[FESTO] Electropneumatics - Workbook Advanced Level.pdf

Learning System for Automation and Technology

Electropneumatics Workbook Advanced level

094467

Authorised applications and liability The Learning System for Automation and Technology has been developed and prepared exclusively for training in the field of automation and technology. The training organization and / or trainee shall ensure that the safety precautions described in the accompanying Technical documentation are fully observed. Festo Didactic hereby excludes any liability for injury to trainees, to the training organization and / or to third parties occurring as a result of the use or application of the station outside of a pure training situation, unless caused by premeditation or gross negligence on the part of Festo Didactic. Order no.: Description: Designation: Edition: Layout: Graphics: Authors:

094467 TEACHW.E-PNEUM. D.S202-C-SIBU-GB 05/2002 06.05.2002, OCKER Ingenieurbüro OCKER Ingenieurbüro D. Waller, H. Werner, Th. Ocker

© Copyright by Festo Didactic GmbH & Co., D-73770 Denkendorf 2002 The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization 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 registrations. Parts of this training documentation may be duplicated, solely for training purposes, by persons authorised in this sense.

3

Preface The Festo Didactic Learning System for Automation and Technology has been formulated according to various prerequisites and vocational requirements. It has been divided into the following categories of training packages:

Basic packages which convey basic knowledge spanning a wide range of technologies

Technology packages which deal with important subjects of open and closed-loop control technology

Function packages to explain the basic functions of automated systems

Application packages to facilitate practice-orientated vocational and further training

The technology packages deal with the technologies of pneumatics, electropneumatics, programmable logic controllers, hydraulics, electrohydraulics, proportional hydraulics and handling technology. Mounting frame

Profile plate

U = 230V~

Storage tray

TP202 • Festo Didactic

4

The modular design of the Learning System permits applications beyond the scope of the individual packages. It is, for instance, possible to design PLC controlled systems with pneumatic, hydraulic and electrical actuators. All training packages are based on an identical structure:

Hardware

Teachware

Software

Seminars

The hardware consists of industrial components and systems which have been adapted for didactic purposes. The courseware has been designed in line with didactic methods and coordinated for use with the training hardware. The courseware comprises:

Textbooks (with exercises and examples)

Workbooks (with practical exercises, explanatory notes, solutions and data sheets)

Transparencies and videos (to create a lively training environment)

The training and learning media is available in several languages, which has been designed for use in the classroom as well as for self-tuition. The software sector serves as a basis for providing computer training program, simulation program and programming software for programmable logic controllers. A comprehensive range of seminars on the subject of the various technology packages completes our program of vocational and further training.


5

Latest information about the technology package pneumaticTP 202 New in Pneumatic 2000:

Industrial components on the profile plate.

Fostering of key qualifications: Technical competence, personal competence and social competence form professional competence.

Training of team skills, willingness to co-operate, willingness to learn, independence and organisational skills.

Aim – Professional competence Content Part A

Course

Exercises

Part B

Fundamentals

Reference to the text book

Part C

Solutions

Function diagrams, circuits, descriptions of solutions and quipment lists

Part D

Appendix

Storage tray, mounting technology and datasheets


6

Table of contents Introduction

9

Notes on safety and operation

11

Training contents of basic level and advanced level

13

Equipment set for the basic level (TP201)

15

Equipment set for the advanced level (TP202)

18

Component and exercise allocation (table)

20

Methodical structure of the exercises

21

Designation of components

22


7

Part A – Course Basic exercises Exercise 1:

Bench drill

A-3

Exercise 2:

Feed unit for sheet metal strip

A-5

Exercise 3:

Filling device

A-7

Exercise 4:

Stamping device

A-9

Exercise 5:

Drilling jig

A-11

Exercise 6:

Clamping unit for grinding

A-15

Exercise 7:

Forming press

A-19

Consolidating exercises Exercise 8:

Embossing device

A-21

Exercise 9:

Handling device

A-23

Exercise 10:

Drilling and reaming machine

A-25

Exercise 11:

Loading station

A-29

Exercise 12:

Internal grinding machine

A-33

Exercise 13:

Assembly unit

A-37

Exercise 14:

Moulding press

A-41

Exercise 15:

Pick-and-place unit

A-45

Exercise 16:

Galvanising process

A-49

Exercise 17:

Loading station

A-53

Exercise 18:

Rotary indexing station

A-57

Exercise 19:

Checking station

A-63

Exercise 20:

Handling device

A-67

Part B – Fundamentals


8

Part C – Solutions Solution 1:

Bench drill

C-3

Solution 2:


C-9

Solution 3:

Filling device

C-17

Solution 4:

Stamping device

C-21

Solution 5:

Drilling jig

C-27

Solution 6:


C-35

Solution 7:

Forming press

C-41

Solution 8:

Embossing device

C-45

Solution 9:

Handling device

C-49

Solution 10:


C-55

Solution 11:

Loading station

C-59

Solution 12:


C-63

Solution 13:

Assembly unit

C-69

Solution 14:

Moulding press

C-75

Solution 15:

Pick-and-place unit

C-81

Solution 16:

Galvanising process

C-87

Solution 17:

Loading station

C-95

Solution 18:


C-103

Solution 19:

Checking station

C-111

Solution 20:

Handling device

C-117

Part D – Appendix Storage tray

D-2

Mounting technology

D-3

Plastic tubing

D-5

Data sheets

...


9

Introduction This workbook forms part of Festo Didactic’s Learning System for Automation and Technology. The system provides a solid basis for practiceorientated vocational and further training. Technology package TP200 is concerned exclusively with electro-pneumatic control systems. The basic level TP201 is suitable for basic training in electro-pneumatic control technology. It conveys knowledge concerning the physical fundamentals of electropneumatics as well as the function and use of electro-pneumatic components. The equipment set permits the construction of simple electro-pneumatic control systems. The advanced level TP202 is intended for further training in electropneumatic control technology. The equipment set permits the construction of a wide range of combinatorial circuits with logic operations of the input and output signals as well as program controls. Prerequisites for assembling control circuits are a fixed workstation and a Festo Didactic profile plate. The profile plate has 14 parallel T-grooves arranged at intervals of 50 mm. A short-circuit proof power supply unit provides a constant power supply (Input: 230 V, 50 Hz, Output: 24 V, max. 5 A). A mobile, silenced compressor may be used for compressed air supply (230 V, maximum 8 bar = 800 kPa). Working pressure should be a maximum of p = 6 bar (= 600 kPa) Optimum operational safety is achieved by operating the control system with unlubricated air at a pressure of p = 5 bar = 500 kPa. The training hardware of both equipment sets (TP201 and TP202) will be required for the practical assembly of the controls documented here. The theoretical fundamentals required to understand this book of exercises can be found in the following textbook: Learning System for Control Technology

Introduction to Electropneumatics

Also available are data sheets on the various components (cylinders, valves, measuring devices, etc.).


10


11

Notes on safety and operation In the interests of your own safety, the following advice should be observed:

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

Lines must be connected up and secured before the compressed air is switched on.

Warning! Cylinders may advance or retract as soon as the compressed air is switched on.

Do not operate the electrical limit switches manually during fault finding (use a suitable tool).

Observe general safety regulations (DIN 58126 and VDE 100).

Distinction is to be made between the two different designs of the electrical limit switches – Actuation from the left – Actuation from the right

Limit switches should be placed so that they contact only the side of the trip cam and never the front at high piston speeds.

In the pneumatic circuits cylinders are shown without magnetic pistons, since these are only required when magnetic end-position switches are used. Festo Didactic training sets only contain cylinders with magnetic pistons.

Do not exceed permissible operating pressure (observe data sheets).

Only use extra-low voltage ≤ 24 V.

All components are provided with 4 mm safety sockets respectively safety plugs. For electical connections use only electrical cable with safety plugs.

Pneumatic circuit design: Components are to be connected by means of the silver-metallic plastic tubing with a 4 mm external diameter. Insert the tubing into the QS push-in fitting up to the stop; no further securing necessary!

Releasing of the QS straight push-in fitting: The tubing can be released by simply pressing the clamping collet (blue ring). (Cannot be disconnected under pressure!)

Switch off the pressure and power supply prior to disconnecting the circuit.


12

The profile plate for the assembly of components is equipped for mounting variants A to D: Variant A, Detent system Light, non load-bearing components (e.g. directional control valves). Simply clip the components into the groove of the profile plate. The components can be released by pressing the blue lever. Variant B, Rotational system Medium-weight, load-bearing components (e.g. actuators). These components are clamped onto the profile plate by means of T-head bolts. The components are clamped or released by means of the blue triple grip nut. Variant C, Screw-in system For heavy, load-bearing components, i.e. components which are rarely removed from the profile plate (such as start-up valves with filter regulator). The components are secured by means of cheese head screws and T-head nuts. Variant D, Plug-in system Light, non load-bearing components with locating pins (e.g. signalling device). These components are secured by means of plug-in adapters.

Please observe the data sheets in Part D for information regarding the individual components.


13

Training contents of basic level and advanced level Basic level (TP201)

Physical fundamentals of electricity and pneumatics

Function and application of electropneumatic components

Designation and drawing of electropneumatic symbols

Representation of motion sequences and switching statuses

Drawing pneumatic and electrical circuit diagrams

Assembly of control systems with relays

Direct and indirect manual control systems

Direct and indirect stroke-dependent control systems

Logical AND/OR functions of the input signals

Electrical latching circuits

Using a magnetic proximity switch

Using a pressure switch

Fault finding in simple electropneumatic control systems

Advanced level (TP202)

Function and use of electro-pneumatic components

Stroke-dependent control systems with sensors

Stroke-dependent control systems with preselect counter

Control systems with marginal conditions (e.g. Single/continuous cycle, EMERGENCY-STOP)

Position-scheduled control/process orientated sequence controls

Timing controls/time orientated sequence controls

Program control systems with latching and resetting sequence

Fault finding in extensive electro-pneumatic control systems


14

List of training aims

Exercise

Training aim

1

To teach the student the principle of the latching sequence.

2

To teach the student the principle of the resetting sequence (with reliable switching reversal).

3

To familiarise the student with the procedure for skipping program steps and with the use of a timer.

4

To teach the student how to realise a stroke-dependent sequence control with resetting sequence.

5

To teach the student how to realise multiple movements of a cylinder and monitor service life using a preselect counter.

6

To familiarise the student with the use of a pneumatic/electric converter To teach the student how to construct a control system using single and double solenoid valves (resetting sequence with extension).

7

To teach the student how to realise a control system with specified EMERGENCY-STOP conditions and how to realise a two-hand safety start-up control via a timer with switch-on delay.

8

To teach the student how to incorporate step repetitions and manual step mode into a sequence.

9

To teach the student how to incorporate EMERGENCY-STOP and marginal conditions in a latching sequence.

10

To teach the student how to realise a control system with an alternative program by means of program switching.

11

To teach the student to program repetition using an additional movement.

12

To familiarise the student with step repetition using the preselect counter.

13

To teach the student how to set up manual activation of the cylinder with protection against collision. To familiarise the student with automatic setting conditions.

