once the piston rod has

retracted a second plug is to follow and the piston then is to advance halfway and

immediately retract again thereby sealing the front lefthand side of the bush. The

bush can then be removed and a new sequence started.

Actuation of the EMERGENCY-STOP mushroom actuator 0S1 is to switch off the

compressed air supply. If cylinder 1A1 is in motion, it is to return into the

retracted end position. If cylinder 1A1 is in the forward end position, it is to

remain there.

If the RESET button 0S5 is actuated, both the cylinder and the stepper sequencer

are to move into the initial position.

1. Complete the circuit diagram.





Exercise 8: Sealing of guide bushes

Training aims

Problem definition

Parameters

Project task



1B1 1B3 1B2

1A1

Sealing device

1. A single cycle is to be introduced by pressing the START button 0S4. The

AUTOMATIC/MANUAL switch 0S3 is switched to AUTOMATIC for this. The pilot air

supply of the stepper sequencer is to be protected by means of a self-latching

loop via valves 0V3, 0V4 and 0V5.

2. The retracted end position of the cylinder is to be monitored via roller lever valve

1B1 and the forward end position via roller lever valve 1B2. The reversal in the

partial stroke range is to be triggered by the pneumatic proximity sensor 1B3.

3. Roller lever valve 1B1 is to transmit its signal to inputs X2 and X4 of the stepper

sequencer, since a second start takes place within a cycle.

Positional sketch



Note

This is a case where a signalling element actuates two stepper modules

simultaneously.

The magnetic limit switch (1S4) simultaneously operates inputs X2 and X4. If the

second step is reset, then this transmits the pulse. If the fourth step is reset, then

the signal is sent to the cylinder via A4 and resets the stepper module. Both step

outputs are connected via the shuttle valve (0V6), i.e. both the second step and

fourth step emit the pulse to the final control element (1V1) via valves (0V7),

(0V10) and (0V11).


Convert an available 5/2-way pneumatic valve into the required 3/2-way

pneumatic valve. Check the functioning of the valve prior to installation.





Name: Date:



1 2 3 4 5=1

0

1A m

1





Name: Date:



0V6

2

1/31

1B3

31

2

Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

1V1 24

35 1

1V2 1V3

14 12

1B1 1B2

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

1B1 2

31

Y

TABTAATAATAA

2

31

1B2

0V7

0V3

0V12

0V13

2

2

2

2

1/3

1/3

1/3

1/3

1

1

1

1

0V8 2

1/31

1B3

10

10

12

10

102

2

2

2

2

3

3

3

3

3

1

1

1

1

1

0V9

0V5

0V4

0V11

0V10

22

33 11

0S50S4

1 1

2 2

s1s2s3s4

1A1

14 12

0S3 Manual/Automatic

0V2

2

2

4

4

3

3

5

5

1

1

2

31

0S1

EMERGENCY-

STOP

0V1 2

31

10

2

31

0S2

AcknowledgeEMERGENCY-STOP

Start Reset





Name: Date:



an equipment list.

Complete the equipment list by entering the number of required components in

the table below.




5/2-way pneumatic double pilot valve


3/2-way valve with mushroom actuator, normally open (EMERGENCY-STOP)

3/2-way pneumatic valve, normally closed




Shuttle valve (OR)


1 Stepper module Type 3TAA/1 TAB

1 Manifold



Equipment list




Name: Date:

Carrying out additional exercises. Sheet 1 of 1

Convert an available 5/2-way pneumatic valve into the required 3/2-way

pneumatic valve. Check the functioning of the valve prior to installation.

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Exercise 8: Sealing of

49408317-Neumatica-avanzada

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Transcript of 49408317-Neumatica-avanzada