Pneumatics Advanced Level
Workbook TP 102
CD-ROM included
Festo Didactic 541089 en
Intended use
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.
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Contents
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
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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
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© Festo Didactic GmbH & Co. KG • 541089
Preface
Festo Didactic’s 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.
© Festo Didactic GmbH & Co. KG • 541089
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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.
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© Festo Didactic GmbH & Co. KG • 541089
Introduction
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.).
© Festo Didactic GmbH & Co. KG • 541089
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Introduction
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© Festo Didactic GmbH & Co. KG • 541089
Notes on safety and operation
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.
© Festo Didactic GmbH & Co. KG • 541089
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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.
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© Festo Didactic GmbH & Co. KG • 541089
Technology package for pneumatics (TP100)
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.
Important elements of TP100
• 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
© Festo Didactic GmbH & Co. KG • 541089
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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.
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© Festo Didactic GmbH & Co. KG • 541089
Training aims of Advanced Level (TP102)
• 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.
© Festo Didactic GmbH & Co. KG • 541089
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Training aims of Advanced Level (TP102)
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Allocation of training aims and exercises
Exercise
1
2
3
4
To be able to design indirect cylinder actuation.
•
•
To be able to select appropriate sensors for applications
•
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 use pneumatic decrementing counters.
•
•
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 design a stepper control with the input commands AUTOMATIC/MANUAL, START and RESET. To be able to realise the following input commands:
•
•
EMERGENCY-STOP, acknowledge EMERGENCY-STOP, START, RESET, STOP at CYCLE END and AUTOMATIC/MANUAL.
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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.
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© Festo Didactic GmbH & Co. KG • 541089
Equipment set – Advanced Level (TP102)
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. Equipment set – Advanced Level (TP102 Order No.: 540711)
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
© Festo Didactic GmbH & Co. KG • 541089
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Equipment set – Advanced Level (TP102)
Equipment set symbols
Desccription
Symbol
2
3/2-way valve with pushbutton, normally closed
1
3 2
3/2-way valve with mushroom actuator, normally open (EMERGENCY-STOP)
1
3
2
3/2-way roller lever valve with idle return
1 2
Back pressure valve
1
3 2
3/2-way pneumatic valve, normally closed
3
12 1
3
4
5/2-way double pilot valve
2
14
12 5
Predetermining counter, pneumatic
1 3 2
12
10 1 2
Time delay valve, normally open
10
1
One-way flow control valve
18
1
3
2
© Festo Didactic GmbH & Co. KG • 541089
Equipment set – Advanced Level (TP102)
Description
Symbol 2
Shuttle valve, 3-fold
1
2
1/3
Shuttle valve
1
2
1/3
1
1/3
2 1/3
1 2
Dual pressure valve, 3-fold
1
2
1/3
1
2
1/3
1
1/3
Double-acting cylinder
Non-return valve, piloted
2
1 21
Description
Symbol A1
Stepper module
A3
TAA
Yn
Y
Yn
Yn+1
P Zn L
P Z L
P Zn L
P Zn+1
X1
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A2
TAA
L
Yn
Yn+1
P Zn L
P Zn+1
X2
A4
TAA
L
TAB
Yn
Yn+1
P Zn L
P Zn+1
X3
Yn
L
P Zn L
Yn+1
P Zn+1 L
Y
Yn+1
P Z L
P Zn+1 L
X4
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Allocation of equipment and exercises
Equipment set TP102 Exercise
1
2
3
4
5
6
7
8
9
10
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
Equipment
Non-return valve, piloted
2
3/2-way pneumatic valve, convertible
2
1
5/2-way double pilot valve
2
2
2
2
1
3
3
4
2
2
2
2
3
1 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
3/2-way valve with mushroom actuator, normally open
2
2
1
2
1
1
1
(EMERGENCY-STOP) Stepper module
1
Time delay valve, normallyopen Predetermining counter, pneumatic
1
1
1 1
1
1 1
Shuttle valve, 3-fold
20
1
1
Shuttle valve
Dual pressure valve, 3-fold
1
1
1
1
3
3
3
3
2
2
3
3
1
1
2
© Festo Didactic GmbH & Co. KG • 541089
Allocation of equipment and exercises
Equipment set TP101 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-way roller lever valve with idle return Pneumatic proximity sensor
2
3 1
2
2
2
2
2
2
2
1
2
2
2
2
1
1
2
2
2
1
1
3/2-way valve with pushbutton, normally closed 3/2-way valve with selector switch, normally closed
1
5/2-way valve with selector switch
2*
1
1 1
Time delay valve, normally closed
1
1
1
1
Shuttle valve
1 1
Dual pressure valve
1 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.
© Festo Didactic GmbH & Co. KG • 541089
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Methodological help for the trainer
• 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 technician’s 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.
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© Festo Didactic GmbH & Co. KG • 541089
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.
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Methodological structure of exercises
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.
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Designation of equipment
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: Valves: Sensors: Signal input: Accessories:
© Festo Didactic GmbH & Co. KG • 541089
1A1, 2A1, 2A2, ... 1V1, 1V2, 1V3, 2V1, 2V2, 3V1, ... 1B1, 1B2, ... 1S1, 1S2, ... 0Z1, 0Z2, 1Z1, ...
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Equipment set – Basic Level (TP101)
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. Equipment set – Basic Level (TP101 Order No.: 540710)
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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
© Festo Didactic GmbH & Co. KG • 541089
Training aims – Basic Level (TP101)
• • • • • • • • • • • • • • • • • • • • • • • • • • • • •
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.
© Festo Didactic GmbH & Co. KG • 541089
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© Festo Didactic GmbH & Co. KG • 541089
Contents
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
© Festo Didactic GmbH & Co. KG • 541089
A-1
Contents
A-2
© Festo Didactic GmbH & Co. KG • 541089
Exercise 1: Opening and closing of an oven door
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).
Problem definition
The hardening system is designed for the continual hardening of mass produced metal parts. The workpieces are hardened and subsequently quenched in an oilquenching bath. The flaps at the entry and exit of the hardening system are to be closed and opened using double-acting cylinders.
Parameters
• 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.
Project task
1. 2. 3. 4. 5. 6.
Complete the pneumatic circuit diagram. Convert the directional control valves contained in the equipment set. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Compile the equipment list.
© Festo Didactic GmbH & Co. KG • 541089
A-3
Exercise 1: Opening and closing of an oven door
Positional sketch
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– Additional exercises
A-4
• 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?
© Festo Didactic GmbH & Co. KG • 541089
Exercise 1: Opening and closing of an oven door
Exercise 1: Opening and closing of an oven door Name:
Date:
Completing the pneumatic circuit diagram
Sheet 1 of 1
– Complete the pneumatic circuit diagram and enter the port designations. 1A1
1V5
1
1
2
2
1V4 4
1V6
2
14
12 5
1
1V3 4
3
2
14
12 5
1
3
1V2
2
10 1 1V1
1S1
2
3
2
10 1
3
1
3
Pneumatic circuit diagram
© Festo Didactic GmbH & Co. KG • 541089
A-5
Exercise 1: Opening and closing of an oven door
Exercise 1: Opening and closing of an oven door 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
A-6
© Festo Didactic GmbH & Co. KG • 541089
Exercise 1: Opening and closing of an oven door
Exercise 1: Opening and closing of an oven door 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? _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________
© Festo Didactic GmbH & Co. KG • 541089
A-7
Exercise 1: Opening and closing of an oven door
Exercise 1: Opening and closing of an over door Name:
Date:
Carrying out additional exercises
Sheet 2 of 2
– 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? _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________
A-8
© Festo Didactic GmbH & Co. KG • 541089
Exercise 2: Separating of drinks bottles
Training aims
• 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.
Problem definition
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?.
Parameters
• It is essential to ensure that only one single start signal is emitted even if the start button is actuated for a longer period.
Project task
1. 2. 3. 4. 5.
Complete the pneumatic circuit diagram. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Compile the equipment list.
© Festo Didactic GmbH & Co. KG • 541089
A-9
Exercise 2: Separating of drinks bottles
Positional sketch
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
A-10
© Festo Didactic GmbH & Co. KG • 541089
Exercise 2: Separating of drinks bottles
Additional exercise
• 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 doubleacting 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).
© Festo Didactic GmbH & Co. KG • 541089
A-11
Exercise 2: Separating of drinks bottles
Exercise 2: Separating of drinks bottles Name:
Date:
Designing the displacement-step diagram
Sheet 1 of 1
– Design the displacement-step diagram for the process described.
1
2
3=1
1
1A1 0
1
2A1 0
Displacement-step diagram
A-12
© Festo Didactic GmbH & Co. KG • 541089
Exercise 2: Separating of drinks bottles
Exercise 2: Separating of drinks bottles Name:
Date:
Completing the pneumatic circuit diagram
Sheet 1 of 1
– Complete the pneumatic circuit diagram. 1B1
1V2
1A1
2B1
1
1
2
1V1
1V3
2V2
2
4
14
12 5
0V2
4
5
3
1 0V1
2 2 12 1
1
3
0Z1
2 12
2
2
5
14
1B1
2V3
1
14
3
1
1
2V1 4
2
2A1
2
12
10 1
3 2B1
2
1
3
2
10 1
3 2
0S1
4
5
2
1
3
Pneumatic circuit diagram
© Festo Didactic GmbH & Co. KG • 541089
A-13
Exercise 2: Separating of drinks bottles
Exercise 2: Separating of drinks bottles 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
A-14
© Festo Didactic GmbH & Co. KG • 541089
Exercise 2: Separating of drinks bottles
Exercise 2: Separating of drinks bottles Name:
Date:
Carrying out additional exercises
Sheet 1 of 1
– What happens if both limit switches on the cylinder are moved? _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________
© Festo Didactic GmbH & Co. KG • 541089
A-15
Exercise 2: Separating of drinks bottles
A-16
© Festo Didactic GmbH & Co. KG • 541089
Exercise 3: Drilling of valve manifold blocks
Training aims
• To be able to design indirect circuit actuation. • To be able to compare different sensors and select appropriate sensors for an application.
Problem definition
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.
Parameters
• Since the drilling axes are intersecting, you need to ensure that the first drilling operation is completed before the second one starts.
Project task
1. 2. 3. 4. 5.
Complete the pneumatic circuit diagram. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Compile the equipment list.
© Festo Didactic GmbH & Co. KG • 541089
A-17
Exercise 3: Drilling of valve manifold blocks
Positional sketch
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. 6. The cylinder movement in abbreviated notation is 1A1+ 1A1– 2A1+ 2A1–
A-18
© Festo Didactic GmbH & Co. KG • 541089
Exercise 3: Drilling of valve manifold blocks
If the cylinder impacts on the back pressure valve, this may be damaged.
Additional exercises
• 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.
© Festo Didactic GmbH & Co. KG • 541089
A-19
Exercise 3: Drilling of valve manifold blocks
Exercise 3: Drilling of valve manifold blocks Name:
Date:
Designing the displacement-step diagram
Sheet 1 of 1
– Design the displacement-step diagram.
1
2
3
4
5=1
1
1A1 0
1
2A1 0
Displacement-step diagram
A-20
© Festo Didactic GmbH & Co. KG • 541089
Exercise 3: Drilling of valve manifold blocks
Exercise 3: Drilling of valve manifold blocks Name:
Date:
Completing the pneumatic circuit diagram
Sheet 1 of 1
– Complete the pneumatic circuit diagram.
1A1
2B1
1S1
1B2
2
1
1B1
3
1B2
1B1
2
1
2B1
3
2B2
2B2
2
1
2A1
3
2
1
3
2
1
3
Pneumatic circuit diagram
© Festo Didactic GmbH & Co. KG • 541089
A-21
Exercise 3: Drilling of valve manifold blocks
Exercise 3: Drilling of valve manifold blocks 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
A-22
© Festo Didactic GmbH & Co. KG • 541089
Exercise 3: Drilling of valve manifold blocks
Exercise 3: Drilling of valve manifold blocks Name:
Date:
Carrying out additional exercises
Sheet 1 of 1
– 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. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________
© Festo Didactic GmbH & Co. KG • 541089
A-23
Exercise 3: Drilling of valve manifold blocks
A-24
© Festo Didactic GmbH & Co. KG • 541089
Exercise 4: Filling of drinks bottles
Training aims
• • • •
Problem definition
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.
Parameters
• 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.
Project task
1. 2. 3. 4. 5. 6.
To be able to design indirect cylinder actuation. 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.
First of all, process the introductory exercises for the stepper module. Complete the pneumatic circuit diagram. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Compile the equipment list.
© Festo Didactic GmbH & Co. KG • 541089
A-25
Exercise 4: Filling of drinks bottles
Positional sketch
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. 5. The cylinder movement in abbreviated notation is 1A+ 1A– 2A– 2A+ Additional exercises
A-26
• 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.
© Festo Didactic GmbH & Co. KG • 541089
Exercise 4: Filling of drinks bottles
Exercise 4: Filling of drinks bottles 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
© Festo Didactic GmbH & Co. KG • 541089
A-27
Exercise 4: Filling of drinks bottles
Exercise 4: Filling of drinks bottles Name:
Date:
Stepper module
Sheet 2 of 3
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.
A1
A2
TAA
Yn
Y
Yn
Yn+1
P Zn L
P Z L
P Zn L
P Zn+1
X1
A3
TAA
L
Yn
Yn+1
P Zn L
P Zn+1
X2
A4
TAA
L
TAB
Yn
Yn+1
P Zn L
P Zn+1
X3
Yn
L
P Zn L
Yn+1
P Zn+1 L
Y
Yn+1
P Z L
P Zn+1 L
X4
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.
A-28
© Festo Didactic GmbH & Co. KG • 541089
Exercise 4: Filling of drinks bottles
Exercise 4: Filling of drinks bottles Name:
Date:
Stepper module
Sheet 3 of 3
– What are the advantages of the stepper module compared to reversing valve technology? _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________
– Which exercises can the individual stepper module undertake? _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________
© Festo Didactic GmbH & Co. KG • 541089
A-29
Exercise 4: Filling of drinks bottles
Exercise 4: Filling of drinks bottles Name:
Date:
Designing the displacement-step diagram
Sheet 1 of 1
– Design the displacement-step diagram.
1
2
3
4
5=1
1
1A1 0
1
2A1 0
Displacement-step diagram
A-30
© Festo Didactic GmbH & Co. KG • 541089
Exercise 4: Filling of drinks bottles
Exercise 4: Filling of drinks bottles Name:
Date:
Completing the pneumatic circuit diagram
Sheet 1 of 1
– Complete the pneumatic circuit diagram. 1A1
1V2
1B1
1
1
2 1V1
2A1 2B1 2B2
1B2
1V3
2V2
2
4
2
12
2V3
2 2
14
12
3
1
1
2V1 4
2
14 5
1
5
1
3
s1 s2 s3 s4
A1
TAA
Yn P L Zn 0S1
1
Y
Yn
Yn+1
P Z L
P Zn L
P P Zn+1 Zn L L
3
1B1
2 1
Yn
3
Yn+1
Yn
Yn
3
P Zn+1 L
X4 2B2
2 1
Yn+1
P P Zn+1 Zn L L
X3 2B1
A4
TAB
Yn+1
P P Zn+1 Zn L L
2 1
A3
TAA
X2
X1
1B2
2
A2
TAA
3
Y
P Z L
Yn+1 P
L Zn+1
2 1
3
Pneumatic circuit diagram
© Festo Didactic GmbH & Co. KG • 541089
A-31
Exercise 4: Filling of drinks bottles
Exercise 4: Filling of drinks bottles 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
A-32
© Festo Didactic GmbH & Co. KG • 541089
Exercise 4: Filling of drinks bottles
Exercise 4: Filling of drinks bottles Name:
Date:
Carrying out additional exercises
Sheet 1 of 1
– How does the circuit react if the roller lever valve 1B2 or the proximity sensor 2B2 are moved? _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________
© Festo Didactic GmbH & Co. KG • 541089
A-33
Exercise 4: Filling of drinks bottles
A-34
© Festo Didactic GmbH & Co. KG • 541089
Exercise 5: Cleaning of workpieces
Training aims
• 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 be able to set time delays according to specifications. • To familiarise yourself with circuits in order to cancel time delays via signal input.
Problem definition
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.
Parameters
• 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.
Project task
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. 5. Check the assembled circuit. 6. Describe the mode of operation of the circuit. 7. Complete the equipment list.
© Festo Didactic GmbH & Co. KG • 541089
A-35
Exercise 5: Cleaning of workpieces
Positional sketch
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– Additional exercises
A-36
•
Design the displacement-step diagram with signal lines.
© Festo Didactic GmbH & Co. KG • 541089
Exercise 5: Cleaning of workpieces
Exercise 5: Cleaning of workpieces Name:
Date:
Designing the displacement-step diagram
Sheet 1 of 1
– Design the displacement-step diagram with signal lines.