14

To teach the student how to construct a two-handed safety start-up with relay. To familiarise the student with restart before the end of the cycle.

15

To teach the student how to develop a latching sequence with marginal conditions.

16

To teach the student how to realise program branchings. To teach the student how to make multiple use of time relays. To familiarise the student with program section repetitions using the preselect counter.

17

Consolidating the student’s knowledge. Program section repetition.

18

To familiarise the student with parallel program division.

19

To familiarise the student with the use of a timer with delayed switch-on as a delayed starting element.

20

Familiarisation with an alternative solution to electropneumatics.


15

Equipment set for the basic level (TP201) This equipment set is designed for basic training in electro-pneumatic control technology. It contains all the components required to achieve the specified training aims and may be extended as required with the addition of other equipment sets. To construct fully operational controls, it is also necessary to have a profile plate, a power supply unit and a compressed air supply. Designation

Order No.

Quantity

Relay, 3-off*

162241

1

Signal input plate, electrical *

162242

1

Indicator/distributor plate, electrical *

162244

2

Plastic tubing, 10 m, silver metallic

151496

1

Single-acting cylinder

152887

1

Double-acting cylinder

152888

2

On/off valve with filter regulator

152894

1

Manifold

152896

1

Proximity sensor, with cylinder mounting

167060

2

Limit switch, electrical, actuation from the left

183322

1

Limit switch, electrical, actuation from the right

183345

1

Pneumatic-electric converter

177459

1

3/2-way solenoid valve, normally closed

167073

1

5/2-way solenoid valve

167074

2

5//2-way double solnoid valve

167076

1

* These components can be attached to the profile plate by means of 4 adapters (Order No. 323571).


Equipment set for the basic level (TP201) (Order No.: 080243)

16

Symbols of the equipment set

Signal input plate, electrical

Indicator/distributor, electrical

Relay, 3-off




Manifold


17

Proximity sensor with cylinder mounting


Limit switch, electrical, Actuation from left or right*



5/2-way double solenoid valve


Symbols of the equipment set

18

Equipment set for the advanced level (TP202) This equipment set for the advanced level is designed for further training in electro-pneumatic control technology. The two equipment sets (TP201 and TP202) contain all the components required to achieve the specified training aims and may be extended as required with the addition of other equipment sets from the Learning System for Automation and Technology. Equipment set for the advanced level (TP202) (Order No: 184461)

Designation

Order No.

Quantity

Relay, 3-off*

162241

4

Signal input plate, electrical*

162242

1

Time relay, 2-off*

162243

1

Preselect counter, electrical, incrementing*

162355

1


167076

2

Proximity sensor, inductive

178574

1

Proximity sensor, capacitive

178575

1

Proximity sensor, optical

178577

1

EMERGENCY-STOP button

183347

1

* These components can be attached to the profile plate by means of 4 adapters (Order No. 323571).


19


Relay, 3-off

Time relay, 2-off with switch-on delay

with switch-off delay

Preselect counter, electrical, incrementing







Symbols of the equipment set advanced level

20

Component and exercise allocation (table) Exercise Designation

1

2

3

4

5

6

7

8

9

10 11 12 13 14 15 16 17 18 19 20

Relay, 3-off*

2

3

3

4

5

5

2

2

5

3

4

5

5

5

6* 6* 6* 6* 6* 6*

Signal input module, electrical *

1

1

1

1

2

2

1

2

2

1

1

2

2

1

2

Time relay, 2-off

1

1

Preselet counter, electrical, incrementing Distributor plate, electrical

1

1 1

2


1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

2

2

2

1

1

1

1

1

1

2

1

2

1

1

1

1

1

1

1

1

2

2

2

2

1

1

1

1


2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

1

3* 3* 3* 3*

On-off valve with filter regulator

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Manifold

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1


1

Proximity sensor, inductive Proximity sensor, capacitive

1

1


1

1

1

1

1

1

1

1

1

1

2

2

2

2

2

2

2

Limit switch, electrical, Actuation from the left

1

1

1

1

1

1

1

Limit switch, electrical, Actuation from the right

1

1

1

1

1

1

1


1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

2

2

1

1

1


2

2

2

2

3

2

2

2

2

2

2

1

1

1

1

1

1

1

1

1

2* 2* 2*

1

1

1

1

1

1

1

1

1

1

1

1 2 2

1

2

1


1

1

1



1

2

2

1

1

1

1

1

1

1

1

1

2

2

2

2

2

2

3

1 1

1

2

2

2

2

2

3

1

2

* Components which are not available in full quantity in equipment sets 201 and 202.


21

Methodical structure of the exercises All 20 exercises in part A are of the same methodical design. The two exercise sheets are divided into: -

Subject

-

Title

-

Training aim

-

Exercise

sowie -

Problem description

-

Positional sketch

-

Displacement-step diagram

The proposed solutions in part C cover a minimum of four pages and are divided into: -

Circuit diagram, pneumatic

-

Circuit diagram, electrical

-

Solution description

-

Component list


22

Designation of components The components in the circuit diagrams are designated in accordance with ISO 1219-2. All components within a circuit have the same main code. Letters are assigned dependent on the component. If there are several components within a circuit, these are numbered consecutively. Pressure lines are identified with the designation P and are numbered separately. Actuators:

1A, 2A1, 2A2, ...

Valves:

1V1, 1V2, 1V3, 2V1, 2V2, 3V, ...

Signal detecter:

1S1, 1S2, ...

Accessories:

0Z1, 0Z2, 1Z, ...

Electrical sensors:

1B1, 1B2, ...

Pressure lines:

P1, P2, ...


A-1

Part A – Course Basic exercises Exercise 1:

Bench drill

A-3

Exercise 2:


A-5

Exercise 3:

Filling device

A-7

Exercise 4:

Stamping device

A-9

Exercise 5:

Drilling jig

A-11

Exercise 6:


A-15

Exercise 7:

Forming press

A-19

Consolidating exercises Exercise 8:

Embossing device

A-21

Exercise 9:

Handling device

A-23

Exercise 10:


A-25

Exercise 11:

Loading station

A-29

Exercise 12:


A-33

Exercise 13:

Assembly unit

A-37

Exercise 14:

Moulding press

A-41

Exercise 15:

Pick-and-place unit

A-45

Exercise 16:

Galvanising process

A-49

Exercise 17:

Loading station

A-53

Exercise 18:


A-57

Exercise 19:

Checking station

A-63

Exercise 20:

Handling device

A-67


A-2


A-3 Aufgabe 1

Electropneumatics

Subject

Bench drill

Title

To teach the student the principle of a latching sequence.

Training aim

Drawing the pneumatic and electrical circuit diagrams.

Exercise

Construction of the pneumatic and electrical circuits.

Checking the circuit sequence.


A-4 Aufgabe 1

Problem description

Workpieces are inserted into the clamping device by hand. Clamping cylinder 1A is to extend when the start button is pressed. When the workpiece is clamped, it is to be drilled via feed unit 2A and the drill retracted once again. At the same time, the swarf is to be blown away by an air jet 3Z. Then, the clamping cylinder 1A is to release the workpiece.

Fig. 1/1: Positional sketch

2A

3Z

1A

1

Fig. 1/2: Displacement-step diagram

2

3

4

5=1

1

1S2

0

1S1

1

2B2

0

2B1

1A

2A


A-5 Aufgabe 2

Electropneumatics

Subject


Title

To teach the student the principle of a resetting sequence (with reliable switching reversal).

Training aim


Exercise




A-6 Aufgabe 2

Problem description

A sheet metal strip is to be fed from a drum towards the cutting tool. The feed unit may only start when the punch-tool is in the upper position (this signal must be simulated by a push button S3). Cylinder 1A holds the sheet metal strip and cylinder 2A retracts. Cylinder 1A releases the strip and cylinder 2A returns to the forward end position.

Operating condition

The sheet metal strip feed unit must be provided with a main switch S1. When cylinder 2A has retracted and cylinder 1A has released the strip, a signal (optical indicator) is to be passed on to the press for the next part to be punched out.


1A

2A

1


2

3

4

5

6=1

1

1B2

0

1B1

1

2S2

0

2S1

1A

2A


A-7 Exercise 3

Electropneumatics

Subject

Filling device

Title

To familiarise the student with the procedure for skipping program steps.

Training aim

To familiarise the student with the use of a timer with switch-on delay.





Exercise

A-8 Exercise 3

Problem description

Bottles are transported along a conveyor belt to a rotary table. Cylinder 1A is to retract only when a bottle has arrived on the conveyor belt (position 1) and the START signal (continuous/single cycle) has been given. The table is then to continue indexing (2A+), when the signal “bottle on indexing table” (position 2) has been sent. When a bottle has reached the filling station (position 3), cylinder 3A is to open the filling valve, remain it open for approx. 2 seconds and then reclose it.

Operating condition

If no bottle is reported as present at the filling station (position 3), the installation must be indexed manually until a bottle is present for filling. Sensing of the bottles is to be simulated by push button.


1

2

1A

3

3A

2A


A-9 Aufgabe 4

Electropneumatics

Subject

Stamping device

Title

To teach the student how to realise a stroke-dependent sequence control with a resetting sequence.

Training aim

Drawing the displacement-step diagram and the pneumatic and electrical circuit diagram.

Exercise




A-10 Aufgabe 4

Problem description

Cylinder 1A is to push parts out of the gravity feed magazine and clamp them. Only then can cylinder 2A stamp the part and retract once again. Next, clamping cylinder 1A is to unclamp. The part is to be ejected by cylinder 3A, which then returns to the retracted end position.


1


2

3

4

5

6

7=1

1

1S2

0

1S1

1

2B2

0

2B1

1

3B2

0

3B1

1A

2A

3A


A-11 Exercise 5

Electropneumatics

Subject

Drilling jig

Title

To teach the student how to realise multiple movements of a cylinder.

Training aim

To familiarise the student with the use of an incrementing preselect counter.


Drawing the pneumatic and electrical circuits.



Exercise

A-12 Exercise 5

Problem description

Rectangular castings are to be drilled in 4 positions. Castings are inserted by hand and clamped by an eccentric cam. Feed unit 3A with hydraulic cushioning cylinder is aligned vertically (Zaxis). Positioning cylinders 1A and 2A move the table in X- and Ydirection so that drilling positions (1), (2), (3) and (4) can be approached consecutively. The first hole is drilled by means of feed unit 3A after the START button has been pressed. Next, double-acting cylinder 1A retracts and the second drilling process takes place. After double-acting cylinder 2A has retracted, feed unit 3A carries out the third double stroke. When cylinder 1A has once again reached its forward end position, the fourth hole is drilled. In the 12th step, cylinder 2A extends once again and the initial position is obtained.

Operating condition

To ensure that the service life of the drill is not exceeded, it is to be monitored via a counter. This is to emit a signal and interrupt the cycle once a predetermined number of drilling operations has taken place. Once the drill has been replaced and the counter has been reset by hand, the cycle is to continue again.


A-13 Exercise 5


1 4

2 3

Fig. 5/2: Displacement-step diagram 1

2

3

4

5

6

7

8

9

10

11

12

13=1

1

1B2

0

1B1

1

2B2

0

2B1

1

3S2

0

3S1

1A

2A

3A


A-14 Exercise 5


A-15 Exercise 6

Electropneumatics

Subject


Title

To familiarise the student with the use of a pneumatic/electric converter.

Training aim

To teach the student how to construct a control system using single and double solenoid valves (Resetting sequence with extension).





Exercise

A-16 Exercise 6

Problem description

Semi-finished flanges of workpieces are to be placed manually in a clamping and grinding unit, pneumatically clamped and ground on the right and lefthand flanges. Once single-acting clamping cylinder 1A has reached its forward end position and the clamping pressure has built up in the piston chamber, feed unit 2A performs a double stroke. The righthand flange is ground. Double-acting cross-feed cylinder 3A extends prior to feed unit 2A carrying out the second double stroke and grinding the lefthand flange. Clamping cylinder 1A releases the workpiece when cylinder 3A has reached its retracted end position.

Operating condition

Clamping cylinder 1A, single-acting, controlled via a solenoid valve. Feed cylinders 2A and cross feed cylinder 3A are both double-acting and each controlled via a double solenoid valve. Monitoring of clamping pressure.


A-17 Exercise 6


1A

2A

3A

1

2

3

4

5

6

7

8

9=1

1

1S2

0

1S1

1

2B2

0

2B1

1

3B2

0

3B1

1A

2A

3A



A-18 Exercise 6


A-19 Aufgabe 7

Electropneumatics

Subject

Forming press

Title

To teach the student how to realise a control system with specified EMERGENCY-STOP conditions.

Training aim

To teach the student how to realise a two-hand safety control via a timer with switch-on delay.





Exercise

A-20 Aufgabe 7

Problem description

A metal plate is inserted by hand into the forming press. A profile is to be stamped into the metal plate by means of a two-handed operation. When the operation is complete, the formed metal part is to be ejected by means of ejecting cylinder 2A.

Operating condition

The START signal is obtained through a two-hand safety control with delayed switch-on timer. When the EMERGENCY-STOP button is pressed, the two cylinders must return immediately to their initial positions.


1A

1


2

3

4

5=1

1

1S2

0

1S1

1

2B2

0

2B1

1A

2A


A-21 Exercise 8

Electropneumatics

Subject

Embossing device

Title

To teach the student how to incorporate step repetitions and manual step mode into a sequence.

Training aim

Drawing the pneumatic and electrical circuits.

Exercise




A-22 Exercise 8

Problem description

Workpieces to be embossed are inserted manually into a retainer and pushed under the embossing stamp by cylinder 1A. Cylinder 2A extends and embosses the workpiece. Then, cylinder 2A retracts again followed by cylinder 1A.

Operating condition

It must be possible to carry out the individual movements step by step via a push button (manual step mode). In addition, steps 2A+/2A- must be repeatable to enable adjustment of the embossing cylinder. Cylinder 2A+ is to be moved in manual step mode, meaning that the 2A- movement must be effected via an additional push button. Step repetition and manual step mode should only be possible when no START signal is present.


1


2

3

4

5=1

1

1B2

0

1B1

1

2S2

0

2S1

1A

2A


A-23 Exercise 9

Electropneumatics

Subject

Handling device

Title

To teach the student how to incorporate EMERGENCY-STOP and marginal conditions in a latching sequence.

Training aim


Exercise


Checking the circuits sequence.


A-24 Exercise 9

Problem description

Round parts are to be fed by a handling device from the outlet channel of processing station I to the inlet channel of processing station II. As an additional start condition, the outlet channel is to be interrogated for round parts.

Operating condition

Separate push buttons for SINGLE/CONTINUOUS CYCLE. EMERGENCY-STOP: Linear drive 2A must be unpressurised. Gripper 1A must remain closed or open according to status. When EMERGENCY-STOP is no longer being actuated, pressing a push button is to bring the linear drive back into the initial position. A second push button is then to release the gripper (if this was closed in the EMERGENCY-STOP status). This push button must also simultaneously latch the start button (after the EMERGENCY-STOP), so that it is only possible to restart via the START button after this button has been pressed.


1


1

2

3

4

5=1

1S2 open

1A

Gripper 0

1S1 closed

1

2B2

2A

Linear drive 0

2B1


A-25 Exercise 10

Electropneumatics

Subject


Title

To teach the student how to realise a control system with an alternative program by means of program switching step jump.

Training aim


Exercise




A-26 Exercise 10

Problem description

Program 1: - Drilling Parts, which only need to be drilled, are clamped by hand. The part is drilled when the START button is actuated. (Cylinder 1A). Program 2: - Drilling and reaming Parts, which also need to be reamed, are also clamped by hand. Then, upon actuation of a PROGRAM SELECTOR button and the START button, cylinder 1A starts the drilling process. When the drilling process is completed, positioning cylinder 2A extends and transfers the drilled part to the reaming station (cylinder 3A). When reaming of the part has taken place, positioning cylinder 2A retracts and the part can be removed. The PROGRAM SELECTOR button must be actuated before the START button in order to start up program 2. If these buttons remain unactuated, then program 1 is to automatically run.


A-27 Exercise 10


Fig. 10/2: Displacement-step diagram Program 1 1

2

Program 2 3=1

1

1

1S2

0

1S1

1

2B2

1A

2

3

4

5

6

7=1

1

1S2

0

1S1

1

2B2

1A

2A

2A 0

2B1

0

2B1

1

3B2

1

3B2

0

3B1

3A

3A 0


3B1

A-28 Exercise 10


A-29 Exercise 11

Electropneumatics

Subject

Loading station

Title

To teach the student to program repetition using an additional movement.

Training aim

To familiarise the student with the use of an incrementing preselect counter.





Exercise

A-30 Exercise 11

Problem description

A plate on a conveyor belt is fitted with two steel parts. The parts advanced via a rail are centred by a spigot and held by an electromagnet whilst being transferred. The motion sequence towards position 1 is to be executed via cylinders 1A and 2A. Position 2 is to be reached by means of the same sequence as that employed for position 1, with the addition of cylinder 3A (see displacement-step diagram).

Operating condition

Sensing of steel parts is to be realised via a push button S2. When the conveyor belt has passed on the next plate for loading and transmitted a signal to the loading unit (simulated by push button S1), the machine is to proceed automatically. The functioning of the electromagnet is to be simulated by means of a lamp H1.


A-31 Exercise 11


Conveyor belt Plate

Position 2

Position 1


2

3

4

5

6

7

8

9

10

11

12

13=1

1

1S2

0

1S1

1

2B2

0

2B1

1

3B2

0

3B1

1A

2A

3A

Position 1


Position 2

A-32 Exercise 11


A-33 Exercise 12

Electropneumatics

Subject


Title

To familiarise the student with step repetition using the preselect counter.

Training aim


Exercise

Construction of the pneumatic and electrical circuit diagrams.



A-34 Exercise 12

Problem description

Workpieces are fed along a conveyor belt. The forwardmost workpiece is pushed against the stop by the following one. When a workpiece is present, it is signalled by a sensor (switch) and the clamping stop is raised (cylinder 1A). Next, cylinder 2A is to clamp the part and signal when the clamping pressure has been reached so that the grinding process can commence. Cylinder 3A is to advance and the grinding wheel switched on simultaneously (simulation by means of visual indicator). Then cylinder 3A is to travel up and down ten times (half strokes) and then return to the initial start position. Next, cylinders 1A and 2A are are to retract simultaneously. Cylinder 2A now is to extend once again and push the part onto the conveyor belt which is to carry it away (only a minimal section of the stroke was required for the clamping operation). When cylinder 2A has returned once again and another workpiece has reached the stop, the cycle is to be repeated.

Operating condition

START and STOP at the end of each cycle are each controlled by one push button.


A-35 Exercise 12


3A

2A 1A


2

3

4

5

6

22

23

24

25

26=1

1

1B2

0

1B1

1

2S2

0

2S1

1

3B3

1A

2A

3A

3B2 0


3B1

A-36 Exercise 12


A-37 Exercise 13

Electropneumatics

Subject

Assembly unit

Title

To teach the student how to set up manual activation of a cylinder including precautions with protection against collision.

Training aim

To familiarise the student with automatic setting conditions.





Exercise

A-38 Exercise 13

Problem description

Bushes which are placed ready for assembly in a gravity feed magazine are pressed into metal blocks which are also introduced in a similar manner. Cylinder 1A pushes a metal block from the magazine to a stop and clamps it. Then, cylinder 2A extends and presses the first bush into place. Next, cylinder 3A is activated, pressing the second bush into place. Then cylinders 1A and 3A retract simultaneously, followed by cylinder 2A retracting. The assembled metal block drops onto a conveyor belt.

Operating condition

The installation is to operate in a continuous cycle. It must be possible to select between manual and automatic operating mode. Manual operation is to be indicated by a lamp H1. Separate push buttons are to actuate each of the cylinders. This installation may only be run in manual mode; only one cylinder is to extend at a time.


A-39 Exercise 13

Fig. 13/1 Positional sketch

1

2

3

4

5

6=1

1

1S2

0

1S1

1

2B2

0

2B1

1

3B2

0

3B1

1A

2A

3A



A-40 Exercise 13


A-41 Exercise 14

Electropneumatics

Subject

Moulding press

Title

To teach the student how to construct a two-handed safetystart-up control with relay.

Training aim

To familiarise the student with restart before the end of the cycle.





Exercise

A-42 Exercise 14

Problem description

Plastic plates are to be formed from duroplastic pellets. The pellets are inserted manually into the lower part of the mould. When the START button is pressed (two-handed safety control), the upper part of the mould is guided into the lower part of the mould. When the forward end position is reached, pressure must be sustained for approximately ten seconds to guarantee hardening of the formed part. Then, the plates are removed from the mould tool by the extractor unit and stacked next to the press.

Operating condition

The START signal must continue until cylinder 1A has assumed its forward end position. The press cylinder may extend immediately the extractor unit has been removed from the working area (half return stroke of cylinder 2A). The two-handed safety control using a relay. The function of the vacuum generator 4Z is to be represented by a lamp.


A-43 Exercise 14


1

2

3

4

5

6

7=1

1

1B2

0

1B1

1

2B3

1A

2A

2B2 0

2B1

1

3S2

0

3S1

3A



A-44 Exercise 14


A-45 Exercise 15

Electropneumatics

Subject

Pick-and-place unit

Title

To teach the student how to develop a latching sequence with marginal conditions.

Training aim

Drawing the pneumatic and electrical circuit diagrams..

Exercise




A-46 Exercise 15

Problem description

A triple-axis unit is used for insertion of parts from position 2 into positions 3 and 4 of a gear housing. The vacuum gripper 4Z is to be simulated by a lamp (gripper suction = lamp on, no gripper suction = lamp off). The start position is to be position 1, where the gripper is raised (Z-axis) and there is no suction. When the START button is pressed, position 2 is to be approached and a part picked up from the feed hopper and then deposited in position 3. Another part is then picked up from position 2 and deposited in position 4. The gripper then returns to initial position 1.