1
2
3
4
5=1
1
1A1 0 1
2A1 0
Displacement-step diagram
© Festo Didactic GmbH & Co. KG • 541089
A-37
Exercise 5: Cleaning of workpieces
Exercise 5: Cleaning of workpieces Name:
Date:
Completing the pneumatic circuit diagram
Sheet 1 of 3
– Complete the pneumatic circuit diagram without realising the parameters. 1A1 1B1 1B2
1V2
1V1
1
4
2A1
1
2
2
14
1V3
2V2
2
2V1
12 5
1
1
4
1
2
2
14
2B2
2B1
2V3
2 12
3
5
1
3
s1 s2 s3 s4
TAA
Yn P
0S2
1 0S1
0S3
2
4
5
3
L Zn
2 1
A1
TAA
A2
TAA
Y
Yn
Yn+1
Yn
Yn+1
P Z L
P Zn L
P P Zn+1 Zn L L
P Zn+1
X1
X2
Yn
P Zn L L
X3
A3
TAB
Yn+1
Yn
P P Zn+1 Zn L L
X4
A4
Yn+1
P Zn+1 L
Y
P Z L
Yn+1 P
L Zn+1
3
2
1
3
Pneumatic circuit diagram
A-38
© Festo Didactic GmbH & Co. KG • 541089
Exercise 5: Cleaning of workpieces
Exercise 5: Cleaning of workpieces Name:
Date:
Completing the pneumatic circuit diagram
Sheet 2 of 3
– Complete the pneumatic circuit diagram including the parameters. 1A1 1B1 1B2
1V2
1V1
2A1
1
4
1V3
1
2
2V2
2
2
14
2V1
12 5
1
1
4
2
2
14
3 0V7
12 5
2
1
3 0V8
1/3
1
2V3
1
2
2B2
2B1
2 1/3
1
s1 s2 s3 s4
A1
TAA
Yn P L Zn
0S3
2
Yn+1
Yn
Yn+1
Yn
Yn+1
Yn
P Z L
P Zn L
P P Zn+1 Zn L L
P Zn+1
P Zn L L
P Zn+1
P Zn L L
X1
X2 0V4
2 3
1
3
4
2
5
3
1
0V5
1
2B2
Yn+1 P
L Zn+1 1B1
0S5
3
1
2 1
2
3
1
3
3
2
2B1
3
2
10 1
2 1 1
P Z L
10
3
1
P Zn+1 L
1/3
0V2 1
Y
2
1
2
0V3
2
2
Yn+1
X4
1/3 0S4
0V1
0S1
X3
2
1
A4
TAB
Yn
1
2
A3
TAA
Y
1B2
0S2
A2
TAA
3
3
3
Pneumatic circuit diagram
© Festo Didactic GmbH & Co. KG • 541089
A-39
Exercise 5: Cleaning of workpieces
Exercise 5: Cleaning of workpieces Name:
Date:
Completing the pneumatic circuit diagram
Sheet 3 of 3
– Modify the circuit diagram such that, during the reset function, cylinder 2A1 advances first and then cylinder 1A1. 1A1 1B1 1B2
1V2
1V1
1
4
2A1
1V3
1
2
2
14
2V2
2
2V1
12 5
1
3
2B1
1
4
2
2
14
0V7
12 5
2
3
1
2
1/3
1
2V3
1
2
2B2
0V8 1
1/3
s1 s2 s3 s4
A1
TAA
Yn P L Zn 1B2
0S2
0S3
2
Y
Yn
Yn+1
P Z L
P Zn L
P P Zn+1 Zn L L
X1
Yn
0V4
Yn+1
Yn+1
Yn
P P Zn+1 Zn L L
P Zn+1
P Zn L L
X3 0V5
Y
P Zn+1 L
P Z L
Yn+1 P
L Zn+1 1B1
2 1/3
1
2
0V3
2
Yn+1
X4
1/3 0S4
A4
TAB
Yn
2
1
3
A3
TAA
X2
2 1
2
A2
TAA
0S5
2 1
2
3
10 1 0S1
3
4
2
5
3
1
1
3
0V1 1
2
2B2
1
3
3
1
0V2
2
2
2B1
3
2
10 1
1
3
1
3 1
3
3
Pneumatic circuit diagram
A-40
© Festo Didactic GmbH & Co. KG • 541089
Exercise 5: Cleaning of workpieces
Exercise 5: Cleaning of workpieces Name:
Date:
Completing the equipment list
Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires an equipment list. – Complete the equipment list by entering the required equipment in the table below. Quantity
Description
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
© Festo Didactic GmbH & Co. KG • 541089
A-41
Exercise 5: Cleaning of workpieces
A-42
© Festo Didactic GmbH & Co. KG • 541089
Exercise 6: Printing of mobile phone housings
Training aims
• To be able to realise the following input commands: EMERGENCY-STOP, acknowledge EMERGENCY-STOP, START, RESET, STOP at CYCLE END and AUTOMATIC/MANUAL.
Problem definition
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.
Parameters
• 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.
Project task
1. 2. 3. 4. 5.
Extend the pneumatic circuit diagram in accordance with the parameters. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Complete the equipment list.
© Festo Didactic GmbH & Co. KG • 541089
A-43
Exercise 6: Printing of mobile phone housings
Positional sketch
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+
A-44
© Festo Didactic GmbH & Co. KG • 541089
Exercise 6: Printing of mobile phone housings
Exercise 6: Printing of mobile phone casings Name:
Date:
Designing the displacement-step diagram
Sheet 1 of 1
– Design the displacement-step diagram with signal lines.
1
2
3
4
5=1
1
1A1 0 1
2A1 0 1
3A1 0
Displacement-step diagram
© Festo Didactic GmbH & Co. KG • 541089
A-45
Exercise 6: Printing of mobile phone housings
Exercise 6: Printing of mobile phone casings Name:
Date:
Completing the pneumatic circuit diagram
Sheet 1 of 1
– Complete the pneumatic circuit diagram. 2A1 2B1 2B2
1A1
1V2
1B1
2V2
1
2
1V1
4
12 5
1
3V2
1
2V1 4
2
14
3A1
1B2
2
0V12
3
12 5
2
0V10
2 1/3
1
4
2 12
5
2
1
0V11 1
0V9
1
14
10
1/3
1
0V13
3
1
3
3
2
10
2
1
3 0V8
1/3
1
3 B2
2
3V1
2
14
3B1
1
2 1/3
s1 s2 s3 s4
0V6
4
2
5
3 1 0V5
14 Start 0S6
A1
12
2
Reset 0S4
3
Yn
1/3
P
Stop at cycle end 0S5
2 L Zn
2 1 1
TAB
Y
Yn
Yn+1
P Z L
P Zn L
P P Zn+1 Zn L L
Yn
X1
Yn+1
Yn
Yn+1
P P Zn+1 Zn L L
X2
Yn
Yn+1
P P Zn+1 Zn L L
X3
P Zn+1 L
X4
Y
P Z L
Yn+1 P
L Zn+1
3
1B2
Manual/Automatic 0S3 4
2
5
1 3
0V2
4
2B1
2
1
2
3
1
2B2
2
1
3 3B2
12 5
2
3
1B1
2
3
2
1
3 3B1
2
2
2
14 0V1 EMERGENCY10 STOP
1
A4
TAA
3
1
0S1
A3
TAA
2
1 1
A2
TAA
1
1
3
1
3
3 Acknowledge EMERGENCY-STOP 0S2
3
2
1
3
Pneumatic circuit diagram
A-46
© Festo Didactic GmbH & Co. KG • 541089
Exercise 6: Printing of mobile phone housings
Exercise 6: Printing of mobile phone casings Name:
Date:
Completing the equipment list
Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires an equipment list. – Complete the equipment list by entering the required equipment in the table below. Quantity
Description
3
Cylinder, double-acting
3
One-way flow control valve 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 valve with mushroom actuator, normally open (EMERGENCY-STOP) 3/2-way pneumatic valve, normally open 3/2-way toggle lever valve with idle return, normally closed 3/2-way back pressure valve, normally closed 3/2-way roller lever valve, normally closed Proximity sensor, pneumatic Shuttle valve (OR) Dual pressure valve (AND)
1
Stepper module Type 3TAA/1TAB
1
Manifold
1
On/off valve with filter regulating valve
1
Compressed air supply
Equipment list
© Festo Didactic GmbH & Co. KG • 541089
A-47
Exercise 6: Printing of mobile phone housings
A-48
© Festo Didactic GmbH & Co. KG • 541089
Exercise 7: Packaging of spark plugs
Training aims
• 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).
Problem definition
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).
Parameters
• 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“.
Project task
1. 2. 3. 4. 5.
Complete the pneumatic circuit diagram and enter the port designations. Carry out the assembly. Check the circuit assembly. Describe the mode of operation of the circuit. Complete the equipment list.
© Festo Didactic GmbH & Co. KG • 541089
A-49
Exercise 7: Packaging of spark plugs
Positional sketch
2A1
0S5 1A1
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 Additional exercises
A-50
• Design the displacement-step diagram for this circuit.
© Festo Didactic GmbH & Co. KG • 541089
Exercise 7: Packaging of spark plugs
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"
© Festo Didactic GmbH & Co. KG • 541089
A-51
Exercise 7: Packaging of spark plugs
Exercise 7: Packaging of spark plugs Name:
Date:
Designing the displacement-step diagram
Sheet 1 of 1
– Design the displacement-step diagram with signal lines.
1
2
3
4
5
6
7
8
9
10
11=1
1
1A1 0 1
2A1 0
Displacement-step diagram
A-52
© Festo Didactic GmbH & Co. KG • 541089
Exercise 7: Packaging of spark plugs
Exercise 7: Packaging of spark plugs Name:
Date:
Completing the pneumatic circuit diagram
Sheet 1 of 1
– Complete the pneumatic circuit diagram. 1A1 1B1 1B2
1V2
1V1
1
4
2A1
1V3
1
2
2V2
2
2
14
2V1
12 5
1
1
4
2B1
2V3
1
2
2B2
2
2
14
12
3
5
1
3
s1 s2 s3 s4 0V7 10 1
0V4
2 1
0S4
1
3
0V1
1
1
0V2 2
Yn P
3
L Zn
2
12 1
3
0S2
4
2
5
3
1
Yn+1
P Z L
P Zn L
P P Zn+1 Zn L L
X1
Yn
A3
TAA
Yn+1
Yn
A4
TAB
Yn+1
P P Zn+1 Zn L L
X2
Yn
X3
Y
P Z L
Yn+1 P
L Zn+1
2 1
3 0Z3
P Zn+1 L
X4 1B1
2
Yn+1
P P Zn+1 Zn L L
2
3
3
2
12 1
0S1
Yn
1
2 1
Y
1B2
1/3 0S3
A2
TAA
3
0S5 2
2
A1
TAA
10
3
10 1
3 2B1
2B2
2 1
3
2 1
3
Pneumatic circuit diagram
© Festo Didactic GmbH & Co. KG • 541089
A-53
Exercise 7: Packaging of spark plugs
Exercise 7: Packaging of spark plugs Name:
Date:
Completing the equipment list
Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires an equipment list. – Complete the equipment list by entering the number of required components in the table below. Quantity
Description
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 selector switch, normally closed 3/2-way valve with pushbutton, normally closed 3/2-way pneumatic valve, normally closed 3/2-way pneumatic valve, normally open 3/2-way roller lever valve, normally closed Proximity sensor, pneumatic Pneumatic predetermining counter Shuttle valve (OR) Dual pressure valve (AND)
1
Stepper module Type 3TAA/1TAB
1
Manifold
1
On/off valve with filter regulating valve
1
Compressed air supply
Equipment list
A-54
© Festo Didactic GmbH & Co. KG • 541089
Exercise 8: Sealing of guide bushes
Training aims
• 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.
Problem definition
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.
Parameters
• 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.
Project task
1. 2. 3. 4. 5.
Complete the circuit diagram. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Complete the equipment list.
© Festo Didactic GmbH & Co. KG • 541089
A-55
Exercise 8: Sealing of guide bushes
Positional sketch
1A1
1B1
1B3
1B2
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.
A-56
© Festo Didactic GmbH & Co. KG • 541089
Exercise 8: Sealing of guide bushes
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).
Additional exercises
• Design the displacement-step diagram with signal lines. • 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.
© Festo Didactic GmbH & Co. KG • 541089
A-57
Exercise 8: Sealing of guide bushes
Exercise 8: Sealing of guide bushes Name:
Date:
Designing the displacement-step diagram
Sheet 1 of 1
– Design the displacement-step diagram with signal lines.
1
2
3
4
5=1
1
1A m 0
Displacement-step diagram
A-58
© Festo Didactic GmbH & Co. KG • 541089
Exercise 8: Sealing of guide bushes
Exercise 8: Sealing of guide bushes Name:
Date:
Completing the pneumatic circuit diagram
Sheet 1 of 1
– Complete the pneumatic circuit diagram. 1A1 1B3
1V2
1V1
1
4
1B1
1V3
1
2
2
14
1B2
2 12
5
1 3
0V13
2 1/3 0V12
1 0V11
2 1/3
1
2
10 0V10
2
1
3
10
0V9 3
1
2
10 1
0V7
0V8
2 1/3
1 0V6 1
1/3
P
2
L Zn
10 0V4
Yn
Yn+1
P Z L
P Zn L
P P Zn+1 Zn L L
X1
2
1B2 3
1/3
1
Start 0S4
3
2
5
1 3
4
EMERGENCY10 STOP 0S1
1
Yn+1
P P Zn+1 Zn L L
Yn
Yn+1
P P Zn+1 Zn L L
X3
P Zn+1 L
X4
Y
Yn+1
P Z L
P
L Zn+1
1B3
3
1B1
2 1
3
2 1
3
3
12 5
2
1
2
Yn
2
14 0V1
Yn+1
A4
TAB
2 1
Manual/Automatic 0S3 4
0V2
Yn
A3
TAA
X2
2 1
Reset 0S5
2 1
A2
3
1
2
TAA
Y
12 0V3
A1
TAA
Yn
1
1/3
1
s1 s2 s3 s4
2
0V5
3
2
3 1 Acknowledge EMERGENCY-STOP
3
3
0S2
2
1
3
Pneumatic circuit diagram
© Festo Didactic GmbH & Co. KG • 541089
A-59
Exercise 8: Sealing of guide bushes
Exercise 8: Sealing of guide bushes Name:
Date:
Completing the equipment list
Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires an equipment list. – Complete the equipment list by entering the number of required components in the table below. Quantity
Description
1
Cylinder, double-acting
2
One-way flow control valve 5/2-way pneumatic double pilot valve 3/2-way valve with pushbutton, normally closed 3/2-way valve with mushroom actuator, normally open (EMERGENCY-STOP) 3/2-way pneumatic valve, 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)
1
Stepper module Type 3TAA/1 TAB
1
Manifold
1
On/off valve with filter regulating valve
1
Compressed air supply
Equipment list
A-60
© Festo Didactic GmbH & Co. KG • 541089
Exercise 8: Sealing of guide bushes
Exercise 8: Sealing of guide bushes 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. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________
© Festo Didactic GmbH & Co. KG • 541089
A-61
Exercise 8: Sealing of guide bushes
A-62
© Festo Didactic GmbH & Co. KG • 541089
Exercise 9: Hardening of material test specimens
Training aims
• 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 select appropriate sensors for an application and adjust these.
Problem definition
Steel tool specimens from various smelters are to undergo reproducible heat treatment. The alloyed steel tool specimens are to be annealed, quenched and tempered. A test specimen is to be placed into a wire cage and the START button actuated. Cylinder 1A1 is to move from the retracted end position into the mid-position. After an annealing time of t1 = 3 seconds, the forward end position is to be approached and the test specimen quenched by a jet of tempered oil or water. Before the cylinder assumes the initial position again, it is to remain in the mid-position for tempering for t2 = 2 seconds.
Project task
1. 2. 3. 4. 5.
Complete the pneumatic circuit diagram. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Check the equipment list.
© Festo Didactic GmbH & Co. KG • 541089
A-63
Exercise 9: Hardening of material test specimens
t1 = 3 s
Positional sketch
t2 = 2 s
1B1
1B3
1B2
Hardening device
1. If the START button 0S1 is pressed, cylinder 1A1 is to move from the retracted end position into the mid-position. The retracted end position is to be monitored via the roller lever valve 1B1 and the mid-position via the pneumatic proximity sensor 1B3. 2. The cylinder is to remain in the mid-position for a preset time of t1 = 3 seconds for the annealing of the test specimen. After this, the righthand end position is to be approached and the roller lever valve 1B2 actuated. 3. The cylinder is to retract into the mid-position again. A further time delay valve now starts and the cylinder returns into the retracted end position after a time period of t2 = 2 seconds. Additional exercise
A-64
• Design the displacement-step diagram with signal lines.
© Festo Didactic GmbH & Co. KG • 541089
Exercise 9: Hardening of material test specimens
Exercise 9: Hardening of material test specimens Name:
Date:
Designing the displacement-step diagram
Sheet 1 of 1
– Design the displacement-step diagram with signal lines.
1
2
3
4
5=1
1
1A1
m 0
Displacement-step diagram
© Festo Didactic GmbH & Co. KG • 541089
A-65
Exercise 9: Hardening of material test specimens
Exercise 9: Hardening of material test specimens Name:
Date:
Completing the pneumatic circuit diagram
Sheet 1 of 1
– Complete the pneumatic circuit diagram. 1A1 1B3
1V5
1V3
1V1
2
1B1
1V6
1B2
2
1 21
1 21
1
1
2
2
1V4
1V2
2
12 0V5
1
2
3
0V6
1/3
1
2
12 1
2 1/3
1
3
0V4
2
10 0V2
0V3
2
1
2
3
10
1
1
3
3
s1 s2 s3 s4 A1
TAA
Yn P L Zn 0S1
1
Y
Yn
Yn+1
P Z L
P Zn L
P P Zn+1 Zn L L
3
Yn
X1
1B3
2
1B2 3
Yn
P P Zn+1 Zn L L
A3
Yn+1
Yn
Yn+1
P P Zn+1 Zn L L
P Zn+1 L
X4 1B1
3
A4
TAB
X3
2 1
TAA
Yn+1
X2
2 1
A2
TAA
Y
P Z L
Yn+1 P
L Zn+1
2 1
3
Pneumatic circuit diagram
A-66
© Festo Didactic GmbH & Co. KG • 541089
Exercise 9: Hardening of material test specimens
Exercise 9: Hardening of material test specimens Name:
Date:
Checking the equipment list
Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires an equipment list. – Check the equipment list by comparing the number of components listed in the table below with your circuit design. Quantity
Description
1
Cylinder, double-acting Non-return valve, piloted One-way flow control valve 3/2-way valve with pushbutton, normally closed 3/2-way pneumatic valve, normally closed 3/2-way pneumatic valve, normally open 3/2-way roller lever valve, normally closed Proximity sensor, pneumatic Time delay valve, normally closed Time delay valve, normally open Shuttle valve (OR) Dual pressure valve (AND)
1
Stepper module Type 3TAA/1 TAB
1
Manifold
1
On/off valve with filter regulating valve
1
Compressed air supply
Equipment list
© Festo Didactic GmbH & Co. KG • 541089
A-67
Exercise 9: Hardening of material test specimens
A-68
© Festo Didactic GmbH & Co. KG • 541089
Exercise 10: Bending of sheet metal strips
Training aims
• To be able to realise a control system with control behaviour in combination with a sequence control in stepper design. • To be able to select appropriate sensors for an application and to adjust these.
Problem definition
Sheet metal strips are to be bent using a bending tool. A sheet metal strip is to be manually inserted into the bending device. Once the START button is actuated, a cylinder is to clamp the workpiece. The first bending cylinder is to pre-bend the metal strip and immediately retract again. The second bending cylinder is to complete the bending of the metal strip. Following this, the second bending cylinder and the clamping cylinder are to retract simultaneously and the newly formed bracket is to be removed manually.
Parameters
• The clamping cylinder is to exhibit monitored behaviour when advancing, i.e. the sequence control is to be started when the forward end position is reached. If the START button is released before the cylinder reaches the forward end position, it is to return into the initial position again.
Project task
1. 2. 3. 4. 5.
Complete the circuit diagram. Carry out the assembly. Check the assembled circuit. Describe the mode of operation of the circuit. Check the equipment list.
© Festo Didactic GmbH & Co. KG • 541089
A-69
Exercise 10: Bending of sheet metal strips
Positional sketch
1A1 2A1
3A1
Bending device
1. The single-acting clamping cylinder 1A1 operates with throttled supply air and is to be actuated via a spring-returned 3/2-way pneumatic valve. The bending cylinders 2A1 and 3A1 are to be actuated via 5/2-way double pilot valves and a stepper module. 2. The end positions of the double-acting bending cylinder 2A1 are to be sensed via a roller lever valve 2B1 and a roller lever valve with idle return 2B2, and those of the double-acting bending cylinder 3A1 via a pneumatic proximity sensor 3B1 and 3B2. A back pressure valve 1B2 is to monitor the forward end position of the single-acting clamping cylinder 1A1 and the retracted end position is to be monitored via the roller lever valve 1B1. 3. The START button 0S1 must be held down until the clamping cylinder 1A1 is advanced and the back pressure valve has responded, whereby the stepper sequencer receives the signal for starting.