Operating condition

Sensing of the magazine (simulated by a switch and indicated via a lamp): When the magazine is empty, the control system is to remain in position 1 or position 2 and must only proceed or restart when the magazine has been filled and the start button pressed. Sensing of the gear housing: This is to guarantee that a gear housing which is inserted into a device is removed after processing (switch and lamp off). The initial start positions of the double-acting cylinders are: 1A+, 2A+, 3A-.


A-47 Exercise 15


2A 1A

3A


down up Vaccuum generator on


Vaccuum generator off

Vaccuum generator on

Vaccuum generator off

A-48 Exercise 15


A-49 Exercise 16

Electropneumatics

Subject

Galvanising process

Title

To teach the student how to realise program branchings.

Training aim

To teach the student how to make multiple use of time relays.

To familiarise the student with program section repetitions using the preselect counter.

To teach the student how to realise a pressure-dependent control system.





Exercise

A-50 Exercise 16

Problem description

An overhead trolley beam transports the parts to be galvanised from a work surface across the three baths and back again. A doubleacting cylinder positions the basket on the work surface or else lowers it into the baths. It remains in the forward end position (bath 2) or swings the basket up and down in the bath (baths 1 and 3). Partial strokes are sensed by three limit switches. If the trolley has approached a horizontal position, a control lamp is illuminated (bath 1 lamp H1, bath 2 lamp H2, bath 3 lamp H3 and work surface lamp H4). In the initial position, the basket hangs above the work surface. When the up/down switch S2 is actuated, the cylinder extends and the basket is deposited on the work surface for loading. When the initial start position has once more been reached, the cylinder can be actuated via start button S. The movements of the trolley (from work surface to bath 1, from bath 1 to bath 2, from bath 2 to bath 3 and from bath 3 back to the work surface) are simulated by four identical time periods t1 = 2 seconds. Once the basket has been dipped into bath 1 (and bath 3), the piston extends four half strokes in the forward stroke area. The basket remains in bath 2 in the forward stroke area t2 = 3 seconds.

Operating condition

When the main power supply has been switched on, the control is to be activated via the SET button S1 and the time interval t1 started simultaneously. During this time period, the cylinder is to be brought into the initial position (as it would have moved into the forward end position by leakage losses when the installation was stopped). When the time t1 has expired, the positioning lamp H4 is illuminated. The installation can only be started once a pneumatic-electrical converter has signalled the supply of compressed air.


A-51 Exercise 16


Bath 1

Bath 2

Bath 3

Fig. 16/2: Displacement-step diagram START

1

Bath 1 2

3

4

5

6

Bath 2 7

8

9

10

Bath 3 11

t2

1

12

13

14

15

16

17=1

1B3

1A

1B2 1B1

0

S1

t1

t1 t1


t1

A-52 Exercise 16


A-53 Exercise 17

Electropneumatics

Subject

Loading station

Title

Consolidating the student’s knowledge.

Training aim

Program section repetition.





Exercise

A-54 Exercise 17

Problem description

A loading station is used for loading boxes. Empty boxes which are supplied via a conveyor belt must be placed onto the transfer unit by hand. Transfer unit 1A moves underneath the swivel device 4M, which then fills the box with containers row by row. The motion sequence can be seen in displacement-step diagram 1. Indicate on the diagram the step which has been reached by the installation shown in the positional sketch.

Operating condition

The functioning of the suction cups is to be simulated by lamp. The motion sequences which recur (see displacement-step diagram 1, steps 3....21), should be brought together in a subroutine which is to be repeated itself a number of times (see displacement-step diagram 2).


4M

3A

1A 2A

The loading station shown here is not in the initial position.


A-55

1B2

1B1

2B2

2B1

3S2

3S1

4B

4S

0

1

0

1

0

1

0


4M

3A

2A

1A

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25=1 1

Exercise 17

1A+ 3A+ 4M+ 4M- 3A- 2A+ 3A+ 4M+ 4M- 2A- 3A- 2A+ 3A+ 4M+ 4M- 2A- 3A- 2A+ 3A+ 4M+ 4M- 3A- 1A-


Abbreviated notation

A-56

1B1

2B2

2B1

3S2

3S1

4B

4S

1

0

1

0

1

0

1B2

Abbreviated notation

4M

3A

2A

1A

1

1

2

3

3

21

21

22

23

24

25=1


0

Exercise 17

1A+ 3A+

4M+ 4M- 2A- 3A- 2A+ 3A+

4M+ 4M- 3A- 1A-

Main program

3 x Subroutine

Main program


A-57 Exercise 18

Electropneumatics

Subject


Title

To familiarise the student with parallel program division.

Training aim

Drawing the pneumatic and electrical circuit diagram.

Exercise




A-58 Exercise 18

Problem description

Workpieces are drilled vertically and horizontally on an eight-station rotary indexing table. Six feed units are used for the various machining operations. Two each for drilling, counterboring and countersinking. Two transferring units load and unload the machine respectively. Lifting cylinders 1A and 3A descend onto the workpieces. These are picked up by suction (functioning of the vacuum generator is to be indicated by a lamp) and then lifted. The stroke of cylinder 5A then causes the table to index on by one position. At the same time, transfer cylinders 2A and 4A approach the positions for placing on the indexing table and depositing via the conveyor belt 2. Then, cylinder 5A latches the rotary indexing table and the two lifting cylinders 1A and 3A deposit the parts. At the same time as the lifting cylinder retracts, processing via feed units 6A to 11A begins. When these have reached their forward end positions, the feed units and the transfer cylinders return to their initial positions.

Operating condition

Choice between manual and automatic operating modes. Separate push buttons for START and STOP (continuous cycle). The start signal must be maintained until the machine has been supplied with lubricant via a centralised lubrication system (the pump motor is to be simulated by a lamp). Then, the start signal is to be stored and indicated by a lamp. Workpiece sensing on conveyor belt 1 is simulated by a switch. The air blast for swarf removal is to be simulated using a solenoid valve.


A-59 Exercise 18

EMERGENCY-STOP The electrical power to the control must be switched off. The feed units are to retract. The transfer units and the cylinder of the indexing table are to complete their movements. When the vacuum generators are active, they must continue to remain active until, after the RESET and a renewed START, the controller gives the command to deposit. RESET If, after indexing on, processing can no longer take place because the EMERGENCY-STOP has been actuated, processing must be carried out in RESET mode via a time control. All cylinders must be brought into their initial position. In the case of the transport units, cylinders 1A and 3A must retract before cylinder 2A and 4A. Note regarding solution For the purpose of simulation, this exercise can be solved using four cylinders: The transer units are to be represented by double-acting cylinders. Cylinders 1A and 2A are sufficient for this as the movements of the two units are synchronised. Cylinder 5A for indexing of the table is also represented by a doubleacting cylinder. All feed units are to be represented by a single-acting cylinder. Only the limit switches of the four cylinders are to be drawn in the electrical circuit diagram.


A-60 Exercise 18


Discharge Conveyor 2

9A Counter 2

8A

1A

Counter 1 Rotary indexing table

Conveyor 1

7A Drilling 1


A-61 Exercise 18

1

Transfer 1

2

3

4

5

6

7=1

1

1S2 (1B2)

0

1S1 (1B1)

1

2S2 (2B2)

0

2S1 (2B1)

1A

2A

1

Transfer 2

2

3

4

5

6

7=1

1

3S2

0

3S1

1

4S2

0

4S1

3A

4A

1

2

3

4

5

6

7=1

1 Rotary indexing table 5A

5S2

0

5S1 1

Drilling 1

2

3

4

5

6

7=1

1

6S2 (6B)

0

6S1 (6S)

1

7S2

0

7S1

1

8S2

0

8S1

1

9S2

0

9S1

1

10S2

0

10S1

1

11S2

0

11S1

6A Drilling 2

Counterboring 1

Counterboring 2

Deburring 1

Deburring 2

7A

8A

9A

10A

11A



A-62 Exercise 18


A-63 Exercise 19

Electropneumatics

Subject

Checking station

Title

To familiarise the student with the use of a timer with delayed switchon as a delayed starting element.

Training aim


Exercise




A-64 Exercise 19

Problem description

Transfer cylinder 1A is to push a container onto the scales. Then, cylinder 2A is to release the scales and cylinder 1A is to return to its initial position. After a waiting time of approx. 3 seconds, cylinder 2A is to block the scales again. If the container is within the weight tolerance (switch S4 is activated), cylinder 3A is to push it onto the conveyor belt to move it on and then to retract once again. However, if the tolerance limit is not maintained (switch S4 not activated), cylinder 4A is to transfer the container to the outlet chute and then to retract again. Then, the container is to be transferred on by the conveyor belt (simulated by a lamp H1).

Operating conditions

The installation is to operate in continuous mode and started by a push button S1 and stopped at the end of the cycle by a second push button S6. The good parts are to be counted. As the sensor for the containers is not attached directly to transfer cylinder 1A, for technical reasons, the run-time of the conveyor belt must be controlled as follows: The conveyor belt continues running until a sensor (push button S4) outside the transfer area, signals the presence of a container and uses this to control a timer. When the time has expired, the conveyor belt can stop and cylinder 1A then commences the cycle once again.


A-65 Exercise 19


1A

3A

4A

1

2

3

4

5

6=1

1

1B2

0

1B1

1

2B2

0

2B1

1

3B1

0

3S1

1

4S2

0

4S1

1A

2A

3A

4A



A-66 Exercise 19


A-67 Exercise 20

Electropneumatics

Subject

Handling device

Title

Familiarisation with an alternative solution to Electropneumatics.

Training aim


Exercise




A-68 Exercise 20

Problem description

Cylindrical parts are to be distributed evenly from outlet channel 1 onto the two inlet channels 2 and 3 (see displacement-step diagram)

Operating condition

The unit is to be operated in continuous cycle only. “START” and “STOP AT END OF CYCLE” are each to be effected by one push button. Sensing of parts at channel 1 is to be simulated by a switch. If this switch is not activated, the unit is to stop at the end of the cycle. After the swivel movement to inlet channels 2 and 3 has been carried out, the gripper is not to open until a short delay time has expired. After actuation of the EMERGENCY-STOP switch, cylinders 1A, 2A and 3A are to retract and cylinder 4M switched to an unpressurised condition. When the EMERGENCY-STOP has been unlatched, the reset button is to return cylinder 4M to the initial position. It must be possible to limit the number of cycles using a preselect counter.


A-69 Exercise 20



2

3

4

5

6

7

8

9

10

11

12

13=1

1

1S2

0

1S1

1

2B2

0

2B1

1

3B2

0

3B1

1

4B

0

4S

1A

2A

3A

4A


A-70 Exercise 20


B-1

Part B - Fundamentals The theoretical fundamentals for the training package Electropneumatics are summarised in the textbook

Learning System for Automation and Technology

Introduction to Electropneumatics. Basic Level TP201


B-2


C-1

Part C – Solutions Solution 1:

Bench drill

C-3

Solution 2:


C-9

Solution 3:

Filling device

C-17

Solution 4:

Stamping device

C-21

Solution 5:

Drilling jig

C-27

Solution 6:


C-35

Solution 7:

Forming press

C-41

Solution 8:

Embossing device

C-45

Solution 9:

Handling device

C-49

Solution 10:


C-55

Solution 11:

Loading station

C-59

Solution 12:


C-63

Solution 13:

Assembly unit

C-69

Solution 14:

Moulding press

C-75

Solution 15:

Pick-and-place unit

C-81

Solution 16:

Galvanising process

C-87

Solution 17:

Loading station

C-95

Solution 18:


C-103

Solution 19:

Checking station

C-111

Solution 20:

Handling device

C-117


C-2


C-3 Solution 1

Bench drill

Fig. 1/3: Circuit diagram, pneumatic

*

**

* For the purposes of this exercise, feed unit 2A is replaced by a double-acting cylinder. ** Detailed representation of the on/off valve with filter regulator.


K1

K4

1S1

S

24 A1

23

4

4 5 11

K2

K1

1S2

2 3 10

14

1

3

A2

K1

13

2

A2

42 A1

41

4

14 1

13

24 V- 1 K2 14

13

4

2B2

5

BU

BN

K3 A2

24 A1

23

11 7 9

K2

BK

6 K3 14

13

7

2B1

8

BU

BN

K4

1

K3

BK

A2

24 A1

23

9

1Y

34

1A+

K1

33

10

2Y

42

41

34

2A+

K3

K2

33

11

3Y

K3

3Z

34

33

12

C-4

Solution 1

Fig. 1/4 Circuit diagram, electrical Ausblasen


C-5 Solution 1

Since in this case the memory function is via a relay, single solenoid valves are generally activated using a latching sequence. It should be remembered that the coil circuit should be interrupted by a second contact for the return motion, for example, in order to achieve spring return of the valve to the initial position. (The final step represents an exception to this since it is possible to dispense with a normally closed contact as all valves are returned to their initial positions through interruption of all the circuits). This is why a latching sequence is used since in the case of power failure all cylinders will return to an accurately defined initial position. This is important for accident prevention, although it is important to watch out for overlapping of movements which may occur on reaching the initial position.

24 V- 1

2

13

S

13

K1 14 1

10 33

K1 14

34

1S1 4

41

K4 42 A1

K1

1Y A2

1A+

When START button S is actuated and normally open contact 1S1 is activated via cylinder 1A, the circuit to relay K1 is closed via the normally closed contact of K4, which then goes into self-holding (latching) via the parallel contact of K1. A further normally open contact of K1 switches the circuit to solenoid coil 1Y. This in turn switches the solenoid valve and cylinder 1A travels into the forward end position.



Fig. 1/5: Step 1, Cylinder 1A+

C-6 Solution 1

Fig. 1/6: Step 2, Cylinder 2A+

24 V- 1

2

13

S

13

4

1

1S2

K1 14 1

3

14

13

K2 4

10

11

33

K1 14

33

K2 34

34

1S1 4

41

23

41

K1

K4 42 A1

K1

K3 24 A1

K2 A2

42

1Y

2Y

A2

1A+

2A+

When cylinder 1A has reached its forward end position, it actuates limit switch 1S2. Then, the circuit for relay K2 is closed via S2 and the setting condition K1, this then goes into self-latching via a parallel normally open contact. A second normally open contact of K2 switches the current to solenoid coil 2Y via normally closed contact K3; this switches the valve and cylinder 2A extends. The principle of the latching sequence is to interrogate the preceding step and its acknowledgement (limit switch) and then to set a new memory for the next step. Finally, the complete sequence (the self-latching circuits) is reset by the last step (or cycle) – no self-latching is required for the last step.


C-7 Solution 1

Quantity

Designation

2

Relay, 3-off

1


1

Indicator/distributor plate, electrical

2


1


1

Manifold

2


1


1


1


2


1

Cable set with safety plug

1

Electrical power supply unit, 24 V


Components list

C-8 Solution 1


C-9 Solution 2


1B1

1B2

2S1

1A


2S2

2A

4

2

4

1Y1

1Y2 5

1

3

2

2Y1

2Y2 5

1

3

0Z2

0Z1

1

2

3

Simplified representation of on/off valve with filter regulator


K1

K4

K8

2S2

S2

S1

A1

22

23

12 5 17

K2

K1

2 3

14

13

A2

K1

3

A2

42 A1

41

14

4 11

14 1

14 13

13

2

BU

1B1 BN

4

K3

K6

K2

BK

6 7

A2

42 A1

41

14

13

5 K3 14

13

6

K4

1

K3

8 18

A2

A1

24

23

7

K5

K8

K4

2S1

9 10

A2

22 A1

21

14

4 13

1

8 K5 14

13

9

K6 A2

A1

24

23

5 12 16 19

K5

10

Fig. 2/4: Circuit diagram, electrical (1)

24 V- 1

C-10

Solution 2


1B2

TP202 • Festo Didactic K7

K8

8

K7

A1

24

21

1 20

14

SET 13

15

13 15

14

11

14

A2

K7

13

A2

42 A1

41

14

13

12

K2

K6

BK BU

BN

24 V- 11

H1

K6 24

23

16

1Y1

24

23

1A-

K2

17

2Y1

24

23

2A-

K4

18

1Y2

34

33

1A+

K6

19

2Y2

34

31

2A+

K8

20

C-11 Solution 2


C-12 Solution 2


When the SET button is pressed, relay K7 goes into self-latching and switches relay K8, which represents the start condition. If appropriate, the SET button should be latched in such a way that it can only be active at the time when the main current supply is applied, in order to safeguard the circuit sequence. Once the feed has been initiated with S1 and S2, K1 goes into selflatching and K2 switches, self-latching at K7 is cancelled via a normally closed contact of K2. A further possibility is to replace the SET key by a relay (see exercise 13).

Fig. 2/6: Step 1, Cylinder 1A-

24 V- 1

2

13

S1

13

K1 14 13

3

17

23

K1 14

23

K2 22

24

S2 14 1

2S2 4 11

K8 14 41

K4 42 A1

A1

K2

K1 A2

1Y1 A2

1A-

When START button S1 is actuated, the circuit for relay K1 is closed via the signal from pressing S2, the limit switch S22, the setting signal for relay K8 and the normally closed contact K4. The relay goes into selflatching via the parallel normally open K1. At the same time, a further normally open contact of K1 switches the circuit for the relay K2. A normally open contact of K2 switches the circuit in the power section to solenoid coil 1Y1. The valve switches and cylinder 1A travels into the retracted end position and there actuates limit switch 1B1.


C-13 Solution 2

Fig. 2/7: Step 2, Cylinder 2A24 V- 1

2

13

S1

13

K1 14 13

3

4

5

6

23

13

K1 14

K3 22

S2

17

K3

18

23

23

14

1B1 BN BK BU

14 1

7 K2

23

K4 24

24

24

13

K2

2S2 4 11

14

K8 14 41

41

K4

K6 42 A1

K2

K1 A2

42 A1

A1

K3 A2

A1

K4 A2

1Y1

2Y1

A2

1A-

Now sensor 1B1 emits a signal which closes the circuit for relay K3 via the normally open contact K2 and the normally closed contact K6. This goes into self-latching via the parallel normally open contact K3. At the same time, relay K4 is switched via a further normally open contact K3. Only now, when self-latching of K3 has been established, is the setting condition K1 or K2 reset by normally closed contact K4 and in the power section, the normally open contact K4 switches the circuit to solenoid coil 2Y1, which in turn switches the valve, cylinder 2A retracts and activates 2S1 in the end position. Owing to its additional switching time, relay K4 serves as a delay between the build-up of self-latching of K3 and the reset of setting condition K2. This guarantees that K3 is in self-latching before the setting signal is set. Then, the next step is activated (K5, K6) by 2S1 via K4. The principle of the latching sequence is based on the interrogation of the preceding step and its acknowledgement (limit switch). The next step is activated on the basis of these conditions; when this happens, the preceding step is reset. The reset sequence is particularly suitable for the control of double solenoid valves, since here the memory behaviour is assumed by the bistable solenoid valve.


2A-

C-14 Solution 2

This can be very important in the case of power failure, in respect of accident prevention. To be able to start up again after power failure or switch off the main power supply (circuit dead), relays K7 and K8 must be switched. This happens here via the SET key. The principle of reversal of the latched sequence which is shown here is completely reliable owing to the use of an additional relay per step and can be used for every type of relay. Where there is a late opening or early closing relay, it may be possible to get by without an additional one. (Normally, only contactors have this type of switching behaviour). In such a case, the circuit up to step 2 would look as follows. Compare this simplified circuit diagram with the electrical circuit diagram. Fig. 2/8 Circuit diagram, simplified

24 V13

S1

13

13

K1 14 13

K2 14

1B1 BN

S2 14 1

23

K1 14

23

K2 24

24

BK BU

23

K1

2S2 4 11

24

K8 14 41

K2

41

K4 42 A1

K1

42 A1

K3 A2

1Y1

2Y1

A2

1A-

2A-


C-15 Solution 2

Quantity

Designation

3

Relay, 3-off

1


2


2


1


1

Manifold

2


1


1


2


1


1



Components list

C-16 Solution 2


C-17 Solution 3

Filling device


1S1

2B1

1S2

1A

2B2

3A

2A

4

2

5

3

1Y

4

2

5

3

2

2Y 1

3Y 1

1

0Z2

0Z1

1 3


2

3

3B1

3B2

3B1

S1 = Single cycle S2 = Continuous cycle

2

K1

K7

K1

K2 14

13

K3

K2

1S2

24 A1

23

4

1

8 10 19

24 A1

23

14

13

4

1

7

18 6 7

K2

S4

1S1

6

4 5 18

14

13

5

A2

K1

4

A2

14

13

3

A2

42 A1

36 41

35

14

S3 13

14

BK S1 13 S2

K6

BU

BN

1 K3 14

13

8 2B2

9

BU

BN

K4 A2

24 A1

23

19 11 13 17

K3

BK

10 K4

14

13

11


24 V-

C-18

Solution 3

st S3 = 1 interrogation S4 = 2nd interrogation


2B1

24 V-

BU

BN

12

rd S5 = 3 interrogation S6 = Idle cycle without filling


K4

S5

BK

14 16 20

A2

24 A1

23

14

13

13 K5 14

13

14 2B2

A2

24 A1 A2

34 A1

33

14

13

17

2

K4

K7

S6

23

16

2

K5

BK

K6

BU

BN

15

1Y

42

41

34

33

1A-

K2

K1

18

2Y

42

41

34

33

2A+

K4

K3

19

3Y

34

33

3A+

K5

20

C-19 Solution 3


C-20 Solution 3


Components list

When S1 or S2 and S3 are activated, the control system is started up. Cylinder 1A retracts and the bottles move along. If S4 is actuated, the cylinder extends again. Then, the indexing table (cylinder 2A) inches round one position. Once a bottle has reached the filling station, it is filled until the time delay closes the container (cylinder 3A), and the control system is brought back into the initial start position. If no bottle is reported as being present at the filling station, the control can be returned to the initial start position via S6. Then the indexing table can be supplied with bottles until a signal is received from S7. Quantity