A-70
© Festo Didactic GmbH & Co. KG • 541089
Exercise 10: Bending of sheet metal strips
4. The bending cylinder 2A1 is to advance and actuate the roller lever valve with idle return 2B2 in its forward end position. This is to reset the first module and switch the second step. The bending cylinder 2A1 is to retract immediately again and actuate the roller lever valve 2B1 in the retracted end position. This is to reset the second module and switch the third step. Bending cylinder 3A1 is to advance and actuate pneumatic proximity sensor 3B2 in the forward end position. This is to reset the third module and switch the fourth step. Clamping cylinder 1A1 is to be exhausted and return into the retracted end position. At the same time, the bending cylinder 3A1 is to retract and actuate pneumatic proximity sensor 3B1 in the retracted end position. This is to reset the fourth module and consequently the stepper sequencer. 5. The cylinder movement in abbreviated notation is 1A1+ 2A1+ 2A1– 3A1+ 3A1– 1A1–
Notes • The safety guards required in practice are not taken into consideration. • Reliable clamping is to be ensured before the bending process is started. The back pressure valve 1B2 ensures that the metal strip is reliably clamped by the clamping cylinder. The manually operated valve 0S1 must be actuated until the back pressure valve 1B2 reacts. This latching safeguards the subsequent bending operations. • As the circuit requires 3 roller lever valves, but only two are contained in the TP101 and TP102 construction kits, valve 2B2 has been replaced by a roller lever valve with idle return.
Additional exercise
• Design the displacement-step diagram with signal lines. • Convert the available 5/2-way double pilot valves into the required 3/2-way double pilot valves. Check the functioning of the valves prior to installation.
© Festo Didactic GmbH & Co. KG • 541089
A-71
Exercise 10: Bending of sheet metal strips
Exercise 10: Bending of sheet metal strips Name:
Date:
Designing the displacement-step diagram
Sheet 1 of 1
– Design the displacement-step diagram with signal lines.
1
2
3
4
5
6=1
1
1A1 0 1
2A1 0 1
3A1 0
Displacement-step diagram
A-72
© Festo Didactic GmbH & Co. KG • 541089
Exercise 10: Bending of sheet metal strips
Exercise 10: Bending of sheet metal strips Name:
Date:
Completing the pneumatic circuit diagram
Sheet 1 of 1
– Complete the pneumatic circuit diagram. 1A1
1V2
1B1
2A1
1B2
2V2
2
1 2
1V1
3V2
1
2
5
3B2
1
4 12
3
3A1
2
4
14 1
3B1
2B2
2
2V1
12
2B1
1
2
14
12
3
5
1
3
s1 s2 s3 s4
A1
TAA
0V4
Yn
1/3
P Zn 2
12 3
1
1B2
3
Yn+1
2
1
Yn
P Z L
P Zn L
P P Zn+1 Zn L L
X1
Yn+1
Yn
P P Zn+1 Zn L L
2B1
3
Yn
Yn+1
P P Zn+1 Zn L L
X3
X2
2
Yn+1
P Zn+1 L
X4
Y
P Z L
Yn+1 P
L Zn+1
2
1
3
10 1
2
A4
TAB
2
12 3
0S1
Yn
1 0V2
2
1
L
Y
2B2
10 1
1B1
A3
TAA
2
1
0V3
A2
TAA
3
3B2
3B1
2
1
3
2
1
3
3
Pneumatic circuit diagram
© Festo Didactic GmbH & Co. KG • 541089
A-73
Exercise 10: Bending of sheet metal strips
Exercise 10: Bending of sheet metal strips Name:
Date:
Checking the equipment list
Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires an equipment list. – Check the equipment list by comparing the number of components listed in the table below with your circuit design. Quantity
Description
2
Cylinder, double-acting
1
Cylinder, single-acting One-way flow control valve 5/2-way pneumatic double pilot valve 3/2-way pneumatic valve, normally closed 3/2-way pneumatic double pilot valve 3/2-way valve with pushbutton, normally closed 3/2-way toggle lever valve with idle return, normally closed 3/2-way back pressure valve, normally closed 3/2-way roller lever valve, normally closed Proximity sensor, pneumatic Shuttle valve (OR) Dual pressure valve (AND)
1
Stepper module Type 3TAA/1 TAB
1
Manifold
1
On/off valve with filter regulating valve
1
Compressed air supply
Equipment list
A-74
© Festo Didactic GmbH & Co. KG • 541089
Exercise 10: Bending of sheet metal strips
Exercise 10: Bending of sheet metal strips Name:
Date:
Carrying out additional exercises.
Sheet 1 of 1
– Convert the available 5/2-way double pilot valves into the required 3/2-way double pilot valves. Check the functioning of the valves prior to installation. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________
© Festo Didactic GmbH & Co. KG • 541089
A-75
Exercise 10: Bending of sheet metal strips
A-76
© Festo Didactic GmbH & Co. KG • 541089
Part B – Fundamentals
The theoretical fundamentals for the pneumatics training package are summarised in the textbook: Pneumatics, Basic Level This book is intended for basic training in pneumatic control technology and teaches the physical fundamentals of pneumatic control technology as well as the function and use of pneumatic components. Numerous illustrations and diagrams aid comprehension. Pneumatic circuits are explained with the help of examples and sample solutions and detailed explanations improve the students’ knowledge of circuit design and sequences. P. Croser, F. Ebel, 2002 edition, 274 pages, bound Order No.: 093131
© Festo Didactic GmbH & Co. KG • 541089
B-1
B-2
© Festo Didactic GmbH & Co. KG • 541089
Contents
Part C – Solutions
Exercise 1: Opening and closing of an oven 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
© Festo Didactic GmbH & Co. KG • 541089
C-1
Contents
C-2
© Festo Didactic GmbH & Co. KG • 541089
Exercise 1: Opening and closing of an oven door Solutions
Exercise 1: Opening and closing of an oven door Name:
Date:
Completing the pneumatic circuit diagram
Sheet 1 of 1
1A1
1V5
1
1
2
2
1V4 4
1V6
2
14
12 5
1
1V3 4
3
2
14
12 5
1
3
1V2
2
10 1 1V1
1S1
2
3
2
10 1
3
1
3
Pneumatic circuit diagram
© Festo Didactic GmbH & Co. KG • 541089
C-3
Exercise 1: Opening and closing of an oven door Solutions
Exercise 1: Opening and closing of an oven door Name:
Date:
Process description
Sheet 1 of 1
Initial position The oven door is closed. The piston rod of cylinder 1A1 is advanced. The 5/2-way double pilot valve 1V4 (final control element) pressurises the piston chamber and exhausts the piston rod chamber. The 5/2-way double pilot valve 1V3 (reversing valve) is switched to flow from 1 to 4. Steps 1-2 – opening the oven door The 3/2-way pneumatic valves 1V1 and 1V2 are actuated simultaneously if the pushbutton on the 3/2-way valve 1S1 is pressed. Pilot ports 12 and 14 of the reversing valve 1V3 are exhausted. The compressed air then pressurises the pilot port 12 of the 5/2-way double pilot valve 1V4 via ports 1 and 4 of the 5/2-way double pilot valve 1V3. Valve 1V4 switches. The piston rod end of cylinder 1A1 is pressurised and the piston returns into the retracted end position. At the same time, the pilot port 12 of the reversing valve 1V3 is pressurised via the 3/2-way pneumatic valve 1V2. The reversing valve 1V3 is connected such as to enable the reversing of the final control element 1V4 via a new start signal. Steps 2-3 – closing the oven door The 3/2-way pneumatic valves 1V1 and 1V2 are simultaneously actuated if the pushbutton at the 3/2-way valve 1S1 is pressed again. The pilot ports 12 and 14 of the reversing valve 1V3 are exhausted. The compressed air then pressurises pilot port 14 of the final control element 1V4 via ports 1 and 1 of the reversing valve 1V3. Cylinder 1A1 is pressurised at the piston end. The piston rod advances. At the same time pilot port 14 of the reversing valve 1V3 is pressurised again as a result of the air via the 3/2-way pneumatic valve 1V1. The control system is in the initial position again and the oven door can be opened again via a new start signal.
C-4
© Festo Didactic GmbH & Co. KG • 541089
Exercise 1: Opening and closing of an oven door Solutions
Exercise 1: Opening and closing of an oven door Name:
Date:
Compiling the equipment list
Sheet 1 of 1
Apart from a 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
1
Cylinder, double-acting
2
One-way flow control valve
2
5/2-way pneumatic double pilot valve
1
3/2-way valve with pushbutton, normally closed
2
3/2-way pneumatic valve, normally open
1
Manifold
1
On/off valve with filter regulating valve
1
Compressed air supply
Equipment list
© Festo Didactic GmbH & Co. KG • 541089
C-5
Exercise 1: Opening and closing of an oven door Solutions
Exercise 1: Opening and closing of an oven door Name:
Date:
Carrying out additional exercises
Sheet 1 of 1
What faults can occur during the tubing up of circuits? What is the effect of such faults? Describe these. The 3/2-way valves have not been correctly converted. Circuit does not function. Port 2 has been mixed up with port 4 on valve 1V4. Cylinder does not advance. How do the 3/2-way valves need to be converted in order to fulfil the necessary function? The valves have to be converted to normally open by swapping the blanking plug and working port. How do the 5/2-way pneumatic valves need to be converted? Working port 4 needs to be closed. Possible solution if a blanking plug is not available: Plug a T-piece (push-in Tconnector) with short tubing onto the valve and connect the remaining two outputs of the T-piece with a short piece of tubing. What is the behaviour of the circuit after pressure loss? The activating circuit stores its status. The result: If the door is moved during pressure loss, it will return to its previous position if pressure is renewed. What is a binary reducing stage? Binary reducing stages are also known as toggle flip flops. Flip-flops, also referred to as bistable elements, are circuits, that realise basic status memories. They assume two statuses: Set and reset. In order to set the flip-flop, a signal needs to be applied at the input, in this case a pressure signal. The flip-flop then remains in the set status until a further signal is applied at the input. A binary digit (0 or 1) can be represented via these statuses. A binary reducing state changes its status with every active pulse edge, i.e. it acts as a frequency divider/reducer.
C-6
© Festo Didactic GmbH & Co. KG • 541089
Exercise 2: Separating of drinks bottles Solutions
Exercise 2: Separating of drinks bottles Name:
Date:
Completing the pneumatic circuit diagram
Sheet 1 of 1
1B1
1V2
1A1
2B1
1
1
2
1V1
1V3
2V2
2
4
14
12 5
0V2
4
3
1
2 2 12 1
1
3
0Z1
2
2
12
12 5
0V1
2
5
14
1B1 2
2V3
1
14
3
1
1
2V1 4
2
2A1
10 1
3 2B1
2
1
3
2
10 1
3 2
0S1
4
5
2
1
3
Pneumatic circuit diagram
© Festo Didactic GmbH & Co. KG • 541089
C-7
Exercise 2: Separating of drinks bottles Solutions
Exercise 2: Separating of drinks bottles Name:
Date:
Process description
Sheet 1 of 2
Initial position Cylinder 1A1 is in the retracted end position. Cylinder 2A1 assumes the forward end position. The pneumatic proximity sensor 1B1 is actuated. The 5/2-way valve 0S1 is detented to flow from 1 to 2. The pneumatic predetermining counter 0Z1 is reset and set to preset value 3. Separating of drinks bottles Actuation of the start pushbutton 0S1 causes the pneumatic signal to be switched to pilot port 14 of the 5/2-way double pilot valve via the 3/2-way valve 0V1 and the pneumatic proximity sensor 1B1. Both of the two 5/2-way double pilot valves1V1 and 2V1 are reversed via output 4 of the 5/2-way double pilot valve 0V2. The piston rod of cylinder 1A1 advances and the piston rod of cylinder 2A1 retracts. If cylinder 1A1 moves out of the retracted end position, the pneumatic proximity sensor 1B1 is no longer actuated and pilot port 14 of the 5/2-way double pilot valve 0V2 is exhausted. The pneumatic proximity sensor 2B1 is actuated if cylinder 2A1 reaches the retracted end position. The output signal of the pneumatic proximity sensor 2B1 reverses the 5/2-way double pilot valve 0V2. At the same time, this output signal is applied to pilot port 12 of the pneumatic predetermining counter and the preset value is reduced by 1. Cylinder 1A1 retracts again and cylinder 2A1 advances. This process is repeated until the pneumatic predetermining counter 0Z1 has counted to 0. Once the value is 0, a pneumatic signal is applied at pilot port 10 of the 3/2-way valve 0V1 by output 2 of the predetermining counter. This causes the air supply to pilot port 14 of the 5/2-way double pilot valve 0V2 to be interrupted. Cylinder 1A1 is in the retracted end position again and cylinder 2A1 in the forward end position.
C-8
© Festo Didactic GmbH & Co. KG • 541089
Exercise 2: Separating of drinks bottles Solutions
Exercise 2:Separating of drinks bottles Name:
Date:
Compiling the equipment list
Sheet 1 of 1
Apart from a 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
2
Cylinder, double-acting
4
One-way flow control valve
3
5/2-way pneumatic double pilot valve
1
5/2-way valve with selector switch
1
3/2-way pneumatic valve, normally open
2
Proximity sensor, pneumatic
1
Pneumatic predetermining counter
1
Manifold
1
On/off valve with filter regulating valve
1
Compressed air supply
Equipment list
© Festo Didactic GmbH & Co. KG • 541089
C-9
Exercise 2: Separating of drinks bottles Solutions
Exercise 2: Separating of drinks bottles Name:
Date:
Carrying out additional exercises
Sheet 1 of 1
– Draw the displacement-step diagram with signal lines. 0S2
1
2
3=1
1
1A1 0
1B1
1
2A1 0
2B1
What happens if both proximity sensors are moved on the cylinder? If the cylinders move into the end position, the pneumatic proximity sensors are not actuated and the circuit no longer starts.
C-10
© Festo Didactic GmbH & Co. KG • 541089
Exercise 3: Drilling of valve manifold blocks Solutions
Exercise 3: Drilling of valve manifold blocks Name:
Date:
Completing the pneumatic circuit diagram
Sheet 1 of 1
1A1
1V2
1V1
1
1
2
2
4
1S1
2V2
1V3
2V1 12
5
1
3
2B2
1
1
2
2
4
1B1
2
3
2
1
3 2B2
2
1
2V3
12 5
1
2A1
14
3 1B2
2
1
1B2
2
14
2B1
1B1
2B1
3
2
1
3
2
1
3
Pneumatic circuit diagram
© Festo Didactic GmbH & Co. KG • 541089
C-11
Exercise 3: Drilling of valve manifold blocks Solutions
Exercise 3: Drilling of valve manifold blocks Name:
Date:
Process description
Sheet 1 of 1
In this exercise, the end position of the double-acting cylinder is monitored via four different sensors. Double-acting cylinder 1A1 Retracted end position: 3/2-way toggle lever valve with idle return 1B1 Forward end position: Back pressure valve 1B2 Double-acting cylinder 2A1 Retracted end position: Pneumatic proximity sensor 2B1 Forward end position: Roller lever valve 2B2 Initial position The double-acting cylinders 1A1 and 2A1 are in the retracted end position. The pneumatic proximity sensor 2B1 is actuated. The roller lever valve with idle return 1B1 is overtravelled by the trip cam of cylinder 1A1 and therefore not actuated. The final control elements 1V1 and 2V1 each assume the switching position with flow from 1 to 2. Drilling using a vertical feed unit Actuation of the START button 1S1 causes the final control element 1V1 to switch via the switched-through pneumatic proximity sensor 2B1. The piston rod of cylinder 1A1 advances and back pressure valve 1B2 is actuated in the forward end position. The final control element 1V1 is reversed again and cylinder 1A1 retracts. Drilling using a horizontal feed unit Just before reaching the retracted end position, the trip cam of cylinder 1A1 overtravels the roller lever valve with idle return 1B1. The final control element 2V1 is switched from 1 to 4 via the output signal of valve 1B1. The piston rod of cylinder 2A1 advances. Upon reaching the forward end position, cylinder 2A1 actuates the roller lever valve 2B2. The output signal of valve 2B2 reverses the final control element 2V1. The piston rod of cylinder 2A1 retracts and actuates the pneumatic proximity sensor 2B1. The interlock of the START button 1S1 is cancelled. A new cycle can be triggered via a renewed manual start signal. This ensures that the feed units cannot collide.
C-12
© Festo Didactic GmbH & Co. KG • 541089
Exercise 3: Drilling of valve manifold blocks Solutions
Exercise 3: Drilling of valve manifold blocks Name:
Date:
Compiling the equipment list
Sheet 1 of 1
Apart from a 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
2
Cylinder, double-acting
4
One-way flow control valve
2
5/2-way pneumatic double pilot valve
1
3/2-way valve with pushbutton, normally closed
1
3/2-way toggle lever valve with idle return, normally closed
1
3/2-way back pressure valve, normally closed
1
3/2-way roller lever valve, normally closed
1
Proximity sensor, pneumatic
1
Manifold
1
On/off valve with filter regulating valve
1
Compressed air supply
Equipment list
© Festo Didactic GmbH & Co. KG • 541089
C-13
Exercise 3: Drilling of valve manifold blocks Solutions
Exercise 3: Drilling of valve manifold blocks Name:
Date:
Carrying out additional exercises
Sheet 1 of 2
– Draw the displacement-step diagram with signal lines. 1S1
1 1
2
3
4
5=1
1B2
1A1 0
1B1 2B2
1
2A1 0
2B1
Displacement-step diagram
C-14
© Festo Didactic GmbH & Co. KG • 541089
Exercise 3: Drilling of valve manifold blocks Solutions
Exercise 3: Drilling of valve manifold blocks Name:
Date:
Carrying out additional exercises
Sheet 2 of 2
How does the circuit react if the roller lever valve is moved? The cylinder does not fully advance, but only up to the position of the roller lever valve. What needs to be considered when mounting the back pressure valve? It is important to adjust the back pressure valve correctly. On a permanently installed valve this is facilitated by releasing the lock nut or by twisting the trip cam on the piston rod. In the test set-up, the back pressure valve is moved along the profile slot.
If the cylinder impacts on the valve, this can be damaged.