Designation

3

Relay, 3-off

1


1

Time relay, 2-off

1


1


2


1


1

Manifold

1


1


2


1


1


1


2


1


1



C-21 Solution 4

Stamping device

2B1


2B2

2A 1A

1S1

1S2

3A

4

2

5

3

2Y1 4

2

5

3

1Y1

1

4

2

5

3

3Y1

0Z2

0Z1

1 3


3B2

2Y2

1Y2 1

3B1

2

3Y2 1

3B1

K4

K1

S

K12

A1

24

23

K6

1S2

K2

41

4

1

14

13

K3 14

13

6

K4

2

K3

A1

24

23

7 2B2

8

BU

BN

A2

20 5 23

A2

3 4

42 A1

K3

6 7

A2

42 A1

9 24

A2

K5

K8

K4

BK

13

9

10 11

A2

12 A1

11

K2

K1

5

41

14

13

4

14

K1

3

14

14 13

11

2

K5 14

13

10


24 V- 1

C-22

Solution 4



K6

21

4

1

6 7

14 15

12 A1

K9

2

9 24

A2

24 A1

21

K12

K8

1S1

11

A1

24

21

24

K8

K7

16

14

13

14

11

15

5 13 25

K7

K10

K6

BK

K7

14

A2

BU

2B1 BN

13

A2

A1

24

23

12

A2

K5

24 V- 11 K9 14

11

17

K10

2

K9

9 24

A2

A1

24

21

18

C-23 Solution 4


3B2

K11

K2

K10

K11

16 2 20

A1

24

21

20 22

K12

K11

22

A2

14

SET 13

21

A2

42 A1

41

22

21

14

11

20

1Y1

24

23

1A+

K2

23

2Y1

24

23

2A+

K4

24

2Y2

24

23

2A-

K6

25

1Y2

34

31

1A-

K8

26

3Y1

34

31

3A+

K10

27

3Y2

34

31

3A-

K12

28


24 V- 19

C-24

Solution 4


C-25 Solution 4

This solution corresponds to a reset sequence of 6 steps with single cycle operation. Only when the last step has been set via the SET button, can another single cycle be started. The signal generators are directly switched to limit the number of relays. Quantity

Designation

4

Relay, 3-off

1


1


1


2


1


1

Manifold

1


1


2


1


1


3


1


1




Components list

C-26 Solution 4


C-27 Solution 5

Drilling jig


1B2

1B1

2B1

1A

*

2B2

3S1

3A

3S2

2A

4

2

5

3

1Y

4

2

5

3

4

2Y 1

2

3Y 1

5

1

3

0Z2

0Z1

1

2

3

* For the purposes of this exercise, feed unit 3A is replaced by a single-acting cylinder. A 3/2-way solenoid valve may also be used as a final control element.

3A

2

3Y


1

3

3S1

3S2

Fig. 5/4: Part of circuit diagram, pneumatic

K1

K14

S

A1

4

1

K1

K2

23

14

11

K3 14

13

6

K4

3S1

A1

4

1

7

A2

5 13 20 27

A2

3 5 35

12 A1

A2

35 6 8

K3

24 A1

8 15 22 29

A2

K5

K3

K16

K4

11

14

11

8

9 11 33

A2

24 A1

23

K2

3S2

5

11

14

13

4

12

K1

3

14

13

2

K5 14

13

9


2B2

24 V- 1

C-28

Solution 5


1B1

24 V- 10


K5 24 A1

23

24

21

36 14 15

K7

K6

K2

12 13 36

14

13

13

A2

K6

12

A2

24 A1

23

11 K7 14

13

14

K8

K7

K16

K4

16 18 34

A2

24 A1

23

22

21

24

21

15 K8 14

13

16

BU

2B1 BN

17

K9

K8

BK

19 20 37

A2

24 A1

23

18 K9 14

11

19

C-29 Solution 5


K10

K11

K10

K16

K4

24 A1

21

32

31

34

31

33 23 25

14

11

37 21 22

K10

A2

24 A1

21

34

31

22

A2

K9

K2

21 K11 14

11

23 1B2

BU

BN

24

K12

K11

BK

26 27 38

A2

24 A1

21

25 K12 14

11

26

K13 A2

24 A1

21

44

41

38 28 29

K12

K2

27 K13 14

11

28

K14

2

K13

K16

K4

A2

24 A1

21

42

41

44

41

29

K15

31

A2

A1

30


24 V- 20

C-30

Solution 5



8 15 22 29

K15

A2

A1

14

11

24 V- 31

H

32

1Y

32

31

34

33

1A-

K11

K5

33

2Y

34

33

2A-

K8

34

3Y

42

K7 42

41

41

33 34

K6

36

34

33

3A+

K3

K1

35

K10

K9

32

31

34

31

37

K13

K12

32

31

34

31

38

C-31 Solution 5


C-32 Solution 5


The preselect counter receives pulses from 3S2. When the preselect figure or the end of the drill life has been reached, the sequencer is stopped. It will not continue running until the drill has been changed (counter reset). Signal generators 3S1 and 3S2 must be switched indirectly to ensure reliable sensing. Otherwise, self-latching would supply a continuous signal (see example) when a latching sequence is being used.

Example

Fig. 5/9:

Kn+1 can be set without acknowledgement 3S1 being activated since current can flow via the self-latching of K3 and Kn.

24 V3S1

K2 K3

K3

Kn+1

Kn Kn+1


C-33 Solution 5

The signal generators indirectly switched (as in the solution to the exercise). Fig. 5/10: Alternative circuit (1)

24 VK1

3S1

K3

K2 K1

K1

Kn+1

Kn

K3

Kn+1

As the connection is interrupted here by K4 via K3, Kn+1 may only be set if Kn and 3S1 are activated. Fig. 5/11: Alternative circuit (2)

24 V3S1

K3

3S2

K4

Kn+1

K4

K2 K3


K3 K4

Kn Kn+1

C-34 Solution 5

Components list

Quantity

Designation

5

Relay, 3-off

2


1


2


1


2


1


1

Manifold

1


1


2


1


1


1


2


1


1



C-35 Solution 6



*

1A

1S1

1S2

2A

2B1

2B2

3A

3B1

3B2

1B

P1 4

2

5

3

2Y1

2Y2

2

1

1Y

4

2

5

3

3Y1 1

3

0Z2

0Z1

1

2

3

* For the purposes of this exercise, feed unit 2A is replaced by a double-acting cylinder.


3Y2 1

K1

K14

1S1

S

1B

BU

BN

4

24 1

23

K9

K7

K5

K2

K13

BK

K2

A1

42

41

14

13

4 5

P2

P1

1S2

K1

2 3 28

14

13

4

A2

K1

3

A2

12 A1

11

4

1

14

13

2

K3

K2

7 29

A2

A1

24

23

5 2B2

6

K4

K7

K3

BK BU

BN

8 9

A2

12 A1

11

14

13

7 K4 14

13

8

K5 A2

A1

24

23

4 11 31

K4

9

BU

2B1 BN

10

K6

K9

K5

BK

12 13

A2

12 A1

11

14

13

11 K6

14

13

12


24 V- 1

C-36

Solution 6



A1

24

21

12 A1

11 18 4 30

A2

K10

K13

K9

21

19 20

A2

12 A1

11

K9

K8

18

11

14

11

17

24

K8

16

24

21

16 17

K8

K11

K7

7 15 4 33

3B2

15

A2

A1

24

23

14

A2

K6

24 V- 13 K10 14

11

19

K11 A2

A1

24

21

15 21 32

K10

20

K12 A2

24 A1

21

24

21

27 22 23

K14

K11

21 K12 14

11

22

C-37 Solution 6


12 A1

11

24

21

1 26 21

K14

K15

K13

18 25 4 34

3B1

25

A2

A1

24

21

24

A2

K13

K12

24 V- 23

K14 34

31

26

K12

25

K15

S

A2

32 A1

31

24

23

27

1Y

34

33

1A+

K1

28

2Y1

24

23

2A+

K3

29 K9 34

31

30

2Y2

24

23

2A-

K5

31 K11 34

31

32

3Y1

34

31

3A+

K7

33

3Y2

44

41

3A-

K13

34

C-38

Solution 6



C-39 Solution 6

In this exercise, two problems can be solved with minimal modifications to the reset sequence:

Memorising of the start signal (K1) for the movement 1A+,

Resetting of the final step (K14) via START button S.


The pressure switch does not switch over until the clamping pressure has been reached; consequently the sequencer stops until the required pressure has built up. In this exercise, sensor 2B1 and 2B2 can be interrogated directly several of times without faulty actuation of the control taking place (compare with exercise 5). Quantity

Designation

5

Relay, 3-off

2


1


1


2


1


1

Manifold

1


1


2


1


1


1


1


2


1


1



Components list

C-40 Solution 6


C-41 Solution 7

Forming press

1A

1S1

2B1

1S2

2B2

2A

4

2

4

1Y

2

2Y 5

1

3

5

0Z2

0Z1

1 3


2

1

3


K1

ES

36 A1

35

14

14 13

14 13

12 13

4 14

K2

K3

S2

S1

K4

K5

11

3

2

14

A2

1

K1

13

2

A2

A1

22

21

24 V- 1

K3

3

K2

A2

42 A1

41

24

23

4

= 0,5s

24

23

5 2B1

6

BU

BN BK

K4

3

A2

A1

7

C-42

Solution 7



1


K5

1S1

34 A1

31

4

1

11 13 15

24

21

10

3 9 14 10

K5

9

A2

42 A1

41

4

1

8

A2

K5

K7

1S2

24 V-

K6 14

11

11 2B2

BU

BN

12

K7

8

K6

BK

A2

24 A1

21

13

1Y

42

41

14

13

1A+

K5

K2

14

2Y

34

31

2A+

K6

15

C-43 Solution 7


C-44 Solution 7


If the EMERGENCY-STOP switch ES is not activated, current path (1) is supplied with current. In order to switch relay K2, the two push buttons S1 and S2 must be actuated simultaneously (START signal). If one of the push buttons is pressed before the other, the time relay with switchon delay is energised which then switches after 0.5 secs. (For safety reasons, the switch-on delay must not exceed 0.5 seconds). The result of this is that the normally closed contact K3 in current path 3 opens and, thus the connection to K2. If two buttons are actuated simultaneously so that the time relay does not switch through, relay K2 is switched and cylinder 1A extends. When the EMERGENCY-STOP switch is actuated, the current to path 1 is interrupted and the solenoid coils are no longer supplied with current. The result of this is that the reset springs reverse the solenoid valves and the cylinders return to the initial position.

Components list

Quantity

Designation

2

Relay, 3-off

1


1

Time relay, 2-off

1


2


1


1

Manifold

1


2


1


1


2


1


1



C-45 Solution 8

Embossing device

1A

1B1

4

2

5

3

1B2

2A

2S1

4

1Y

2

2Y 1

5

0Z2

0Z1

1 3


2

1

3

2S2


K1'

A1

18 13 16

14

11

4 2 6 10

K1

A2

A1

12

11

14

13

3

A2

K6

K1

S1

2

K2

K1

S2

7 11 14 17

A2

22 A1

21

14

13

4

1B1

5

K3

K7

K1

6

8 10 19

A2

22 A1

21

34

31

K2 14

11

7 K3 14

11

8

1B2

9

K4

K7

K3

K1

12 13 20

A2

12 A1

24 11

21

44

41

10

K2 24

21

11 K4

14

11

12


24 V- 1

C-46

Solution 8

S1 = START-button S2 = Manual step mode


TP202 • Festo Didactic S3 = Step repetition A2

24 A1

21

14

11

4

1

20 15 16

K5

K1

K1'

2S2

24 V- 13

K2 34

31

14 K5 14

11

15

K6

1 6

K5

K1'

2S1

A2

24 A1

21

24

21

4

1

16

K2 44

41

17

10

K1'

K7

S3

A2

32 A1

31

14

13

18

1Y

34

31

1A+

K3

19

2Y

32

31

34

31

2A+

K5

K4

20

C-47 Solution 8


C-48 Solution 8


By pressing the START button, the program is started in accordance with the displacement-step diagram.

Manual step mode

By pressing push button S2, it is possible to carry out one movement per actuation in accordance with the program or control sequence.

Step repetition

When, after pressing S2, cylinder 1A has advanced via K3 and cylinder 2A via K4, self-latching at K4 can be reset via K7 by means of push button S3. As a result of this, K4 is de-energised and cylinder 2A retracts. Cylinder 2A is now able to advance again via S2.

Components list

Quantity

Designation

2

Relay, 3-off

2


1


2


1


1

Manifold

1


1


1


1


2


1


1



C-49 Solution 9


2B1 1S1

1S2


2B2

*

2A

1A

4

2

5

3

2

1Y

2Y1 1

1

2

3

2Y2

1

3

0Z2

0Z1

1

2

3

* For the purposes of this exercise, linear drive 2A is replaced by a double-acting cylinder. 2A

2B1

2

4

2Y1

2

2Y2 1


Fig. 9/4: Part of circuit diagram, pneumatic

2B2

3

5

1

3

S1 = Single cycle S2 = Continuous cycle S3 = STOP 4 6

32 A1

31

24

21

14

13

2 5

K2

S3

K5

S2

A2

14

13

3

A2

12 A1

11

14

K1

2 K2 14

13

4

K3

K1

11 25

A2

A1

24

23

5 K2 24

23

6

A2

A1

22

21

19 8 26

K4

ES

K1

K9

K5

11

14

13

1

NA

7

K5

1S2

K4

1 3 18

A2

A1

2

1

14

11

8

1B

9

2B1

BU

BN

10

K6

K9

K3

BK

12 13 21

A2

24 A1

21

14

13

11

K6 14

11

12


S1

24 V-

C-50

Solution 9

1B = Sensing of parts ES = EMERGENCY-STOP


S4 = RESET linear drive

TP202 • Festo Didactic BU

BN

K8

K7

BK

24 A1

21

17 18 23

2B2

16

30 14 15 29

14

11

15

A2

K7

14

A2

K7

24 A1

21

4

1

13

K6

1S1

24 V-

K8 12

11

17

K9

1

K8

K5

A2

24 A1

21

34

31

18

A2

32 A1

31

22

29 20 30

K10

S4

K4

21

19 K10 14

11

20

K11

K13

K12

K6

22 28

A2

14 A1

12 13

11

32

31

21 K11 14

11

22

C-51 Solution 9


K12

A1

24

21 23

K13

K3

21 24

24

A2

24 A1

K12

23

25

A2

K13

42 23

41

34

21

24 K4 24

23

26 S5 32

31

27

1Y

24

1A+

K11

21

28

2Y1

22

34 21

31

2A+

K10

K7

29

2Y2

32

42 31

41

3A-

K10

K7

30


K5

K8

31

24 V- 23

C-52

Solution 9

S5 = RESET gripper


C-53 Solution 9

Line 1 is supplied with current via relay K4 (provided the EMERGENCYSTOP button has not been pressed). The cycle is started via S1 or S2. A latching sequence is then constructed for this motion sequence through current paths 9 to 18. When the EMERGENCY-STOP switch (ES) has been actuated, the gripper is to remain in its current position, whether open or closed. The signal “close gripper” is acquired via relay K6. This signal must be stored after actuation of EMERGENCY-STOP to keep the gripper in a closed position (see current paths 21 and 22). However, this memory must be erased if, at the time of the EMERGENCY-STOP actuation, the control had opened the gripper. In this case, the “open” signal K8 MUST BE STORED (SEE CURRENT PATHS 23 AND 24). Relay K13 is required to ensure that the reset button for gripper S5 is only active when the EMERGENCY-STOP key has already been switched off and the controller has been stopped. This is only released when no start signal or EMERGENCY-STOP signal is present and push button S5 has been actuated. Coil Y2 is actuated by signal K7 and the linear drive proceeds. Selflatching of relay K10 is required to switch the linear drive to unpressurised on actuation of the EMERGENCY-STOP and to memorise this status. This is then reset by RESET button S4 and the unit is returned once again to the initial start position. A new start signal is not memorised until the gripper has actuated limit switch 1S2 (K5). The cycle only starts if parts are present in the outlet channel (sensor 1B) and the initial position of the linear drive (sensor 2B1) is being signalled. Owing to multiple sensing, limit switch 1S2 must be switched indirectly via relay K5.



C-54 Solution 9

Components list

Quantity

Designation

5

Relay, 3-off

2


1


2


1


1

Manifold

1


1


2


1


1


1


2


1


1



C-55 Solution 10



*

1A

1S1

2B1

1S2

*

2B2

3A

3B1

2A

4

2

1Y

4

2

4

2Y 5

1

3

3Y 5

1

3

5

0Z2

0Z1

1

2

3

* In order to assemble this control system on the profile plate, feed unit 1A is replaced by a double-acting cylinder and feed unit 3A by a single-acting cylinder.


2

1

3

3B2

K1

K8

K2

2 5 8

A2

12 A1

11

42

14 41

13

K1 14

13

2

BU

2B1 BN

3

1

K4

K2

S

K3

BK

5 7 19

A2

A1

12

11

14

14 13

13

4

K8

K1

K2

22

24 21

23

14

13

5

K3

1S1

4 9

A2

A1

4

1

6

K4 A2

24 A1

23

4

1

4 8 19 9

K2

1S2

7

K4

K1

24

34 21

33

8

K5

K4

K3

10 12 20

A2

34 A1

31

24

23

9 K5

14

11

10


24 V- 1

C-56

Solution 10

S = START-button

PS = PROGRAM SELECTION button


2B2


BU

BN

24 V- 11

K6

K5

BK

K7

K6 24 A1

21

21 16 18

3B2

15

13 15 21

14

11

14

A2

K6

13

A2

24 A1

21

12 K7 14

11

16 3B1

17

K8

1 5

K7

A2

24 A1

21

18

1Y

42

41

34

33

1A+

K4

K2

19

2Y

34

31

2A+

K5

20

3Y

32

31

34

31

3A+

K7

K6

21

C-57

Solution 10


C-58 Solution 10


Relay K1 is switched via the PROGRAM SELECTOR BUTTON PS. This is only possible prior to actuation of the START button. If program 2 (drilling and reaming) is selected, the latched sequence runs through as usual. However, if program 1 (drilling) is required, it is simply necessary to press the start button. If 1S2 and contact K2 switch the relay K4, the sequencer is reset by K4 and cylinder 1A retracts.

Components list

Quantity

Designation

3

Relay, 3-off

1


1


1


2


1


1

Manifold

1


1


2


1


1


1


2


1


1



C-59 Solution 11

Loading station


*

1A

1S1

1S2

2A

2B1

3B1

2B2

3B2

3A

4

2

1Y

4

2

2Y 5 1 3

2

5 1

3

3Y 5 1 3

0Z2

0Z1

1

2

3

* For the purposes of this exercise, cylinder 1A is replaced by a single-acting cylinder.


4

K1

K10

2 4 15

A2

A1

42

41

4

1

1

K1 14

11

2

2B1

3

S2

K2 A2

A1

42

41

4

24 1

14 21

11

5 6 21 22

K7

K1

K9

4 K2 14

11

5

K3 A2

A1

24

21

12

11

4

1

15 7 22 8

K2

K4

1S2

6 K3 14

11

7

K4 A2

A1

24

21

12

11

4

1

6 9 12 24

K3

K5

1S1

8 K4 24

21

9

K4'

25

A2

A1

10

2B2

11

K5 A2

34 A1

31

24

21

8 12 13 23

K4

K5

12

K6 A2

34 A1

31

12

11

21 13 22 14

K5

K6

13


S1

24 V-

C-60

Solution 11

S1 = START button S2 = Sensing of steel parts



4

A2

25

A2

A1

K8

A1

31 32

K3

34

24

21

K1

31

15 K1

R2

R1

14

13

16

3B1

BU

BN

17

BK

K9

Electromagnet

K7

K6

14

4

A2

A1

18

3B2 BK

K10

BU

BN

19

1 16

A2

A1

20

32

31

34

42

41

1A+

K6

42

41

44

41

22

K5

K2

1Y

Electromagnet

H1

K6

K2

31

21 K5 44

41

23

44

2A+

2Y

K4

41

24

3Y

14

11

14

3A+

K4'

K8

11

25

C-61

Solution 11


C-62 Solution 11


The cycles of the control are counted to enable cylinder 3A to extend. Where there is a preselected figure 2, cylinder 3A is extended together with cylinder 2A on the second cycle of the control system in order to bring the part past position 2. If cylinder 3A has extended, start condition K1 is reset via 3B2 (K10) and the counter is reset to zero.

Components list

Quantity

Designation

4

Relay, 3-off

1


1


2


1


2


1


1

Manifold

1


1


2


1


1


1


2


1


1



C-63 Solution 12



*

3A

1A

1B1

2A

1B2

2S1

2S2

3B1

3B3

2B

P1

4

2

5

3

4

2

4

2Y

1Y 1

3Y 5

1

3

5

0Z2

0Z1

1

2

3

* For the purposes of this exercise, cylinder 1A is replaced by a single-acting cylinder and feed unit 3A by a double-acting cylinder. The inductive proximity sensor 3B2 is switched to mid-position by the trip cam.