Use and comparison of different sensors Sensor
Type of actuation
Use
Observe
Roller lever valve with idle return
Mechanical
Signal overlap
Actuation direction, when the sensor actuated
Back pressure end stop
Compressed air
Monitoring of cylinder end position
Correct adjustment
Pneumatic limit switch
Magnetic
START interlock
Position on cylinder
Roller lever valve
Mechanical
Monitoring of cylinder
Response point
end position
© Festo Didactic GmbH & Co. KG • 541089
C-15
Exercise 3: Drilling of valve manifold blocks Solutions
C-16
© Festo Didactic GmbH & Co. KG • 541089
Exercise 4: Filling of drinks bottles Solutions
Exercise 4: Filling of drinks bottles Name:
Date:
Stepper module
Sheet 1 of 3
Introductory exercise with the stepper module (without drive or sensors) Connect the correct step connections so that it runs through automatically. – Which connections need to be interconnected? Connection
Connection
Yn
––––––––––––––––––––––––––––––––––––––––––––
P
Compressed air
Blanking plug
Yn+1 P
Zn
––––––––––––––––––––––––––––––––––––––––––––
Zn+1
L
Not connected, open
L
X1
––––––––––––––––––––––––––––––––––––––––––––
A1
X2
––––––––––––––––––––––––––––––––––––––––––––
A2
X3
––––––––––––––––––––––––––––––––––––––––––––
A3
X4
––––––––––––––––––––––––––––––––––––––––––––
A4
– What are the consequences of the interruption in the tubing connections? Create an evaluation table. Connection
Effect
A1 – X1
Not running. Stepper module stops.
A2 – X2
Not running. Stepper module stops.
A3 – X3
Not running. Stepper module stops.
A4 – X4
Not running. Stepper module stops.
Zn – Zn+1
Not running. Stepper module stops.
Yn – Yn+1
Not running. Stepper module stops.
© Festo Didactic GmbH & Co. KG • 541089
C-17
Exercise 4: Filling of drinks bottles Solutions
Exercise 4: Filling of drinks bottles Name:
Date:
Stepper module
Sheet 2 of 3
Mode of operation of a stepper sequencer A start signal is input at stepper module 1 via input Yn. This triggers the output command, e.g. 1A1+. At the same time, step 2 is prepared and the last step in the sequence (in this case step 4) is cancelled via the output connection Z. If step 1 receives the "command executed" acknowledgement via limit switch 1B2, step 2 is set and an output signal, e.g. 2A1+ is triggered. At the same time, step 3 is prepared and step 1 cancelled. The next steps are run in parallel.
A1
A2
TAA
Yn
Y
Yn
Yn+1
P Zn L
P Z L
P Zn L
P Zn+1
X1
A3
TAA
L
Yn
Yn+1
P Zn L
P Zn+1
X2
A4
TAA
L
TAB
Yn
Yn+1
P Zn L
P Zn+1
X3
Yn
L
P Zn L
Yn+1
P Zn+1 L
Y
Yn+1
P Z L
P Zn+1 L
X4
Resetting a stepper sequencer If the sequencer stops at 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.
C-18
© Festo Didactic GmbH & Co. KG • 541089
Exercise 4: Filling of drinks bottles Solutions
Exercise 4: Filling of drinks bottles Name:
Date:
Stepper module
Sheet 3 of 3
What are the advantages of a stepper module compared to reversing valve technology? Stepper technology has indisputable advantages compared to reversing valve technology (cascaded control systems) or the use of roller lever valves with idle return: • Minimal design complexity (circuit diagram) • Simplified reading and understanding of circuit diagram (black box principle) • Less tubing required (assembly time) • Parameters can be more easily realised • Less work required when modifying a control system • Greater operational reliability • Simplified monitoring via visual indicator and manual override. What tasks can the individual stepper module assume? The individual stepper module completes three tasks: • Switching through (transmission) of signals from input X to output A • Preparation of the following step • Cancelling the previous step
© Festo Didactic GmbH & Co. KG • 541089
C-19
Exercise 4: Filling of drinks bottles Solutions
Exercise 4: Filling of drinks bottles Name:
Date:
Completing the pneumatic circuit diagram
Sheet 1 of 1
1A1
1V2
1B1
1
1
2 1V1
2A1 2B1 2B2
1B2
1V3
2V2
2
4
2
12
2V3
2 2
14
12
3
1
1
2V1 4
2
14 5
1
5
1
3
s1 s2 s3 s4
A1
TAA
Yn P L Zn 0S1
1
Y
Yn
Yn+1
P Z L
P Zn L
P P Zn+1 Zn L L
3
1B1
2 1
Yn
3
Yn+1
Yn
Yn
3
P Zn+1 L
X4 2B2
2 1
Yn+1
P P Zn+1 Zn L L
X3 2B1
A4
TAB
Yn+1
P P Zn+1 Zn L L
2 1
A3
TAA
X2
X1
1B2
2
A2
TAA
3
Y
P Z L
Yn+1 P
L Zn+1
2 1
3
Pneumatic circuit diagram
C-20
© Festo Didactic GmbH & Co. KG • 541089
Exercise 4: Filling of drinks bottles Solutions
Exercise 4: Filling of drinks bottles Name:
Date:
Process description
Sheet 1 of 2
Initial position Cylinder 1A1 assumes the retracted end position, the piston rod of cylinder 2A1 is advanced and roller lever valve 1B1 is actuated. The pneumatic proximity sensor 2B2 is switched through via the permanent magnet on the piston and a signal is therefore applied at input X4 of the stepper sequencer. Output A4 is active. A signal is applied at the dual pressure valve 0V1 via Yn+1. Filling bottles, cylinder 1A1 Actuation of the START button 0S1 causes the memory of the first module (Type A) to be reset via the dual pressure valve 0V1. The output signal A1 reverses the final control element 1V1 and the cylinder 1A1 advances. Upon reaching the forward end position, the cylinder actuates the roller lever valve 1B2. This causes the first module at input X1 to be pressurised. The spring returned 3/2-way valve of the first module is reversed and the memory is reset at the subsequent second module (Type A). The output signal A2 of the second module reverses the final control element 1V1. Cylinder 1A1 returns into the retracted end position. Signal A2 also cancels the memory valve of the first module. It can only be switched via a new start signal and the output signal Yn+1. Bottle release, cylinder 2A1 Cylinder 1A1 in the retracted end position actuates the roller lever valve 1B1. Its signal acknowledges the output signal A2 at X2 and switches through to the third module (type A). The output signal A3 reverses the final control element 2V1 and cylinder 2A1 retracts. The pneumatic proximity sensor 2B1 acknowledges the movement and switches through to the fourth module (type B) via X3. Its signal reverses the final control element and cylinder 2A1 advances. The pneumatic proximity sensor 2B2 acknowledges the end position of the cylinder via X4. The spring returned 3/2-way valve of the fourth module (type B) is switched. The signal Yn+1 is applied at the dual pressure valve 0V1 again.
© Festo Didactic GmbH & Co. KG • 541089
C-21
Exercise 4: Filling of drinks bottles Solutions
Exercise 4: Filling of drinks bottles Name:
Date:
Process description
Sheet 2 of 2
Single cycle If the START button 1S1 is only briefly pressed, i.e. not detented for continuous cycle, only signal Yn+1 is applied at the dual pressure valve 0V1 at the end of a cycle. A new cycle cannot be started until the START button is actuated again. Continuous cycle If the START button 1S1 is detented, a continuous signal is applied at input 1 of the dual pressure valve 0V1. A new cycle starts automatically if the initial position of the cylinder is signalled via connection Yn+1 of the fourth stepper module (type B). Cycle end Disengaging the START button 1S1.
Simplified description
Filling of bottles, cylinder 1A1 Actuation of the START button 1S1 triggers the output signal A1 via 0V1, which switches 1V1 via connection 14. Cylinder 1A1 advances and actuates 1B2. 1B2 triggers the output signal A2 via input X1. 1V1 reverses; cylinder 1A1 retracts and actuates 1B1. Signal is applied at input X2. Releasing of bottles, cylinder 2A1 Signal at X2 pressurises output A3. 2V1 reverses; cylinder 2A1 retracts and actuates 2B1. 2B1 effects connection X3 and thus pressurises A4. 2V1 reverses; cylinder 2A1 advances and actuates 2B2. 2B2 produces X4 and Yn+1. Dual pressure valve 0V1 is pressurised on one side.
C-22
© Festo Didactic GmbH & Co. KG • 541089
Exercise 4: Filling of drinks bottles Solutions
Exercise 4: Filling of drinks bottles Name:
Date:
Compiling the equipment list
Sheet 1 of 1
Apart from a 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
2
Cylinder, double-acting
4
One-way flow control valve
2
5/2-way pneumatic double pilot valve
1
3/2-way valve with selector switch, normally closed
2
3/2-way roller lever valve, normally closed
2
Proximity sensor, pneumatic
1
Dual pressure valve (AND)
1
Stepper module Type 3TAA/1TAA
1
Manifold
1
On/off valve with filter regulating valve
1
Compressed air supply
Equipment list
© Festo Didactic GmbH & Co. KG • 541089
C-23
Exercise 4: Filling of drinks bottles Solutions
Exercise 4: Filling of drinks bottles Name:
Date:
Carrying out additional exercises
Sheet 1 of 2
– Design the displacement-step diagram with the signal lines. 0S1
1 1
2
3
4
5=1
1B2
1A1 0
1B1
1
2B2
2A1 0
2B1
Displacement-step diagram
C-24
© Festo Didactic GmbH & Co. KG • 541089
Exercise 4: Filling of drinks bottles Solutions
Exercise 4: Filling of drinks bottles Name:
Date:
Carrying out additional exercises
Sheet 2 of 2
How does the circuit react, if sensors 1B2 and 2B2 are displaced? If the pneumatic proximity sensor 2B2 is displaced when the cylinder is advanced, the proximity sensor is not attenuated and a start condition is not available. The system will not start up. If the roller lever valve 1B2 is displaced such that it is not actuated in the cylinder end position, the cylinder no longer retracts.
© Festo Didactic GmbH & Co. KG • 541089
C-25
Exercise 4: Filling of drinks bottles Solutions
C-26
© Festo Didactic GmbH & Co. KG • 541089
Exercise 5: Cleaning of workpieces Solutions
Exercise 5: Cleaning of workpieces Name:
Date:
Completing the pneumatic circuit diagram
Sheet 1 of 3
1A1 1B1 1B2
1V2
1V1
1
4
2A1
1V3
1
2
2
2V2
2
14
2V1
12 5
1
3 0V7
1
4
2
2
14
12 5
2
1
3 0V8
1/3
1
2V3
1
2
2B2
2B1
2 1/3
1
s1 s2 s3 s4
A1
TAA
Yn P L Zn 0S2
1 0S1
0S3
2
4
5
3
1
3
A3
TAA
Yn
Yn+1
Yn
Yn+1
Yn
Yn+1
Yn
P Z L
P Zn L
P P Zn+1 Zn L L
P Zn+1
P Zn L L
P Zn+1
P Zn L L
X1
X2 2B2
2 1
3
X3 2B1
2 1
3
Yn+1
P Zn+1 L
X4 1B1
2 1
A4
TAB
Y
1B2
2
A2
TAA
3
Y
P Z L
Yn+1 P
L Zn+1
2 1
3
2
1
3
Pneumatic circuit diagram without parameter conditions
© Festo Didactic GmbH & Co. KG • 541089
C-27
Exercise 5: Cleaning of workpieces Solutions
Exercise 5: Cleaning of workpieces Name:
Date:
Completing the pneumatic circuit diagram
Sheet 2 of 3
1A1 1B1 1B2
1V2
1V1
1
4
2A1
1V3
1
2
2V2
2
2
14
2V1
12 5
1
1
4
2
2
14
3 0V7
12 5
2
1
3 0V8
1/3
1
2V3
1
2
2B2
2B1
2 1/3
1
s1 s2 s3 s4
A1
TAA
Yn P L Zn
0S3
2
Yn+1
Yn
Yn+1
Yn
Yn+1
Yn
P Z L
P Zn L
P P Zn+1 Zn L L
P Zn+1
P Zn L L
P Zn+1
P Zn L L
X1
X2 0V4
2 3
1
3
4
2
5
3
1
0V5
1
2B2
3
Yn+1 P
L Zn+1 1B1
0S5
3
1
2 1
2 1
3
3
2
2B1
3
2
10 1
2 1 1
P Z L
10
3
1
P Zn+1 L
1/3
0V2 1
Y
2
1
2
0V3
2
2
Yn+1
X4
1/3 0S4
0V1
0S1
X3
2
1
A4
TAB
Yn
1
2
A3
TAA
Y
1B2
0S2
A2
TAA
3
3
3
Pneumatic circuit diagram with parameter conditions
C-28
© Festo Didactic GmbH & Co. KG • 541089
Exercise 5: Cleaning of workpieces Solutions
Exercise 5: Cleaning of workpieces Name:
Date:
Completing the pneumatic circuit diagram
Sheet 3 of 3
1A1 1B1 1B2
1V2
1V1
1
4
2A1
1V3
1
2
2
14
2V2
2
2V1
12 5
1
3
2B1
1
4
2
2
14
0V7
12 5
2
3
1
2
1/3
1
2V3
1
2
2B2
0V8 1
1/3
s1 s2 s3 s4
A1
TAA
Yn P L Zn 1B2
0S2
0S3
2
A3
TAA
Yn
Yn+1
Yn
Yn+1
Yn
Yn+1
Yn
P Z L
P Zn L
P P Zn+1 Zn L L
P Zn+1
P Zn L L
P Zn+1
P Zn L L
X1
X2 0V4
3
X3 0V5
1/3 0S4
2
0V3
2
Yn+1
Y
P Zn+1 L
X4
2
1
A4
TAB
Y
2 1
2
A2
TAA
P Z L
Yn+1 P
L Zn+1 1B1
2 1/3
1
0S5
2 1
2
3
10 1 0S1
3
4
2
5
3
1
1
3
0V1 1
2
2B2
1
3
1
3
0V2
2
2
2B1
3
2
10 1
1
3
1
3 1
3
3
Pneumatic circuit diagram with latching of the reset function
© Festo Didactic GmbH & Co. KG • 541089
C-29
Exercise 5: Cleaning of workpieces Solutions
Exercise 5: Cleaning of workpieces Name:
Date:
Process description
Sheet 1 of 2
Components used: Delays (t1 = 3 sec; t2 = 2 sec) are designated. Component 0V1 is the already familiar time delay valve with normally closed position. Component 0V2 is a time delay valve with interchanged positions, i.e. normally open. The output signal of this time delay valve needs to be inverted. A 3/2-way pneumatic valve with normally open position 0V3 assumes this function. The 5/2-way pneumatic valve with selector switch 0S1 facilitates the switching of AUTOMATIC/MANUAL. "MAN" in combination with the actuation of pushbutton 0S2 causes the sequencer and cylinder to be reset, i.e. all valves and cylinders assume the initial position. "AUTO" in combination with the actuation of the START button 0S2 initiates the automatic execution of a cycle (single cycle). The delays can be shortened or cancelled via the pushbuttons 0S4 (immersion time) and 0S5 (draining time). Initial position Cylinder 1A1 is in the retracted end position. The pneumatic proximity sensor 1B1 is attenuated and switched to flow from 1 to 2. Cylinder 2A1 is in the retracted end position. The roller lever valve 2B1 is actuated. The 5/2-way pneumatic valve with selector switch 0S1 is switched to AUTOMATIC, flow from 1 to 2. Steps 1-2 Cylinder 1A1 moves to the right above the electroplating bath (movement 1A1+). The START signal is input to the first module of the stepper sequencer, connection Yn, via the 3/2-way valve 0S2 and via the dual pressure valve 0V6, (module 4 is deactivated via line Z). The final control element 1V1 is reversed via output A1 and cylinder 1A1 advances. Steps 2-3 Cylinder 2A1 immerses the wire cage into the electroplating bath (movement 2A1+). Cylinder 1A1 switches through the pneumatic proximity sensor 1B2. Its signal is applied at input X1 of the stepper module 0Z1. The sequencer switches through to the second module. The final control element is reversed via output A2. Cylinder 2A1 advances and actuates the roller lever valve 2B2 in the forward end position.
C-30
© Festo Didactic GmbH & Co. KG • 541089
Exercise 5: Cleaning of workpieces Solutions
Exercise 5: Cleaning of workpieces Name:
Date:
Process description
Sheet 2 of 2
Steps 3-4 Cylinder 2A1 raises the wire cage (movement 2A1-). After the set time t1 = 3 sec, the time delay valve 0V1 switches to flow. Its signal pressurises input X2 of the second module of the stepper sequencer. The third module is reset. The final control element 2V1 is reversed via output A3 and the shuttle valve 0V8. Cylinder 2A1 retracts and actuates the roller lever valve 2B1 in the retracted end position. Steps 4-5 Cylinder 1A moves to the left (movement 1A-). After the set time t2 = 2 sec, the time delay valve 0V2 exhausts the pilot line of the 3/2-way pneumatic valve 0V3. This switches to normally open. Connection X3 of the stepper sequencer is pressurised via the shuttle valve 0V5 (the signal switch-off of the time delay valve 0V2 has been inverted). Signal X3 switches through to the fourth module. The dual pressure valve 0V7 is supplied with compressed air via output A4. The final control element 1V1 is reversed via the simultaneously applied output signal of the roller lever valve 2B1. Cylinder 1A1 retracts and actuates the pneumatic proximity sensor 1B1. Its signal switches through the fourth module of the stepper sequencer. The signal Yn+1 is applied at the dual pressure valve 0V6. A new cycle can now commence via a start signal.
© Festo Didactic GmbH & Co. KG • 541089
C-31
Exercise 5: Cleaning of workpieces Solutions
Exercise 5: Cleaning of workpieces Name:
Date:
Completing the equipment list
Sheet 1 of 1
Apart from a circuit diagram, comprehensive project documentation also requires an equipment list. – Complete the equipment list by entering the number of required components in the table below. Quantity
Description
2
Cylinder, double-acting
4
One-way flow control valve
2
5/2-way pneumatic double pilot valve
1
5/2-way valve with selector switch
4
3/2-way valve with pushbutton, normally closed
2
3/2-way pneumatic valve, normally open
2
3/2-way roller lever valve, normally closed
2
Proximity sensor, pneumatic
4
Shuttle valve (OR)
1
Dual pressure valve (AND)
1
Time delay valve, normally closed
1
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
C-32
© Festo Didactic GmbH & Co. KG • 541089
Exercise 5: Cleaning of workpieces Solutions
Exercise 5: Cleaning of workpieces Name:
Date:
Carrying out additional exercises
Sheet 1 of 1
– Design the displacement-step diagram with signal lines.
0S2
0S5 0S4 1 1
1A1 0
2
3
4
5=1
0V1
0V2
1B2
t1
t2
1B1
1
2B2
2A1 0
2B1
Displacement-step diagram
© Festo Didactic GmbH & Co. KG • 541089
C-33
Exercise 5: Cleaning of workpieces Solutions
C-34
© Festo Didactic GmbH & Co. KG • 541089
Exercise 6: Printing of mobile phone housings Solutions
Exercise 6: Printing of mobile phone housings Name:
Date:
Completing the pneumatic circuit diagram
Sheet 1 of 1
2A1 2B1 2B2
1A1
1V2
1B1
2V2
1
2
1V1
4
12 5
1
3V2
1
2V1 4
2
14
3A1
1B2
2
0V12
3
12 5
2
0V10
2 1/3
1
4
2 12
5
2
1
0V11 1
0V9
1
14
10
1/3
1
0V13
3
1
3
3
2
10
2
1
3 0V8
1/3
1
3 B2
2
3V1
2
14
3B1
1
2 1/3
s1 s2 s3 s4
0V6
4
2
14
A1
12 5
Start 0S6
1
2
3 0V5
Reset 0S4
3
Yn
1/3
P
Stop at cycle end 0S5
2 L Zn
2 1 1
TAB
Y
Yn
Yn+1
Yn
P Z L
P Zn L
P P Zn+1 Zn L L
X1
Yn+1
Yn
Yn+1
P P Zn+1 Zn L L
X2
Yn
Yn+1
P P Zn+1 Zn L L
X3
P Zn+1 L
X4
Y
P Z L
Yn+1 P
L Zn+1
3
1B2
Manual/Automatic 0S3 4
2
5
1 3
2B1
2
1 4
0V1
5
2
1
2
3
1
3
2B2
2
1
3B2 12
EMERGENCY10 STOP
3
1B1
2
3
2
1
3 3B1
2
2
2
14
1
A4
TAA
3
0V2
0S1
A3
TAA
2
1 1
A2
TAA
1
1
3
1
3
3 Acknowledge EMERGENCY-STOP 0S2
3
2
1
3
Pneumatic circuit diagram
© Festo Didactic GmbH & Co. KG • 541089
C-35
Exercise 6: Printing of mobile phone housings Solutions
Exercise 6: Printing of mobile phone housings Name:
Date:
Process description
Sheet 1 of 3
Initial position The double-acting cylinder 1A1 is in the retracted end position and actuates the roller lever valve 1B1. The double-acting cylinder 2A1 is advanced and actuates the pneumatic proximity sensor 2B2. The double-acting cylinder 3A1 is in the retracted end position and actuates the roller lever valve 3B1. The 5/2-way pneumatic valve with selector switch 0S3 is detented to flow from 1-2. The 3/2-way pneumatic valve with the „EMERGENCY-STOP“ mushroom actuator 0S1 is unlatched. The memory valve 0V2 has flow from 1 to 2. The stepper sequencer is reset. Continuous cycle Steps 1-2 Cylinder 1A1 advances, cylinder 2A1 retracts. The START signal 0S6 switches the memory valve 0V6 from 1 to 4. A continuous signal is applied at the dual pressure valve 0V7. Combined with signal Yn+1 of the last module of the sequencer, the dual pressure valve 0V7 is able to input the start pulse into the stepper sequencer. The output signal A1 simultaneously reverses the final control elements 1V1 and 2V1 via string s1. Cylinder 1A1 advances and cylinder 2A1 retracts throttled. Steps 2-3 Feed cylinder 3A1 advances, whereby cylinder 1A1 remains advanced. As soon as cylinder 1A1 reaches the forward end position and cylinder 2A1 reaches the retracted end position, the sequencer is advanced via the acknowledgement signal X1. The dual pressure valve 0V3 ensures that only one signal arrives at X1, if both the back pressure valve 1B2 and the pneumatic proximity sensor 2B1 are actuated. Signal A2 reverses the final control element 3V1 via string s2. The doubleacting cylinder 3A1 advances and actuates the roller lever valve with idle return 3B2 in the end position.
C-36
© Festo Didactic GmbH & Co. KG • 541089
Exercise 6: Printing of mobile phone housings Solutions
Exercise 6: Printing of mobile phone housings Name:
Date:
Process description
Sheet 2 of 3
Steps 3-4 Cylinder 1A1 retracts, cylinder 2A1 advances. The acknowledgement signal of the roller lever valve with idle return 3B2 advances the stepper sequencer by one step via connection X2. The actuating signal A3 reverses the final control elements 1V1 and 2V1 via the pilot line s3. Cylinder 1A1 moves into the retracted end position and actuates the roller lever valve 1B1, cylinder 2A1 moves into the forward end position and actuates the pneumatic proximity sensor 2B2. Steps 4-5 Feed cylinder 3A1 retracts, whereby cylinder 2A1 remains advanced. Once cylinders 1A1 and 2A1 have acknowledged their end positions (initial position) (1B1 and 2B2 actuated), the signal of the dual pressure valve 0V4 at input X3 advances the stepper sequencer by one step. The actuating signal reverses the final control element 3V1 via string s4. Cylinder 3A1 retracts and one cycle is completed. Two signals are now applied again at the dual pressure valve 0V7, i.e. the continuous signal from the memory valve 0V6 and the signal Yn+1 from the stepper sequencer. Consequently all further cycles are executed without a renewed START signal.
© Festo Didactic GmbH & Co. KG • 541089
C-37
Exercise 6: Printing of mobile phone housings Solutions
Exercise 6: Printing of mobile phone housings Name:
Date:
Process description
Sheet 3 of 3
Parameters • STOP at CYCLE END The memory valve 0V6, realised via a 5/2-way double solenoid valve in the exercise, can be converted via the 3/2-way valve with pushbutton 0S5. The line at the dual pressure valve 0V7 is exhausted. The start signal Yn+1 for the next cycle is thus blocked via the dual pressure valve 0V7. • EMERGENCY-STOP Actuation of the EMERGENCY-STOP valve 0S1 causes the 3/2-way pneumatic valve 0V1 to be reversed. The memory valve 0V1 is reversed, with flow from 1 to 4. The start processors are exhausted. The final control element 2V1) is reversed via connection 14. Cylinder 2A1 advances. Port 12 of the final control element 2V1 is exhausted via the 3/2-way pneumatic valve 0V13. This ensures that the final control element is able to switch to flow from 1 to 4. The air supply line to control element 3V1 is exhausted via the 3/2-way pneumatic valve 0V11 and consequently cylinder 3A1 is stationary. • EMERGENCY-STOP release and RESET After an EMERGENCY-STOP, the cylinders must be returned to their initial position. RESET is achieved by actuating the 3/2-way valve via pushbutton 0S4. The following sequence is to be observed: 1. EMERGENCY-STOP (0S1) 2. Switch from AUTOMATIC to MANUAL (0S3) 3. Release EMERGENCY-STOP (0S2) 4. RESET (0S4)
C-38
© Festo Didactic GmbH & Co. KG • 541089
Exercise 6: Printing of mobile phone housings Solutions
Exercise 6: Printing of mobile phone housings Name:
Date:
Completing the equipment list
Sheet 1 of 1
Apart from a circuit diagram, comprehensive project documentation also requires an equipment list. – Complete the equipment list by entering the number of required components in the table below. Quantity
Description
3
Cylinder, double-acting
3
One-way flow control valve
5
5/2-way pneumatic double pilot valve
1
5/2-way valve with selector switch
4
3/2-way valve with pushbutton, normally closed
1
3/2-way valve with mushroom actuator, normally open (EMERGENCY-STOP)
3
3/2-way pneumatic valve, normally open
1
3/2-way toggle lever valve with idle return, normally closed
1
3/2-way back pressure valve, normally closed
2
3/2-way roller lever valve, normally closed
2
Proximity sensor, pneumatic
5
Shuttle valve (OR)
3
Dual pressure valve (AND)
1
Stepper module Type 3TAA/1TAB
1
Manifold
1
On/off valve with filter regulating valve
1
Compressed air supply
Equipment list
© Festo Didactic GmbH & Co. KG • 541089
C-39
Exercise 6: Printing of mobile phone housings Solutions
Exercise 6: Printing of mobile phone housings Name:
Date:
Carrying out additional exercises
Sheet 1 of 1
– Design the displacement-step diagram with signal lines. 0S6 1 1
2
1B2
3
4
1A1
5=1
1B1
0
2B2
1
2A1 0 1
2B1 3B2
3A1 0
3B1
Displacement-step diagram
C-40
© Festo Didactic GmbH & Co. KG • 541089
Exercise 7: Packaging of spark plugs Solutions
Exercise 7: Packaging of spark plugs Name:
Date:
Completing the pneumatic circuit diagram
Sheet 1 of 1
1A1 1B1 1B2
1V2
1V1
1
4
2A1
1V3
1
2
2V2
2
2
14
2V1
12 5
1
3 0V9
1
4
2B1
2
2
14
12 5
2
1
3 0V10
1/3
1
2V3
1
2
2B2
2 1/3
1
s1 s2 s3 s4 0V7 10 1
0V4
2 1
0S4
1
3
0V1
1
1
0V2 2
Yn P
3
L Zn
2
12 1
0S2
4
5
2
1
Yn+1
P Z L
P Zn L
P P Zn+1 Zn L L
X1
3
Yn
A3
TAA
Yn+1
Yn
A4
TAB
Yn+1
P P Zn+1 Zn L L
X2
Yn
X3
Y
P Z L
Yn+1 P
L Zn+1
2 1
3 0Z3
P Zn+1 L
X4 1B1
2
Yn+1
P P Zn+1 Zn L L
2
3
3
2
12 1
0S1
Yn
1
2 1
Y
1B2
3
1/3 0S3
A2
TAA
3
0S5 2
2
A1
TAA
10
3
10 1
3 2B1
2B2
2 1
3
2 1
3
Pneumatic circuit diagram
© Festo Didactic GmbH & Co. KG • 541089
C-41
Exercise 7: Packaging of spark plugs Solutions
Exercise 7: Packaging of spark plugs Name:
Date:
Process description
Sheet 1 of 2
Initial position The double-acting cylinder 1A1 at the gravity feed magazine is in the retracted end position and actuates the pneumatic proximity sensor 1B1. The double-acting cylinder 2A1 at the flat magazine is also in the retracted end position and actuates the roller lever valve 2B1. The 5/2-way valve with selector switch 0S1 is detented for flow from 1 to 2 (AUTOMATIC). The 3/2-way valve with selector switch 0S5 is actuated (a roller lever valve is simulated, which indicates a full cardboard box magazine). Continuous cycle Steps 1-2 Cylinder 1A1 at the gravity feed magazine advances. The START signal of the 3/2-way valve 0S2 causes the pneumatic valve 0V2 to be switched to flow from 1 to 2 via the shuttle valve 0V1. The pneumatic valve 0V2 moves into a self-latching loop via valves 0S5, 0V4 (normally open position) and the shuttle valve (0V1). As a result of this self-latching loop, a continuous signal is applied at the dual pressure valve 0V5. Combined with the signal Yn+1 of the last module of the sequencer, the cylinders are actuated. The output signal A1 of the sequencer switches the final control element 1V1 to flow from 1 to 4. Cylinder 1A1 advances unthrottled and actuates the pneumatic proximity sensor 1B2 in the forward end position.
C-42
© Festo Didactic GmbH & Co. KG • 541089
Exercise 7: Packaging of spark plugs Solutions
Exercise 7: Packaging of spark plugs Name:
Date:
Process description
Sheet 2 of 2
Steps 2-3 to 9-10 Cylinder 2A1 at the flat magazine executes four double strokes. The stepper sequencer receives the acknowledgement signal X1 from the pneumatic proximity sensor and steps up. The output signal A2 of the sequencer, together with the signal of the actuated roller lever valve 2B1, is applied at the dual pressure valve 0V8 and switches the final control element to flow from 1 to 4. Cylinder 2A1 advances unthrottled and in the forward end position actuates the roller lever valve 2B2. Its signal is applied at the dual pressure valve 0V6 together with signal A2 and reverses the final control element 2V1. Cylinder 2A1 retracts again. The roller lever valve 2B2 also transmits a pulse to the counter of the pneumatic predetermining counter 0Z3. After the set 4 strokes, the output signal of the counter is applied at the dual pressure valve 0V3. Together with the signal of the roller lever valve 2B1, the 4 strokes are acknowledged at X2 and the sequencer steps up. The pneumatic valve 0V7 is exhausted via the same output signal of the counter. Only one signal is still applied at the dual pressure valve 0V8 and cylinder 2A1 is therefore no longer able to advance. Steps 10-11 Cylinder 1A1 at the gravity feed magazine retracts. The output signal A3 reverses the final control element 1V1. Cylinder 1A1 retracts and actuates the pneumatic proximity sensor 1B1. The 3rd module switches through and its signal Yn+1 initiates a new cycle. Please note: This module must be the last module of the stepper sequencer. One module must be bridged.
STOP at CYCLE END Actuation of the 3/2-way valve 0S4 causes the pneumatic valve 0V4 to exhaust the self-latching loop. The pneumatic valve 0V2 switches into the normally closed position and no signal is therefore applied at the dual pressure valve 0V5. The sequencer can only be activated again via a renewed start signal. RESET If the 5/2-way valve with selector switch 0S1 is detented to MANUAL, the cylinders and sequencer can be moved into the initial position via the actuation of the 3/2-way valve 0S2.
© Festo Didactic GmbH & Co. KG • 541089
C-43
Exercise 7: Packaging of spark plugs Solutions
Exercise 7: Packaging of spark plugs Name:
Date:
Completing the equipment list
Sheet 1 of 1
Apart from a circuit diagram, comprehensive project documentation also requires an equipment list. – Complete the equipment list by entering the number of required components in the table below. Quantity
Description
2
Cylinder, double-acting
4
One-way flow control valve
2
5/2-way pneumatic double pilot valve
1
5/2-way valve with selector switch
1
3/2-way valve with selector switch, normally closed
3
3/2-way valve with pushbutton, normally closed
1
3/2-way pneumatic valve, normally closed
2
3/2-way pneumatic valve, normally open
2
3/2-way roller lever valve, normally closed
2
Proximity sensor, pneumatic
1
Pneumatic predetermining counter
3
Shuttle valve (OR)
4
Dual pressure valve (AND)
1
Stepper module Type 3TAA/1TAB
1
Manifold
1
On/off valve with filter regulating valve
1
Compressed air supply
Equipment list
C-44
© Festo Didactic GmbH & Co. KG • 541089
Exercise 7: Packaging of spark plugs Solutions
Exercise 7: Packaging of spark plugs Name:
Date:
Carrying out additional exercises
Sheet 1 of 1
– Design the displacement-step diagram with signal lines. 0S3
1 1
2
1B2
3
4
5
6
7
8
9
10
11=1
1A1 0
1B1
1
2B2
2A1 0
2B1
2B2
2B1
2B2
2B1
2B2 2B1
Displacement-step diagram
© Festo Didactic GmbH & Co. KG • 541089
C-45
Exercise 7: Packaging of spark plugs Solutions
C-46
© Festo Didactic GmbH & Co. KG • 541089
Exercise 8: Sealing of guide bushes Solutions
Exercise 8: Sealing of guide bushes Name:
Date:
Completing the pneumatic circuit diagram
Sheet 1 of 1
1A1 1B3
1V2
1V1
1
4
1B1
1V3
1
2
2
14
1B2
2 12
5
1 3
0V13
2 1/3 0V12
1 0V11
2 1/3
1
2
10 0V10
2
1
3
10
0V9 3
1
2
10 1
0V7
0V8
2 1/3
1 0V6 1
1/3
P
2
L Zn
10 0V4
Yn
Yn+1
P Z L
P Zn L
P P Zn+1 Zn L L
X1
2
1B2 3
1/3
1
Start 0S4
3
2
5
1 3
4
EMERGENCY10 STOP 0S1
1
Yn+1
P P Zn+1 Zn L L
Yn
Yn+1
P P Zn+1 Zn L L
X3
P Zn+1 L
X4
Y
P Z L
Yn+1 P L Zn+1
1B3
3
1B1
2 1
3
2 1
3
3
12 5
2
1
2
Yn
2
14 0V1
Yn+1
A4
TAB
2 1
Manual/Automatic 0S3 4
0V2
Yn
A3
TAA
X2
2 1
Reset 0S5
2 1
A2
3
1
2
TAA
Y
12 0V3
A1
TAA
Yn
1
1/3
1
s1 s2 s3 s4
2
0V5
3
2
3 1 Acknowledge EMERGENCY-STOP
3
3
0S2
2
1
3
Pneumatic circuit diagram
© Festo Didactic GmbH & Co. KG • 541089
C-47
Exercise 8: Sealing of guide bushes Solutions
Exercise 8: Sealing of guide bushes Name:
Date:
Process description
Sheet 1 of 3
Initial position The piston rod of the double-acting cylinder 1A1 is in the retracted end position and actuates the roller lever valve 1B1. The 3/2-way pneumatic valves 0V5, 0V9, 0V10 and 0V11 assume the normally open position. The 3/2-way pneumatic valve 0V4, required for the latching circuit, assumes the normally closed position. The mode selector switch 0S3 is set to AUTOMATIC (flow from 1 to 2) Steps 1-2 The piston rod moves into the forward end position. The START signal of the 3/2-way valve 0S4 causes the pneumatic valve 0V4 to be switched to flow via the shuttle valve 0V3. The pilot air can now flow to the sequencer, port P, via valve 0V5. Via the shuttle valve 0V3, this pilot air simultaneously transmits a continuous signal to the 3/2-way pneumatic valve 0V4. This valve switches into a self-latching loop and the compressed air supply for the sequencer is protected. Pressure is applied at both sides of the dual pressure valve 0V6 via the start signal and signal Yn+1 and this switches through. The sequencer is able to actuate the final control element. The output signal A1 of the sequencer reverses the pneumatic valve 0V10 and the final control element 1V1 via the shuttle valve 0V7. The piston rod advances and actuates the roller lever valve 1B2 in the forward end position. The over-travelling of the proximity sensor 1B3 does not have any effect.
C-48
© Festo Didactic GmbH & Co. KG • 541089
Exercise 8: Sealing of guide bushes Solutions
Exercise 8: Sealing of guide bushes Name:
Date:
Process description
Sheet 2 of 3
Steps 2-3 Piston rod moves into the retracted end position. The signal of the roller lever valve 1B2 is applied at intput X1 and steps up the sequencer. The output signal A2 flows via the shuttle valve 0V8, the pneumatic valve 0V9) and shuttle valves 0V12 and 0V13 and resets the final control element 1V1. The piston rod retracts and actuates the roller lever valve 1B1. Steps 3-4 Piston rod advances halfway. The sequencer is stepped up via the acknowledgement signal X2 of the roller lever valve 1B1. (The AND gate of the 4th module is not yet prepared and the signal at X4 therefore cannot step up the sequencer. Also, the traversing of proximity sensor 1B3 has no effect, since the 3rd module has not yet been prepared). The output signal A3 flows via the shuttle valve 0V7 and the pneumatic valve 0V10 to the pilot port 14 of the final control element 1V1 and reverses this. The piston rod advances and actuates the pneumatic proximity sensor 1B3. Steps 4-5 Piston rod moves into the retracted end position. The acknowledgement signal of the pneumatic proximity sensor 1B3 can now step up the sequencer via connection X3. The output signal A4 flows via the shuttle valve 0V8, the pneumatic valve 0V9 and shuttle valves 0V12 and 0V13 to pilot port 12 of the final control element 1V1 and reverses this. The piston rod retracts. The roller lever valve 1B1 acknowledges the end position of the piston rod at connection X4. The signal Yn+1 is applied at the dual pressure valve 0V6 again and the next cycle can commence via a new start signal.
© Festo Didactic GmbH & Co. KG • 541089
C-49
Exercise 8: Sealing of guide bushes Solutions
Exercise 8: Sealing of guide bushes Name:
Date:
Process description
Sheet 3 of 3
Behaviour during EMERGENCY-STOP EMERGENCY-STOP, piston rod in "forward movement" If the EMERGENCY-STOP mushroom actuator 0S1 is actuated, the self-latching loop of the compressed air supply for the sequencer is first of all interrupted via valve 0V5. This means that the sequencer cannot emit any output signals. The signal blocks valves 0V9 and 0V10 and reverses the final control element 1V1 via valves 0V11, 0V12 and 0V13). The piston rod moves into the retracted end position. EMERGENCY-STOP, piston rod in "retract movement" The final control element 1V1 is already switched to flow from 1 to 2. The piston rod consequently moves into the retracted end position. EMERGENCY-STOP, piston rod in forward end position The final control element 1V1 is switched to flow from 1 to 4. The roller lever valve 1B2 is actuated and blocks the valve 0V11. Consequently, the line for the signal to the final control element is interrupted and the piston rod remains in the forward end position. EMERGENCY-STOP release and RESET After an EMERGENCY-STOP, the cylinders must be returned to their initial position. RESET is achieved by actuating the 3/2-way valve using pushbutton 0S5. The following sequence is to be observed: 1. EMERGENCY-STOP (0S1) 2. Switch from AUTOMATIC to MANUAL (0S3) 3. Release EMERGENCY-STOP (0S2) 4. RESET (0S5)
C-50
© Festo Didactic GmbH & Co. KG • 541089
Exercise 8: Sealing of guide bushes Solutions
Exercise 8: Sealing of guide bushes Name:
Date:
Completing the equipment list
Sheet 1 of 1
Apart from a circuit diagram, comprehensive project documentation also requires an equipment list. – Complete the equipment list by entering the number of required components in the table below. Quantity
Description
1
Cylinder, double-acting
2
One-way flow control valve
2
5/2-way pneumatic double pilot valve
3
3/2-way valve with pushbutton, normally closed
1
3/2-way valve with mushroom actuator, normally open (EMERGENCY-STOP)
5
3/2-way pneumatic valve, normally closed
1
3/2-way pneumatic valve, normally open
2
3/2-way roller lever valve, normally closed
1
Proximity sensor, pneumatic
5
Shuttle valve (OR)
1
Dual pressure valve (AND)
1
Stepper module Type 3TAA/1 TAB
1
Manifold
1
On/off valve with filter regulating valve
1
Compressed air supply
Equipment list
© Festo Didactic GmbH & Co. KG • 541089
C-51
Exercise 8: Sealing of guide bushes Solutions
Exercise 8: Sealing of guide bushes Name:
Date:
Carrying out additional exercises
Sheet 1 of 1
– Design the displacement-step diagram with signal lines. 0S1
1
2
3
4
5=1
1
1A m
1B2 1B3
0
1B1
1B1
Displacement-step diagram
C-52
© Festo Didactic GmbH & Co. KG • 541089
Exercise 9: Hardening of material test specimens Solutions
Exercise 9: Hardening of material test specimens Name:
Date:
Completing the pneumatic circuit diagram
Sheet 1 of 1
1A1 1B3
1V5
1B1
1
2
2 1V4
1 12 1V1
1V6
1
2 1V3
1B2
2 1 12 1V2
2
12 0V5
1
2
3
0V6
1/3
1
2
12 1
2 1/3
1
3
0V4
2
10 0V2
0V3
2
1
2
3
10
1
1
3
3
s1 s2 s3 s4 A1
TAA
Yn P L Zn 0S1
1
Y
Yn
Yn+1
P Z L
P Zn L
P P Zn+1 Zn L L
3
Yn
X1
1B3
2
1B2
3
Yn
P P Zn+1 Zn L L
A3
Yn+1
Yn
Yn+1
P P Zn+1 Zn L L
P Zn+1 L
X4 1B1
3
A4
TAB
X3
2 1
TAA
Yn+1
X2
2 1
A2
TAA
Y
P Z L
Yn+1 P
L Zn+1
2 1
3
Pneumatic circuit diagram
© Festo Didactic GmbH & Co. KG • 541089
C-53
Exercise 9: Hardening of material test specimens Solutions
Exercise 9: Hardening of material test specimens Name:
Date:
Process description
Sheet 1 of 2
Initial position The piston of cylinder 1A1 is in the retracted end position and actuates the roller lever valve 1B1; the continuous signal Yn+1 is therefore applied at the dual pressure valve 0V1. The 4th module (type B) of the stepper sequencer is reset and its signal A4 blocks the time delay valve 0V3. The pneumatic valve 0V4 is not actuated and is in the normally open position. Consequently, the pilot port 12 of the final control element 1V2 is pressurised. The piston rod chamber of the cylinder is pressurised at a pressure of p = 6 bar (600 kPa). Steps 1-2 Cylinder 1A1 moves into mid position for annealing. The first module (type A) of the sequencer is reset via the START signal of the 3/2-way valve 0S1. Its signal A1 actuates the final control element 1V1, i.e. a spring returned 3/2-way pneumatic valve. The time delay valve 0V3 moves into the normal position (flow). The pneumatic valve 1V2 moves into the normal position. Cylinder 1A1 advances and in the mid-position actuates the pneumatic proximity sensor 1B3. Steps 2-3 Awaiting the annealing time, cylinder moves into righthand end position for quenching. The acknowledgement signal of the pneumatic proximity sensor 1B3 is applied at connections X1 and X3 of the stepper sequencer, but can only be switched through via the reset 1st module. Signal A2 actuates the time delay valve 0V2. The cylinder remains in the mid-position during the set annealing time of t1 = 3 seconds. Valves 1V1 and 1V2 are exhausted. After 3 seconds, the final control element 1V1 is switched via the time delay valve 0V2. The cylinder moves into the forward end position and actuates the roller lever valve 1B2.
C-54
© Festo Didactic GmbH & Co. KG • 541089
Exercise 9: Hardening of material test specimens Solutions
Exercise 9: Hardening of material test specimens Name:
Date:
Process description
Sheet 2 of 2
Steps 3-4 Cylinder moves into mid-position for start-up. The acknowledgement signal of the roller lever valve 1B2 switches through to the 3rd stepper module. Its signal A3 switches the final control element 1V2 to flow. Cylinder 1A1 moves to the left into mid-position and re-activates the pneumatic proximity sensor 1B3. Steps 4-5 Awaiting the tempering time, cylinder moves into lefthand end. The acknowledgement signal of the pneumatic proximity sensor 1B3 switches to the 4th module (type B) of the sequencer via connection X3. The signal at X1 has no effect, since module 1 is not reset. Signal A4 actuates the time delay valve 0V3. After the tempering time of t2 = 2 seconds, the final control element is switched to flow via the time delay valve 0V3. The cylinder moves into the initial position. A new cycle can be started via a renewed START signal.
© Festo Didactic GmbH & Co. KG • 541089
C-55
Exercise 9: Hardening of material test specimens Solutions
Exercise 9: Hardening of material test specimens Name:
Date:
Checking the equipment list
Sheet 1 of 1
Apart from a circuit diagram, comprehensive project documentation also requires an equipment list. – Check the equipment list by comparing the number of components listed in the table below with your circuit design. Quantity
Description
1
Cylinder, double-acting
2
Non-return valve, piloted
2
One-way flow control valve
1
3/2-way valve with pushbutton, normally closed
2
3/2-way pneumatic valve, normally closed
1
3/2-way pneumatic valve, normally open
2
3/2-way roller lever valve, normally closed
1
Proximity sensor, pneumatic
1
Time delay valve, normally closed
1
Time delay valve, normally open
2
Shuttle valve (OR)
1
Dual pressure valve (AND)
1
Stepper module Type 3TAA/1 TAB
1
Manifold
1
On/off valve with filter regulating valve
1
Compressed air supply
Equipment list
C-56
© Festo Didactic GmbH & Co. KG • 541089
Exercise 9: Hardening of material test specimens Solutions
Exercise 9: Hardening of material test specimens Name:
Date:
Carrying out additional exercises
Sheet 1 of 1
– Design the displacement-step diagram with signal lines. 0S1
1
2
1
1A1
m 0
1B3
3
1B2
4
5=1
1B3
t1
t2
0V2
0V3
1B1
Displacement-step diagram
© Festo Didactic GmbH & Co. KG • 541089
C-57
Exercise 9: Hardening of material test specimens Solutions
C-58
© Festo Didactic GmbH & Co. KG • 541089
Exercise 10: Bending of sheet metal strips Solutions
Exercise 10: Bending of sheet metal strips Name:
Date:
Completing the pneumatic circuit diagram
Sheet 1 of 1
1A1
1V2
2A1
1B2
1B1
2V2
2
1 2
1V1
3V2
1
2 12
3
5
3A1
3B2
1
2
4
14 1
3B1
2B2
2
2V1
12
2B1
1
4
2
5
3
14
12
3
1
s1 s2 s3 s4
A1
TAA
0V4
Yn
1/3
P Zn 2
12
1B1
3
1
1B2
3
Yn+1
2
1
Yn
P Z L
P Zn L
P P Zn+1 Zn L L
X1
Yn+1
Yn
P P Zn+1 Zn L L
2B1
3
Yn
Yn+1
P P Zn+1 Zn L L
X3
X2
2
Yn+1
P Zn+1 L
X4
Y
P Z L
Yn+1 P
L Zn+1
2
1
3
10 1
2
A4
TAB
2
12 3
0S1
Yn
1 0V2
2
1
L
Y
2B2
10 1
A3
TAA
2
1
0V3
A2
TAA
3
3B2
3B1
2
1
3
2
1
3
3
Pneumatic circuit diagram
© Festo Didactic GmbH & Co. KG • 541089
C-59
Exercise 10: Bending of sheet metal strips Solutions
Exercise 10: Bending of sheet metal strips Name:
Date:
Process description
Sheet 1 of 2
Initial position The three drives are in the retracted end position. Sensors 1B1, 2B1 and 3B1 are actuated. The memory valve 0V3 is switched to flow from 1 to 2. Memory valve 0V2 is closed. Steps 1-2 Clamping cylinder 1A1 advances (1A1+). The final control element 1V1 switches to flow if the START button 0S1 is actuated. The single-acting clamping cylinder 1A1 advances with throttled supply air and in the forward end position actuates the back pressure valve 1B2. Two signals (start signal and acknowledgement signal of movement 1A1+) are applied at the dual pressure valve 0V1). The final control element 1V1 remains actuated via the memory valve 0V2 and the shuttle valve 0V4. The clamping cylinder remains in the forward end position. Steps 2-3 The first bending cylinder 2A1 advances (2A1+). A signal is also applied at the dual pressure valve 0V5 via the memory valve 0V2. Together with signal Yn+1, the first module (type A) of the stepper sequencer is reset and its signal A1 reverses the final control element 2V1. The bending cylinder 2A1 advances and actuates the roller lever valve with idle return 2B2. Steps 3-4 The first bending cylinder 2A1 retracts (2A1-). The second module (type A) is reset via the acknowledgement signal of the roller lever valve with idle return 2B2 and its signal A2 reverses the final control element 2V1. The bending cylinder 2A1 moves into the retracted end position and actuates the roller lever valve 2B1. Steps 4-5 The second bending cylinder 3A1 advances (3A1+). The acknowledgement signal of the roller lever valve 2B1 causes the third module (type A) to be reset; its signal A3 reverses the final control element 3V1. The bending cylinder 3A1 moves into the forward end position and actuates the pneumatic proximity sensor 3B2.
C-60
© Festo Didactic GmbH & Co. KG • 541089
Exercise 10: Bending of sheet metal strips Solutions
Exercise 10: Bending of sheet metal strips Name:
Date:
Process description
Sheet 2 of 2
Steps 5-6 The second bending cylinder 3A1 and the clamping cylinder 1A1 retract (3A1-), (1A1-). First of all, the acknowledgement signal of the pneumatic proximity sensor 3B2 switches through to the fourth module (type B), and its signal A4 reverses the final control element 3V1. Cylinder 3A1 retracts and actuates the pneumatic proximity sensor 3B1. Secondly, the memory valve 0V2 is reversed, as a result of which there is no continuous signal at the final control element 1V1. The clamping cylinder 1A1 also retracts and actuates the roller lever valve 1B1, whereby the initial position is obtained again. The fourth module of the sequencer is switched through and its signal Yn+1 is applied at the dual pressure valve 0V5. The memory valve 0V3 is back in the righthand switching position (flow from1 to 2). A new cycle can be started via a START signal.
© Festo Didactic GmbH & Co. KG • 541089
C-61
Exercise 10: Bending of sheet metal strips Solutions
Exercise 10: Bending of sheet metal strips Name:
Date:
Checking the equipment list
Sheet 1 of 1
Apart from a circuit diagram, comprehensive project documentation also requires an equipment list. – Check the equipment list by comparing the number of components listed in the table below with your circuit design. Quantity
Description
2
Cylinder, double-acting
1
Cylinder, single-acting
3
One-way flow control valve
2
5/2-way pneumatic double pilot valve
1
3/2-way pneumatic valve, normally closed
2
3/2-way pneumatic double pilot valve
1
3/2-way valve with pushbutton, normally closed
1
3/2-way toggle lever valve with idle return, normally closed
1
3/2-way back pressure valve, normally closed
2
3/2-way roller lever valve, normally closed
2
Proximity sensor, pneumatic
1
Shuttle valve (OR)
2
Dual pressure valve (AND)
1
Stepper module Type 3TAA/1 TAB
1
Manifold
1
On/off valve with filter regulating valve
1
Compressed air supply
Equipment list
C-62
© Festo Didactic GmbH & Co. KG • 541089
Exercise 10: Bending of sheet metal strips Solutions
Exercise 10: Bending of strip metal sheets Name:
Date:
Carrying out additional exercises
Sheet 1 of 1
– Design the displacement-step diagram with signal lines. 0S1
1
2
3
4
5
6=1
1
1B2
1A1
1B1
0 1
2B2
2A1 0
2B1
1
3B2
3A1 0
3B1
Displacement-step diagram
© Festo Didactic GmbH & Co. KG • 541089
C-63
Exercise 10: Bending of sheet metal strips Solutions
C-64
© Festo Didactic GmbH & Co. KG • 541089
Part D – Appendix
Organiser __________________________________________________________ D-2 Assembly technology ________________________________________________ D-3 Plastic tubing_______________________________________________________ D-4
Data sheets
3/2-way valve with pushbutton, normally closed _______________________ 152860 3/2-way valve with mushroom actuator, normally open (EMERGENCY-STOP) 152864 3/2-way roller lever valve with idle return, normally closed_______________ 152867 Back pressure valve ______________________________________________ 152868 Pneumatic predetermining counter __________________________________ 152877 Shuttle valve, 3-fold ______________________________________________ 152882 Dual pressure valve, 3-fold_________________________________________ 152883 Stepper module__________________________________________________ 152886 Double-acting cylinder ____________________________________________ 152888 Time delay valve, normally open ____________________________________ 539759 3/2-way pneumatic valve, convertible________________________________ 539768 5/2-way double pilot valve _________________________________________ 539769 Shuttle valve ____________________________________________________ 539771 One-way flow control valve_________________________________________ 539773 Non-return valve, piloted __________________________________________ 540715
Circuit diagrams
Exercise 4: Filling of drinks bottles Exercise 5: Cleaning of workpieces Exercise 6: Printing of mobile phone housings Exercise 7: Packaging of spark plugs Exercise 8: Sealing of guide bushes Exercise 9: Hardening of material test specimens Exercise 10: Bending of sheet metal strips
© Festo Didactic GmbH & Co. KG • 541089
D-1
Organiser
Equipment set in the organiser
All components of the equipment set for the technology package TP102 are stored in an organiser within a Systainer. The organiser also serves as a drawer insert for use in conjunction with our laboratory furniture.
D-2
© Festo Didactic GmbH & Co. KG • 541089
Assembly technology
The components of the equipment set are intended for assembly on the Festo Didactic profile plate, which consists of 14 parallel T-slots, set at 50 mm intervals. Three variants are available for the assembly of equipment on the profile plate: Variant A A latching system, without auxiliary means, clamping mechanism with lever and spring, adjustable in slot direction, for lightweight non-loadable components. Variant B A rotary system, without auxiliary means, knurled nut with locking disc and T-head bolts, vertical or horizontal alignment, for medium weight loadable components Variant C A screwed system, with auxiliary means, socket head screw with T-head bolt, vertical or horizontal alignment, for heavy loadable components and equipment that is rarely released from the profile plate. The proven ER units on a plug-in board can be attached to the profile plate using adapters. In the case of variant A, a slide is engaged in the T-slot of the profile plate. The slide is pre-tensioned by means of a spring and, by pressing the blue lever, is pulled back whereby the component can be removed from or attached to the profile plate. Components are aligned along the slot and can be moved in the direction of the slot. With variant B, components are attached to the profile plate by means of a T-head bolt and blue knurled nut. A locking disc serves to fix the device in position, which can be secured in all four 90° directions. Components can thus be mounted to the profile plate either lengthwise or perpendicular to the slot. Once the desired locking disc position is set, the device is mounted on the profile plate. By turning the knurled nut in a clockwise direction, the T-head bolt is turned in the slot by 90° as a result of thread friction. The component is pulled against the profile plate by further turning the knurled nut.
© Festo Didactic GmbH & Co. KG • 541089
D-3
Variant C is used for heavy or similar devices, screwed on to the profile plate only once or removed very seldom. Components are attached by means of socket head screws with internal hex and T-head bolts. The time-tested ER units on a plug-in board with locating pins in a 50 mm grid can be mounted on the profile plate using adapters. A black adapter is required for each locating pin. The adapters are plugged into the T-slot, positioned at intervals of 50 mm and secured by means of a 90° turn. The locating pins of the ER unit are plugged into the adapter holes.
Plastic tubing
The polyurethane tubing is particularly flexible and kink resistant. Technical data Pneumatics Colour
Silver metallic
Outer diameter
4 mm
Inner diameter
2.6 mm
Minimum bending radius within temperature range of -35 to +60°C
17 mm
Maximum operating pressure within Temperature range of -35 to +30°C
10 bar (1000 kPa)
Temperature range of +30 to +40°C Temperature range of +40 to +60°C
9 bar (900 kPa) 7 bar (700 kPa)
Subject to change
D-4
© Festo Didactic GmbH & Co. KG • 541089
152860 3/2-way valve with pushbutton actuator, normally closed
2
1
3
Design
The 3/2-way valve with pushbutton actuator, normally closed is assembled in a polymer housing. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative "A").
Function
The valve is actuated by pressing the pushbutton. Releasing of the pushbutton returns the valve to the normal position via a return spring.
Technical data
Pneumatic Medium
Compressed air, filtered (lubricated or unlubricated) (or vacuum; port 1)
Design
Poppet valve, directly actuated on one side, with return spring
Actuation
Pushbutton
Pressure range
-95 – 800 kPa (-0.95 – 8 bar)
Standard nominal flow rate 1...2
60 l/min
Actuating force at 600 kPa (6 bar)
6N
Connection
QSM-4 fittings for plastic tubing PUN 4 x 0.75
© Festo Didactic GmbH & Co. KG, 07/2005
Subject to change
1/1
© Festo Didactic GmbH & Co. KG, 07/2005
152864 3/2-way valve with mushroom actuator
2
1
3
Design
The 3/2-way valve with plug-in connections is assembled in a yellow polymer housing. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative „A“).
Function
The valve is actuated by pressing the red mushroom actuator. The switching status is maintained after the actuator has been released. Rotation to the right returns the mushroom actuator to its normal position and returns the valve to its initial position via the return spring.
Technical data
Pneumatic Medium
Compressed air, filtered (lubricated or unlubricated)
Design
Poppet valve, directly actuated on one side, with return spring
Actuation
Mushroom actuator
Pressure range
-90 – 800 kPa (-0.90 – 8 bar)
Standard nominal flow rate 1...2
60 l/min
Actuating force at 600 kPa (6 bar)
6N
Connection
QSM-4 fittings for plastic tubing PUN 4 x 0.75
© Festo Didactic GmbH & Co. KG, 07/2005
Subject to change
1/1
© Festo Didactic GmbH & Co. KG, 07/2005
152867 3/2-way roller lever valve with idle return, normally closed
2
1
3
Design
The 3/2-way roller lever valve with idle return and push-in elbow fittings is screwed onto a plastic base. The unit is mounted on the profile plate via the rotary detent system with blue triple grip nut (mounting alternative "B").
Function
The valve is actuated when the trip roller has been traversed by a cylinder trip cam passing in the positive direction. The valve is returned to the normal position via a return spring after the trip roller has been released. The trip roller flips down when traversed in the opposite direction.
Technical data
Pneumatic Medium
Compressed air, filtered (lubricated or unlubricated)
Design
Poppet valve, directly actuated on one side, with return spring
Pressure range
0 – 800 kPa (0 – 8 bar)
Standard nominal flow rate 1...2
80 l/min
Actuating force at 600 kPa (6 bar)
12.5 N
Connection
QSML-M5-4 fittings for plastic tubing PUN 4 x 0.75
© Festo Didactic GmbH & Co. KG, 06/2005
Subject to change
1/1
© Festo Didactic GmbH & Co. KG, 06/2005
152868 Back pressure valve
2
1
3
Design
The back pressure valve with poppet action and quick push-pull T-connectors is screwed on to an assembly base. The unit is mounted on the profile plate via a quick release detent system with blue triple grip nut (mounting alternative „B“).
Function
The back pressure valve with poppet action is actuated via the end face of the cylinder cam. If the stem is actuated, compressed air exhausts to atmosphere until the nozzle outlet is closed. At this point, a signal is generated at output 2 up to the level of the supply pressure. There is thus only low air consumption within the stem actuation range of 1 mm.
Note
The connections are identified according to the different tubing lengths: 1 = long tubing 2 = short tubing The supply pressure can be regulated via a restrictor. Prior to the back pressure valve being used, a functional check should be carried out. If necessary, the back pressure valve can be adjusted to the cylinder end position by loosening the lock nut.
Comment
Technical data
The output signal should be amplified if the supply pressure is very low.
Pneumatic Medium
Compressed air, filtered (lubricated or unlubricated)
Supply pressure range
0 – 800 kPa (0 – 8 bar)
Closing force at 600 kPa (6 bar)
12.5 N
Connection
QS-4 fittings for plastic tubing PUN 4 x 0.75
© Festo Didactic GmbH & Co. KG, 07/2005
Subject to change
1/1
© Festo Didactic GmbH & Co. KG, 07/2005
152877 Pneumatic preselect counter
2 12
10 1
Design
The pneumatic preselect counter with straight push-in fittings is fitted on a polymer base. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative „A“).
Function
The counter counts pneumatic signals downwards from a preselected figure. When the zero position has been reached, the counter emits a pneumatic output signal. This output signal is maintained until the counter is reset. The counter is pre-set by pressing the reset key (alongside the number window) and simultaneously keying-in (adjustment key on the counter roll) of the preselect value. The figure, once set, is retained whilst the counter is reset.
Note
The valve ports are identified by numbers: 1 = Supply port 2 = Output signal 10 = Reset signal 12 = Counting signal
© Festo Didactic GmbH & Co. KG, 07/2005
Subject to change
1/1
152877 Pneumatic preselect counter
Technical data
2/2
Pneumatic Medium
Compressed air
Design
Mechanical counter with pneumatic drive
Display
5-digit, height of figures 4.5 mm
Reset
Push button or pneumatic signal
Pressure range
200 – 800 kPa (2 – 8 bar)
Minimum pulse duration
Count: 10 ms, Reset: 180 ms
Counting rate continuous operation
2 Hz
Connection
QSMS-4, QSML-M5-4 fittings for plastic tubing PUN 4 x 0.75
Subject to change
© Festo Didactic GmbH & Co. KG, 07/2005
152882 Shuttle (OR) valve, 3-fold
2
1
2
1/3 1
2
1/3 1
1/3
Design
The manifold consisting of three OR gates is screwed on to an assembly base equipped with the required straight push-in fittings. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative „A“).
Function
Each OR gate has two inlets (1, 1/3) and one output (2). The inlet which is not pressurised is automatically blocked. If different pressures are applied, then the higher pressure reaches the outlet (2).
Note
The valve ports are identified by numbers: 2 = Working or outlet port 1, 1/3 = Supply lines
Technical data
Pneumatic Medium
Compressed air, filtered (lubricated or unlubricated)
Design
OR gate (shuttle valve)
Pressure range
160 – 800 kPa (1.6 – 8 bar)
Standard nominal flow rate 1, 1/3...2
100 l/min
Connection
QSM-M5-4-I fittings for plastic tubing PUN 4 x 0.75
© Festo Didactic GmbH & Co. KG, 07/2005
Subject to change
1/1
© Festo Didactic GmbH & Co. KG, 07/2005
152883 Dual pressure (AND) valve, 3-fold
2
1
2
1/3
1
2
1/3
1
1/3
Design
A manifold consisting of three AND gates is screwed on to an assembly base equipped with the required straight push-in fittings. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative „A“).
Function
Each AND gate has two inlets (1, 1/3) and one outlet (2). Outlet (2) is only pressurised for as long as pressure is applied at both inlets. If different pressures are applied, then the lower pressure reaches outlet (2).
Note
The valve ports are identified by numbers: 2 = Working or outlet port 1, 1/3 = Supply lines
Technical data
Pneumatic Medium
Compressed air, filtered (lubricated or unlubricated)
Design
AND gate (dual pressure valve)
Pressure range
160 – 800 kPa (1.6 – 8 bar)
Standard nominal flow rate 1, 1/3...2
100 l/min
Connection
QSM-M5-4-I fittings for plastic tubing PUN 4 x 0.75
© Festo Didactic GmbH & Co. KG, 07/2005
Subject to change
1/1
© Festo Didactic GmbH & Co. KG, 07/2005
152886 Stepper module
A1
A2
TAA
Yn
Y
Yn
Yn+1
P Zn L
P Z L
P Zn L
P Zn+1
X1
Design
A3
TAA
L
Yn
Yn+1
P Zn L
P Zn+1
X2
A4
TAA
L
TAB
Yn
Yn+1
P Zn L
P Zn+1
Yn
L
X3
P Zn L
Yn+1
P Zn+1 L
Y
Yn+1
P Z L
P Zn+1 L
X4
This unit consists of three TAA and one TAB stepper module which are screwed on to an assembly base, which is equipped with the required straight push-in fittings. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative „A“).
© Festo Didactic GmbH & Co. KG, 06/2005
Subject to change
1/2
152886 Stepper module
Function
In the case of module type TAB, an OR gate is positioned upstream of the Yn inlet of the double pilot valve. If a signal is applied at Yn or L, the valve is reversed and a signal appears at outlet A. In addition, this signal also resets the preceding stepper module, the visual indicator and the AND gate is supplied with pressure. When the acknowledgement signal reaches X, the AND flow is released and the signal Yn+1 appears. This signal is also maintained if the entire sequencer is reset at L and can thus be used for a renewed start. When the sequencer chain is started, the module is reset externally at port Z via the reset signal Zn+1 of the first module of the sequencer. With the TAA modules, an OR gate is connected upstream of port Z in the double pilot valve. This is why, in this case, the double pilot valve is returned via a signal at Zn+1 from the following stepper.
Note
The valve ports are identified by letters: P = Supply port A1, A2, A3, A4 = Outputs X1, X2, X3, X4 = Acknowledgements L = Reset (clear) Yn+1 = Set: Output Yn = Set: Input Zn = Reset: Output = Reset: Input Zn+1
Technical data
2/2
Pneumatic Medium
Compressed air, filtered (lubricated or unlubricated)
Design
Poppet valve with integrated AND and OR gate
Standard nominal flow rate P…A
60 l/min
Pressure range
200 – 800 kPa (2 – 8 bar)
Connection
QSM-M5-4-I fittings for plastic tubing PUN 4 x 0.75
Subject to change
© Festo Didactic GmbH & Co. KG, 06/2005
152888 Double-acting cylinder
Design
The double-acting cylinder with trip cam and push-in fittings is mounted on a plastic retainer. The unit is mounted on the profile plate via a quick release detent system with two triple grip nuts (mounting alternative "B").
Function
The piston rod of the double-acting cylinder is reversed by means of alternating supply of compressed air. End position cushioning at both ends prevents a sudden impact of the piston on the cylinder housing. The end position cushioning can be adjusted by means of two regulating screws. The magnetic field of a permanent magnet attached to the cylinder piston actuates the proximity switches.
Technical data
Pneumatic Medium
Compressed air, filtered (lubricated or unlubricated)
Design
Piston cylinder
Operating pressure max.
1000 kPa (10 bar)
Piston diameter
20 mm
Max. stroke length
100 mm
Thrust at 600 kPa (6 bar)
189 N
Return force at 600 kPa (6 bar)
158 N
Connection
QS-G1/8-4 fittings for plastic tubing PUN 4 x 0.75
© Festo Didactic GmbH & Co. KG, 07/2005
Subject to change
1/1
© Festo Didactic GmbH & Co. KG, 07/2005
539759 Time delay valve, normally open
2 10
1
3
Design
The time delay valve is screwed on an assembly base equipped with straight push-in fittings. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative „A“).
Function
After the pilot signal is applied at port 10, a preset time elapses before the time delay valve is actuated. It returns to its initial position via a return spring once the signal is removed. The time delay is infinitely adjustable by means of a regulatig screw.
Note
The valve ports are identified by numbers: 1 = Supply port 2 = Working or outlet port 3 = Exhaust 10 = Pilot
© Festo Didactic GmbH & Co. KG, 06/2005
Subject to change
1/2
539759 Time delay valve, normally open
Technical data
2/2
Pneumatic Medium
Compressed air, filtered (lubricated or unlubricated)
Design
Poppet valve with return spring
Pressure range
200 to 600 kPa (2 to 6 bar)
Pilot pressure
>160 kPa (1.6 bar)
Standard nominal flow rate 1...2
50 l/min
Time delay
0.2 to 3 s (adjustable)
Setting accuracy
±0.3 ms
Time delay to reset
>200 ms
Connection
QSM-M5-4-I fittings for plastic tubing PUN 4 x 0.75
Subject to change
© Festo Didactic GmbH & Co. KG, 06/2005
539768 3/2-way pneumatic valve, pneumatically actuated, one side
2 12 1 or
3 2
10 1
3
Symbol used in circuit diagrams.
4
2
5
1 3
14
The internal structure of this valve
Design
The 5/2-way pneumatic valve with push-in connectors and a single blanking plug is screwed on to an assembly base, which is equipped with P-connection and silencers. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative „A“).
Function
The pneumatic valve switches at port 14 (Z) (10 (Z)) via a pneumatic signal and is returned to the initial position via a spring when the signal has been removed.
Note
The valve ports are identified by numbers: 1 = Supply port 2, 4 = Working or outlet ports 3, 5 = Exhausts (via silencers in function plate) 14, 10 = Pilot port By blocking a working line (2 or 4), the 5/2-way valve can be converted into a 3/2-way valve: Blanking plug in outlet 4 = normally open Blanking plug in outlet 2 = normally closed
© Festo Didactic GmbH & Co. KG, 07/2005
Subject to change
1/2
539768 3/2-way pneumatic valve, pneumatically actuated, one side
Technical Data
Pneumatic Medium
Compressed air, filtered
Design
Spool valve, indirectly actuated on one side, with return spring
Pressure range
200 to 1000 kPa (2 to 10 bar)
Operating pressure range
-90 to 1000 kPa (-0.9 to 10 bar)
Standard nominal
500 l/min
flow rate 1…2, 1...4
2/2
Switching time at 600 kPa (6 bar)
On: 8 ms Off: 18 ms
Connection
QS-1/8-4-I, QSM-M5-4-I fittings for plastic tubing PUN 4 x 0.75
Subject to change
© Festo Didactic GmbH & Co. KG, 07/2005
539769 5/2-way double pilot valve, pneumatically actuated, both sides
4
2
14
12 5
1 3
Symbol used in circuit diagrams 4
2
14
12 5
1 3
The internal structure of this valve allows flowing of compressed air in both dir
Design
The 5/2-way double pilot valve with push-in fittings is screwed onto the function plate, which is equipped with P-connection and silencers. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative "A").
Function
The double pilot valve is actuated by applying pneumatic signals alternately to ports 14 and 12. It remains in its last switched position until a counter signal is received.
Technical Data
Pneumatic Medium
Compressed air, filtered (lubricated or unlubricated) or vacuum
Design
Spool valve, directly actuated on both sides
Control pressure range
200 to 1000 kPa (2 to 10 bar)
Operating pressure range
-90 to 1000 kPa (-0.9 to 10 bar)
Standard nominal
500 l/min
flow rate 1...2, 1...4 Response time at 600 kPa (6 bar)
6 ms
Connection
QS-1/8-4-I, QSM-M5-4-I fittings for plastic tubing PUN 4 x 0.75
© Festo Didactic GmbH & Co. KG, 07/2005
Subject to change
1/1
© Festo Didactic GmbH & Co. KG, 07/2005
539771 Shuttle valve (OR)
2 1
1/3
Design
The shuttle valve with push-in elbow fittings is mounted on a function plate. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative "A").
Function
The shuttle valve is switched through to output 2 by applying a signal either to input 1 or 1/3 (OR-Function). If both inputs are pressurised simultaneously, then the higher pressure reaches the output.
Technical Data
Pneumatic Medium
Compressed air, filtered (lubricated or unlubricated)
Design
OR-Gate (Shuttle valve)
Pressure range
100 to 1000 kPa (1 to 10 bar)
Standard nominal flow rate 1, 1/3...2
500 l/min
Connection
QSL-1/8-4 fittings for plastic tubing PUN 4 x 0.75
© Festo Didactic GmbH & Co. KG, 06/2005
Subject to change
1/1
© Festo Didactic GmbH & Co. KG, 06/2005
539773 One-way flow control valve
1
2
Design
The adjustable one-way flow control valve is screwed into the function plate, incorporating a straight push-in fitting. The unit is slotted into the profile plate via a quick release detent system with a blue lever (mounting alternative “A”).
Function
The one-way flow control valve consists of a combination of a flow control valve and a non-return valve. The non-return valve blocks the flow of air in one direction, whereby the air flows via the flow control valve. The throttle cross section is adjustable by means of a knurled screw. The setting can be fixed by means of a knurled nut. Two arrows indicate the direction of flow control on the housing. In the opposite direction, the air flow is unrestricted via the non-return valve.
Technical Data
Pneumatic Medium
Compressed air, filtered, (lubricated or unlubricated)
Design
One-way flow control valve
Pressure range
20 to 1000 kPa (0.2 to 10 bar)
Standard nominal flow rate
in throttled direction:
0 – 110 l/min
free flow direction:
110 l/min (Throttle open) 65 l/min (Throttle closed)
Connection
© Festo Didactic GmbH & Co. KG, 06/2005
QSM-M5-4 for plastic tubing PUN 4 x 0.75
Subject to change
1/1
© Festo Didactic GmbH & Co. KG, 06/2005
540715 Non-return valve, piloted
2
1 21
Design
Non-return valve directly connected to the cylinder connection via a push-in sleeve.
Function
The non-return valve shuts off flow from port 2 to port 1. The non-return valve can be released through the application of compressed air at port 21.
Technical data
Pneumatics Medium
Compressed air, filtered, lubricated or unlubricated
Design
Non-return valve, piloted
Operating pressure
0.5 to 10 bar (50 to 1000 kPa)
Standard nominal flow rate
108 l/min
Connection
QSM-M5-4 for plastic tubing PUN 4 x 0.75
© Festo Didactic GmbH & Co. KG, 07/2005
Subject to change
1/1
© Festo Didactic GmbH & Co. KG, 07/2005
© Festo Didactic GmbH & Co. KG • 541089
0S1
Exercise 4: Filling of drinks bottles
1
2
3
P
Yn
L Zn
1B2
s1 s2 s3 s4
P Z L
Y
1
2
X1
P Zn L
Yn
TAA
3
14
1V1
5
4
A1
1V2
1
Yn
1B1 1
2
X2
P P Zn+1 Zn L L
Yn+1
TAA
3
2
2
1B1
3
12
1
1
2
1A1
1V3
2B1
A2
1B2
Yn
1
2
X3
P P Zn+1 Zn L L
Yn+1
TAA
3
A3
Yn
TAB
2B2 1
2
X4
P P Zn+1 Zn L L
Yn+1
14
3
5
2V1 4
2V2
2
1
1
3
2
2
1
A4
2A1 2B1 2B2
P Zn+1 L
Yn+1
P
Yn+1
L Zn+1
P Z L
Y
12
2V3
© Festo Didactic GmbH & Co. KG • 541089
0S1
Exercise 4: Filling of drinks bottles Solution
1
2
3
P
Yn
L Zn
1B2
s1 s2 s3 s4
P Z L
Y
1
2
X1
P Zn L
Yn
TAA
3
14
1V1
5
4
A1
1V2
1
Yn
1B1 1
2
X2
P P Zn+1 Zn L L
Yn+1
TAA
3
2
2
1B1
3
12
1
1
2
1A1
1V3
2B1
A2
1B2
Yn
1
2
X3
P P Zn+1 Zn L L
Yn+1
TAA
3
A3
Yn
TAB
2B2 1
2
X4
P P Zn+1 Zn L L
Yn+1
14
3
5
2V1 4
2V2
2
1
1
3
2
2
1
A4
2A1 2B1 2B2
P Zn+1 L
Yn+1
P
Yn+1
L Zn+1
P Z L
Y
12
2V3
© Festo Didactic GmbH & Co. KG • 541089
Exercise 5: Cleaning of workpieces, without parameter
0S1 2
3
5 1
1
2
4
0S2
3
0S3
1
2 3
s1 s2 s3 s4
L Zn
P
Yn
14
P Z L
Y
X1
P Zn L
Yn
TAA
1V1
1V2
5
4
1
A1
3
2
2
Yn
TAA
1V3
X2
P P Zn+1 Zn L L
Yn+1
12
1
1
2
1A1 1B1 1B2
A2
P Zn+1
Yn
TAA
X3
P Zn L L
Yn+1
14
2V1
2V2
5
4
2
1
3
A3
1
2
2A1
P Zn+1
Yn+1
2B2
Yn
TAB
2V3
X4
P Zn L L
12
2
1
2B1
A4
P Zn+1 L
Yn+1
P
Yn+1
L Zn+1
P Z L
Y
© Festo Didactic GmbH & Co. KG • 541089
Exercise 5: Cleaning of workpieces, complete
0S1
2
3
5
1
1
2
4
0S2
3
0S3
1
2 3
0V1
s1 s2 s3 s4
1B2
L Zn
P
Yn
14
P Z L
Y
1
2
X1
P Zn L
Yn
TAA
1V1
2B2
3
1V2
5
4
1
1
1
2
2
3
3
1
0V4
A1
Yn
TAA
2
1V3
0S4
2
X2
P P Zn+1 Zn L L
Yn+1
1
3 0V7
2
2 12
1
1
2
1A1 1B1 1B2
1
1/3 2
1/3
10
0V2
3
A2
10
P Zn+1
Yn+1
14
0V3
X3
P Zn L L
Yn
TAA
2V1
1
2V2
2
5
4
3
1
2
Yn
TAB
2
3
1/3
X4
1/3
2B2
2V3
P Zn L L
1
P Zn+1
Yn+1
1
2
2B1
12
2
1
3 0V8
2
A3
1
0V5
2
1
2A1
0S5
2B1
A4
1
1
2
2
3
3
P Zn+1 L
Yn+1
P
Yn+1
1B1
L Zn+1
P Z L
Y
1
2 3
© Festo Didactic GmbH & Co. KG • 541089
0S1
2
3
5
1
1
2
4
0S2
3
Exercise 5: Cleaning of workpieces, with latching of the reset function
0S3
0V1
1
2 3
1B2
s1 s2 s3 s4
1
2
P Z L
Y
3
L Zn
P
Yn
14
1
2
X1
P Zn L
Yn
TAA
1V1
3
1V2
1
1
2B2
0S4
2
A1
3
Yn
1
1
1/3
2
2
X2
P P Zn+1 Zn L L
Yn+1
3
3
2
1V3
TAA
1
0V7
12
2
2 2
1
1
0V4
5
4
1A1 1B1 1B2
10
0V2
A2
1/3
10
P Zn+1
Yn+1
0V3
X3
P Zn L L
Yn
TAA
14
2V1
1
2
2V2
A3
2
3
1
0V5
5
4
1
1
2
Yn
TAB
1
1
0V8
12
2
1
2B1
2
3
1/3
X4
P P Zn+1 Zn L L
Yn+1
3
2
2A1
2
2V3
2B1
A4
1/3
0S5
2B2
1
1
2
2
3
3
P Zn+1 L
Yn+1
P
Yn+1
1B1
L Zn+1
P Z L
Y
1
2 3
© Festo Didactic GmbH & Co. KG • 541089
Exercise 5: Cleaning of workpieces, without parameter Solution
0S1 2
3
5 1
1
2
4
0S2
3
0S3
1
2 3
s1 s2 s3 s4
1B2
L Zn
P
Yn
14
P Z L
Y
1
2
X1
P Zn L
Yn
TAA
1V1
3
1V2
5
4
1
2B2
A1
Yn
TAA
2
1
2
X2
3
1V3
P P Zn+1 Zn L L
Yn+1
1
3 0V7
2
2 12
1
1
2
1A1 1B1 1B2
1/3
A2
2B1
P Zn+1
Yn+1
14
1
2
X3
P Zn L L
Yn
TAA
2V1
3
2V2
5
4
2
1
1B1
P Zn+1
Yn
TAB
1
2
X4
3
1/3
2B2
2V3
P Zn L L
Yn+1
1
2
2B1
12
2
1
3 0V8
A3
1
2
2A1
A4
P Zn+1 L
Yn+1
P
Yn+1
L Zn+1
P Z L
Y
© Festo Didactic GmbH & Co. KG • 541089
Exercise 5: Cleaning of workpieces, complete Solution
0S1
2
3
5
1
1
2
4
0S2
3
0S3
1
2 3
0V1
s1 s2 s3 s4
1B2
L Zn
P
Yn
14
P Z L
Y
1
2
X1
P Zn L
Yn
TAA
1V1
2B2
3
1V2
5
4
1
1
1
2
2
3
3
1
0V4
A1
Yn
TAA
2
1V3
0S4
2
X2
P P Zn+1 Zn L L
Yn+1
1
3 0V7
2
2 12
1
1
2
1A1 1B1 1B2
1
1/3 2
1/3
10
0V2
3
A2
10
P Zn+1
Yn+1
14
0V3
X3
P Zn L L
Yn
TAA
2V1
1
2V2
2
5
4
3
1
2
Yn
TAB
2
3
1/3
X4
1/3
2B2
2V3
P Zn L L
1
P Zn+1
Yn+1
1
2
2B1
12
2
1
3 0V8
2
A3
1
0V5
2
1
2A1
0S5
2B1
A4
1
1
2
2
3
3
P Zn+1 L
Yn+1
P
Yn+1
1B1
L Zn+1
P Z L
Y
1
2 3
© Festo Didactic GmbH & Co. KG • 541089
0S1
2
3
5
1
1
2
4
0S2
3
Exercise 5: Cleaning of workpieces, with latching of the reset function Solution
0S3
0V1
1
2 3
1B2
s1 s2 s3 s4
1
2
P Z L
Y
3
L Zn
P
Yn
14
1
2
X1
P Zn L
Yn
TAA
1V1
3
1V2
1
1
2B2
0S4
2
A1
3
Yn
1
1
1/3
2
2
X2
P P Zn+1 Zn L L
Yn+1
3
3
2
1V3
TAA
1
0V7
12
2
2 2
1
1
0V4
5
4
1A1 1B1 1B2
10
0V2
A2
1/3
10
P Zn+1
Yn+1
0V3
X3
P Zn L L
Yn
TAA
14
2V1
1
2
2V2
A3
2
3
1
0V5
5
4
1
1
2
Yn
TAB
1
1
0V8
12
2
1
2B1
2
3
1/3
X4
P P Zn+1 Zn L L
Yn+1
3
2
2A1
2
2V3
2B1
A4
1/3
0S5
2B2
1
1
2
2
3
3
P Zn+1 L
Yn+1
P
Yn+1
1B1
L Zn+1
P Z L
Y
1
2 3
© Festo Didactic GmbH & Co. KG • 541089
Exercise 6: Printing of mobile phone housings
1
0S1
1
2
3
0V1
3
2
EMERGENCY10 STOP
Reset 0S4
1
Start 0S6
3
0V2
5
4
1
2
12
12
0S2
1
2
3
1
1/3
Stop at cycle end 0S5
1
3 0V5
2
Acknowledge EMERGENCY-STOP
3
2
1 3
1
5
14
2
5
4
2
3
0V6
Manual/Automatic 0S3 4
1
2
14
3
1B2
2
2
1 3
L Zn
P
Yn P Z L
Y
s1 s2 s3 s4
2B1
X1
P Zn L
Yn
TAA
2
14
1
1V1
3B2
3
A1
5
4
2
1
Yn
TAA
1
1
2
X2
P P Zn+1 Zn L L
Yn+1
1V2
3
1
0V9
3
2
1A1
1B1
1
2
12
1B1
2
A2
3
2
14
X3
P P Zn+1 Zn L L
Yn
TAA
0V10
Yn+1
1/3
1
0V12
1B2
1
2B2
2
1/3
5
2
2
1
1
2V1 4
2V2
1
3
A3
3B1
1
2
X4
P P Zn+1 Zn L L
Yn
TAB
0V13
Yn+1
10
1/3
3
2
2A1 2B1 2B2
3
1
12 2
3
A4
P Zn+1 L
Yn+1
14
P
Yn+1
0V11
L Zn+1
P Z L
Y
10
3V1
3V2
5
4
1
2
1
2
1
1
0V8
3
3
2
3A1
2
12
3B1
1/3
3 B2
© Festo Didactic GmbH & Co. KG • 541089
Exercise 6: Printing of mobile phone housings Solution
1
0S1
1
2
3
0V1
3
2
EMERGENCY10 STOP
Reset 0S4
1
Start 0S6
3
0V2
5
4
1
2
12
12
0S2
1
2
3
1
1/3
Stop at cycle end 0S5
1
3 0V5
2
Acknowledge EMERGENCY-STOP
3
2
1 3
1
5
14
2
5
4
2
3
0V6
Manual/Automatic 0S3 4
1
2
14
3
1B2
2
2
1 3
L Zn
P
Yn P Z L
Y
s1 s2 s3 s4
2B1
X1
P Zn L
Yn
TAA
2
14
1
1V1
3B2
3
A1
5
4
2
1
Yn
TAA
1
1
2
X2
P P Zn+1 Zn L L
Yn+1
1V2
3
1
0V9
3
2
1A1
1B1
1
2
12
1B1
2
A2
3
2
14
X3
P P Zn+1 Zn L L
Yn
TAA
0V10
Yn+1
1/3
1
0V12
1B2
1
2B2
2
1/3
5
2
2
1
1
2V1 4
2V2
1
3
A3
3B1
1
2
X4
P P Zn+1 Zn L L
Yn
TAB
0V13
Yn+1
10
1/3
3
2
2A1 2B1 2B2
3
1
12 2
3
A4
P Zn+1 L
Yn+1
14
P
Yn+1
0V11
L Zn+1
P Z L
Y
10
3V1
3V2
5
4
1
2
1
2
1
1
0V8
3
3
2
3A1
2
12
3B1
1/3
3 B2
© Festo Didactic GmbH & Co. KG • 541089
Exercise 7: Packaging of spark plugs
0S4
0S1
1
2
3
2
5
1
1 3
2 1/3
1
2
0V1
4
0S3
3 12
10
0V2
0V4
1
1
1 2
0S5 2
2
3
3
3
0S2
1
2
s1 s2 s3 s4
3
1B2
L Zn
P
Yn P Z L
Y
1
14
2
X1
P Zn L
Yn
TAA
3
1V1
5
4
2B1
1V2
1
1
2
A1
12
3
Yn
TAA
10
0Z3
X2
P P Zn+1 Zn L L
Yn+1
3
2
2 12
1
1
2
1A1 1B1 1B2
0V7
1V3
1
2
1
10
A2
3
Yn
TAA
X3
P P Zn+1 Zn L L
Yn+1
14
2V1
2B2
2V2
5
4
1
1
2
A3
2
1
Yn
TAB
12
2
1
3
1B1 1
2
X4
3
2B1
P P Zn+1 Zn L L
Yn+1
3
2
2A1
2V3
2B2
A4
P Zn+1 L
Yn+1
P
Yn+1
L Zn+1
P Z L
Y
© Festo Didactic GmbH & Co. KG • 541089
Exercise 7: Packaging of spark plugs Solution
0S4
0S1
1
2
3
2
5
1
1 3
2 1/3
1
2
0V1
4
0S3
3 12
10
0V2
0V4
1
1
1 2
0S5 2
2
3
3
3
0S2
1
2
s1 s2 s3 s4
3
1B2
L Zn
P
Yn P Z L
Y
1
14
2
X1
P Zn L
Yn
TAA
3
1V1
5
4
2B1
1V2
1
1
2
A1
3
12
2
Yn
TAA
10
0Z3
X2
P P Zn+1 Zn L L
Yn+1
1
3 0V9
2
2 12
1
1
2
1A1 1B1 1B2
0V7
1V3
1
2
1
1/3
10
A2
3
Yn
TAA
X3
P P Zn+1 Zn L L
Yn+1
14
2V1
2B2
2V2
5
4
1
1
2
A3
2
1
Yn
TAB
3
1B1 1
2
X4
P P Zn+1 Zn L L
Yn+1
1
3
2
2B1
12
2
1
3 0V10
2
2A1
2V3
2B2
1/3
A4
P Zn+1 L
Yn+1
P
Yn+1
L Zn+1
P Z L
Y
© Festo Didactic GmbH & Co. KG • 541089
Exercise 8: Sealing of guide bushes
Start 0S4 3
0S1
1
2
EMERGENCY10 STOP
1
2
3
0V1
1
0V3
1
2
3
5
4
1
3
3
Reset 0S5
12
2
0S2
1
1
1/3
3 Acknowledge EMERGENCY-STOP
2
1 3
0V2
5
1
2
2
1/3
0V4
1
2
Manual/Automatic 0S3 4
14
2
12
10
0V5
0V6 1
2
2
3
3
P
Yn
L Zn 1B2
s1 s2 s3 s4
P Z L
Y
1
2
X1
P Zn L
Yn
TAA
10
3
1
0V7
0V10
2
1
A1
2 3
Yn
TAA
X2
P P Zn+1 Zn L L
Yn+1
1/3
14
1V1
1V2
1B3
A2
0V11
1 3
1B1
Yn
TAA
1
2
1B2
3
1
0V13
1V3
3
X3
P P Zn+1 Zn L L
Yn+1
1
2
12
2
2 2
1
1
10
5
4
1A1 1B3
2
A3
1B1 1
Yn
TAB
2
X4
3
2
10
P P Zn+1 Zn L L
Yn+1
1
1/3 0V12
1
0V8
0V9
2
1
1/3
A4
2 3
P Zn+1 L
Yn+1
1/3
P Z L
Y
L Zn+1
P
Yn+1
© Festo Didactic GmbH & Co. KG • 541089
Exercise 8: Sealing of guide bushes Solution
Start 0S4 3
0S1
1
2
EMERGENCY10 STOP
1
2
3
0V1
1
0V3
1
2
3
5
4
1
3
3
Reset 0S5
12
2
0S2
1
1
1/3
3 Acknowledge EMERGENCY-STOP
2
1 3
0V2
5
1
2
2
1/3
0V4
1
2
Manual/Automatic 0S3 4
14
2
12
10
0V5
0V6 1
2
2
3
3
P
Yn
L Zn 1B2
s1 s2 s3 s4
P Z L
Y
1
2
X1
P Zn L
Yn
TAA
10
3
1
0V7
0V10
2
1
A1
2 3
Yn
TAA
X2
P P Zn+1 Zn L L
Yn+1
1/3
14
1V1
1V2
1B3
A2
0V11
1 3
1B1
Yn
TAA
1
2
1B2
3
1
0V13
1V3
3
X3
P P Zn+1 Zn L L
Yn+1
1
2
12
2
2 2
1
1
10
5
4
1A1 1B3
2
A3
1B1 1
Yn
TAB
2
X4
3
2
10
P P Zn+1 Zn L L
Yn+1
1
1/3 0V12
1
0V8
0V9
2
1
1/3
A4
2 3
P Zn+1 L
Yn+1
1/3
P Z L
Y
L Zn+1
P
Yn+1
© Festo Didactic GmbH & Co. KG • 541089
Exercise 9: Hardening of material test specimens
0S1
1
2 3
s1 s2 s3 s4
1B3
L Zn
P
Yn P Z L
Y
1
0V2
2
X1
P Zn L
Yn
TAA
3
1
0V5 2
1B2
A1
12
Yn
TAA
1
1
2
X2
P P Zn+1 Zn L L
Yn+1
1/3
1V1
3
2 3
1
2
A2
3
Yn
X3
P P Zn+1 Zn L L
Yn+1
TAA
10
0V3
1V3
1V5
1
2
2
Yn
TAB
1B1 1
2
X4
P P Zn+1 Zn L L
Yn+1
1
0V6
3
2
1B2
1V4
1B1
1 21
2
1
A3
1V6
1 21
2
1B3
1A1
12
1
2
1/3
A4
3
10
1V2
3
P Zn+1 L
Yn+1
0V4
1
2
3
P
Yn+1
L Zn+1
P Z L
Y
1
2
© Festo Didactic GmbH & Co. KG • 541089
Exercise 9: Hardening of material test specimens Solution
0S1
1
2 3
s1 s2 s3 s4
1B3
L Zn
P
Yn P Z L
Y
1
0V2
2
X1
P Zn L
Yn
TAA
3
1
0V5 2
1B2
A1
12
Yn
TAA
1
1
2
X2
P P Zn+1 Zn L L
Yn+1
1/3
1V1
3
2 3
1
2
A2
3
Yn
X3
P P Zn+1 Zn L L
Yn+1
TAA
10
0V3
1V3
1V5
1
2
2
Yn
TAB
1B1 1
2
X4
P P Zn+1 Zn L L
Yn+1
1
0V6
3
2
1B2
1V4
1B1
1 21
2
1
A3
1V6
1 21
2
1B3
1A1
12
1
2
1/3
A4
3
10
1V2
3
P Zn+1 L
Yn+1
0V4
1
2
3
P
Yn+1
L Zn+1
P Z L
Y
1
2
© Festo Didactic GmbH & Co. KG • 541089
1B1
Exercise 10: Bending of sheet metal strips
1
2
0S1
3
12
1
1
0V3
2
2
3
3
1
0V4
2
1B2
10
12
1/3
1
1V1
2
1V2
3
1
1 2
2
12
3
0V2
1A1
1
1B1
2
3
1B2
10
s1 s2 s3 s4
2B2
Zn
L
P
Yn P Z L
Y
1
2
X1
P Zn L
Yn
TAA
3
14
A1
2V1
Yn
2B1
1
2
X2
P P Zn+1 Zn L L
Yn+1
5
4
TAA
2V2
3
2
1
1
3
2
2A1
3B2
A2
12
2B1
Yn
TAA
1
2
X3
P P Zn+1 Zn L L
Yn+1
2B2
3
A3
Yn
TAB
3B1
1
2
X4
P P Zn+1 Zn L L
Yn+1
14
3
3V2
5
4
2
1
A4
12
P Zn+1 L
Yn+1
3B2
3
2
3A1
1
3B1
P
Yn+1
L Zn+1
P Z L
Y
© Festo Didactic GmbH & Co. KG • 541089
1B1
Exercise 10: Bending of sheet metal strips Solution
1
2
0S1
3
12
1
1
0V3
2
2
3
3
1
0V4
2
1B2
10
12
1/3
1
1V1
2
1V2
3
1
1 2
2
12
3
0V2
1A1
1
1B1
2
3
1B2
10
s1 s2 s3 s4
2B2
Zn
L
P
Yn P Z L
Y
1
2
X1
P Zn L
Yn
TAA
3
14
A1
2V1
Yn
2B1
1
2
X2
P P Zn+1 Zn L L
Yn+1
5
4
TAA
2V2
3
2
1
1
3
2
2A1
3B2
A2
12
2B1
Yn
TAA
1
2
X3
P P Zn+1 Zn L L
Yn+1
2B2
3
A3
Yn
TAB
3B1
1
2
X4
P P Zn+1 Zn L L
Yn+1
14
3
3V2
5
4
2
1
A4
12
P Zn+1 L
Yn+1
3B2
3
2
3A1
1
3B1
P
Yn+1
L Zn+1
P Z L
Y