2

1

3

3B2

K1

S3

S1

S2

A1

4

1

4 29

K2

2S1

2 4

14

13

A2

K1

3

A2

32 A1

31

14

13

2

K3

K14

K2

K1

5 7 32

A2

14 A1

11

4

14 1

24 13

23

4 K3 14

13

5 1B2

6

K4

K3

8 10 33

A2

24 A1

23

7 K4 p 14 p1 2

13

8 2B

9

BU

BN

K5

K4

BK

11 14 22 35

A2

A1

24

23

10

K5'

K5

37

A2

A1

14

13

11 3B3

BU

BN

12

K6

BK

20 14 16

A2

A1

13


24 V- 1

C-64

Solution 12

S1 = START-button S2 = Part of the stop S3 = STOP-button


C-65 Solution 12



1B1

K13

K12

K2

17 30 31 35

A2

24 A1

21

24

23

29 K13 24

21

30

K14

4

2S2

A2

A1

4

1

31

1Y

32

31

34

33

1A+

K12

K3

32

2Y

42

41

34

33

2A+

K12

K4

33 K13 42

41

34

3Y

42

41

32

31

44

41

3A+

K11

K7

K5

35

K10 34

31

36

H1

K12'

K5'

12

11

14

11

37


24 V- 28

C-66

Solution 12

Grinding wheel


C-67 Solution 12

When the installation is started up and the initial position of cylinder 2A (2S1) and a workpiece (S2) are signalled, cylinder 1A extends. Then cylinder 2A extends and clamps the part. When the clamping pressure has been reached, cylinder 3A is extended via K5. Sensor B5 is activated in the forward end position. This in turn activates relay K6. Then feed cylinder 3A retracts again. In addition, K6 passes on a counting pulse to the preselect counter.


Sensor 3B2 is activated when the cylinder has retracted by a half. This then reverses the valve via further contacts (K6, K7, K9) and cylinder 3A extends again. This sequence is carried out until the preselected figure has been reached. If 3B2 is activated on the return stroke, the valve may not switch since counter contact K9 interrupts the circuit. The sequence is switched on via a second counter contact. Quantity

Designation

5

Relay, 3-off

2


1


2


1


2


1


1

Manifold

1


1


1


2


1


1


1


1


2


1


1



Components list

C-68 Solution 12


C-69 Solution 13

Assembly unit

2A

*

1A

1S1

2B1


2B2

3B1

1S2

3B2

3A

4

2

5

3

2Y1 4

2

5

3

1Y1

2Y2 1

1Y2 1

2

5

3

3Y1

0Z2

0Z1

1

2

3

* For the purposes of this exercise, cylinder 1A is replaced by a single-acting cylinder.


4

3Y2 1

S2

4 32 36 40

K1

A2

2B1

2

1

K2

5 6

A2

12 A1

11

14

14 13

13

3

K5

K11

S1

24

23

2

K1 12

11

4

K2 14

11

5

A2

A1

24

21

19 7 29

K3

K2

6

K4

K7

K3

1S2

8 9

A2

12 A1

11

14

4 11

1

7 K4 14

11

8

K5 A2

A1

24

21

4 11 33

K4

9 2B2

10

K6

K9

K5

12 13

A2

12 A1

11

24

21

11 K6

14

11

12


A1

14

13

24 V- 1

C-70

Solution 13

S1 = OFF/ON S2 = MAN/AUT


TP202 • Festo Didactic K7 K8

K11

K7

BK

42 A1

41

24

21

16 17 28

BU

BN

15

7 15 37

3B2

14

A2

A1

24

21

13

A2

K6

24 V-

K8 14

11

16

K9 A2

A1

24

21

11 19 31 39

K8

17

BU

3B1 BN

18

K10

K3

K9

1S1

BK

20 22 23

A2

22 A1

21

24

4 21

1

19 K10 14

13

20

K12 42

41

21

K11 A2

A1

24

23

15 4 35

K10

22

C-71

Solution 13


K12 K13

S5

S4

S3

A1

32

32 31

14 31

13

32 30

14

13

21 24

K12

A2

A1

34

33

24

A2

K10

23

25

K14

36 34

A2

A1

42

14 41

32 13

31

26

K15

40 38

A2

A1

14

42 13

42 41

41

27

H1

28

1Y1

34

31

1A+

K3

29 K13 14

13

30

1Y2

34

31

1A-

K9

31

K13

K1

42

41

22

21

32


24 V-

C-72

Solution 13

MAN



2Y1

34

31

33

2A+

K5

24 V-

K14 14

13

34

2Y2

24

23

2A-

K11

35

K14

K1

42

41

32

31

36

3Y1

34

31

3A+

K7

37 K15 14

13

38

3Y2

42

41

3A-

K9

39

K15

K1

42

41

42

41

40

C-73

Solution 13


C-74 Solution 13


When the “MAN/AUT” switch S2 or relay K1 is not actuated, voltage is applied at line 1 (MANUAL mode). The cylinder can be extended individually via push buttons S3, S4 and S5. Cylinder 1A extends and remains in the extended position for as long as push button S3 is actuated or an additional push button is pressed. Movement is prevented if two or three push buttons are pressed simultaneously. To ensure that there is no interference with AUTOMATIC mode, the lines to the normally closed contacts of relays K13, K14 and K15 are each interrupted by a normally closed contact of K1. As soon as line 2 (AUTOMATIC mode) is supplied with current, selflatching is set via the normally closed contact K12 in current path 12. At the same time, when K10 goes into self-latching, relay K12 is switched via a normally open contact K10. This also goes into self-latching and the normally closed contact K12 in current path 21 opens. Thus, the last step which is normally required as a start condition can be activated without the use of a SET button.

Components list

Quantity

Designation

5

Relay, 3-off

2


2


1


2


1


1

Manifold

1


1


2


1


1


3


1


1



C-75 Solution 14

Moulding press


1A

1B1

2B1 2B2

1B2

2B3

*

3A

3S1

2A

4

2

5

3

1Y

4

2

5

3

4

2Y 1

2

3Y 1

5

1

0Z2

0Z1

1

2

3

* For the purposes of this exercise, the double-acting cylinder is replaced by a singleacting cylinder.


3

3S2

K3

K1

S1

3

A2

42 A1

41

14

13

S2 14

13

2

K2

4

K1

A2

14 A1

13

3

K3

1

K2

K5

K14

7 30

A2

42 A1

42 41

14 41

24 11

24 23

23

4 1B2

5

K4

24 7 9

A2

A1

6

K5

4

K11

K3

K4

8 10 31

A2

12 A1

11

14

14 13

13

7 K5 14

13

8

K6

K4

10

A2

A1

24

23

9

K7 A2

24 A1

23

18

17

31 11 13

K5

K6

10 K7

14

13

11


24 V- 1

C-76

Solution 14

S1, S2 = START-button


1B1

24 V- 12


15 16 27 33

24 13 15 32

K9

24 A1 A2

24 A1

K10

24 A1

21

4

1

7 19

K11

K10

3S1

33 17 18 25

14

11

18

A2

K10

17

A2

24 A1

21

K9

1

21

K8

3S2

23

11 4

K9

16

14

2B3

15

14

11

14

A2

K7

K8

13 K11 24

21

19

BU

2B1 BN

20

K12

BK

27 26

A2

A1

21

C-77

Solution 14


2B2

24 V-

BU

BN

22

K13

BK

4 25

24

42 A1

41

32

31

14

11

A2

K14

K4

K8

K13

24

A2

A1

23

K10

K14

34

31

24

21

25 K12 14

11

26

K15

K12

K9

28 29

A2

22 A1

21

34

31

27 K15 14

11

28

H1

K15 24

21

29

1Y

24

23

1A+

K3

30

K7

K5

42

41

34

33

31

2Y

44

41

2A+

K8

32

3Y

42

41

44

41

3A+

K10

K9

33

C-78

Solution 14


Vacuum generator


C-79 Solution 14

The two-hand safety control is realised in current paths 1 to 4. Relay K2 serves here as a delaying element. The maximum time duration allowable between the actuation of S1 and S2 is dependent on the switching time of this relay.


If the two push buttons S1 and S2 are activated simultaneously, cylinder 1A extends. These buttons must remain depressed until the cylinder has reached its forward end position. The start condition is decided by the connections in current paths 24 26. It has been established that the signal from signal generator B5 only becomes effective when the extractor unit leaves the working area, i.e. on the return stroke of cylinder 2A. Relay K15 starts the operation of the vaccum generator which must be specially stored as the sequence is set before the retraced end position of cylinder 2A is reached. Quantity

Designation

5

Relay, 3-off

1


1

Time relay, 2-off

2


1


2


1


1

Manifold

1


1


1


2


1


1


1


2


1


1



Components list

C-80 Solution 14


C-81 Solution 15

Pick-and-place unit


1A

1S1

2B1

1S2

*

2B2

3A

3B1

2A

4

2

5

3

1Y

4

2

5

3

4

2Y 1

3Y 1

5

0Z2

0Z1

1

2

3

* For the purposes of carrying out this exercise on the profile plate, cylinder 3A is replaced by a single-acting cylinder.


2

1

3

3B2

S3

S2

K1

K15

S1

2 4 22

A2

12 A1

11

14

13

14

14 13

13

K1 14

13

2

H1

24

23

3

K2

K15

K1

K3

1S2

5 7 40

A2

22 A1

21

24

42 23

41

4

1

4 K2 14

13

5

BU

2B1 BN

6

K4

K3

4

K2

BK

8 10 36

A2

24 A1

23

12

11

7 K3 14

13

8 3B2

9

K4 A2

24 A1

23

12

11

7 11 41 13

K3

K5

10 K4

24

21

11


24 V- 1

C-82

Solution 15

Magazine

S1 = START-button S2 = Gear housing S3 = Magazine


3B1

24 V- 12


K5 A2

13 16 17 42

10 14 15 38

A1

A1

K6

34

34

K5

31

11

4

1

31

K7

1S1

12

24

21

15

12

K5

14

A2

K4

K6

11

13 K6 24

21

16

K7 A2

A1

34

31

12

15 18 36 20

K6

K8

11

17 K7 24

21

18

K7'

42

A2

A1

19

K8 A2

A1

34

31

12

17 21 38 22

K7

K9

11

20 K8 24

21

21

K9 A2

A1

34

31

34

12 33

11

20 23 25 37

K8

K1

K10

22 K9 24

21

23

K9'

43

A2

A1

24

C-83

Solution 15


K10

31

A2

25 28 31 39

22 26 43 27

A1

A1

K11

34

34

K10

31

41 42

K12

42

41

24

27

A2

K9

K11

K10

21

26 K11 14

13

28

K11'

40

A2

A1

29

BU

2B2 BN

30

K12 A2

A1

24

23

14

27 31 32 44

K11

BK

K12

13

31

K13 A2

A1

24

23

14

44 32 33

K12

K13

11

32

K14 A2

K15 A2

A1

24

21

32

31

34

1 4

K14

S2

A1

24

21

14

39 33 34

K13

K14

11

33

H2

24

23

35


24 V- 25

C-84

Solution 15

Gear housing


TP202 • Festo Didactic H3

K7

K3

42

K13 32

31

41

41 44

K9

37

34

33

24 V- 36

1Y

42

41

44

41

1A-

K8

K5

38

K14

K11

32

31

34

33

39

2Y

42

41

34

33

2A-

K11'

K2

40

3Y

42

3A+

K4

41

41

K7'

K6

12

11

44

41

42

K10

K9'

42

41

14

11

43

K13

K12

32

31

34

33

44

C-85

Solution 15


Vacuum generator

C-86 Solution 15


If one of the magazines is empty, then the installation remains stationary at position 1 or 2 by resetting the START signal, and waits there until the magazine has been filled and a new START signal is issued (see current paths 1, 4, 22). In order to fulfil the gear sensing, it is necessary to establish whether a gear housing is available (starting precondition). When the assembly has been completed, the gear housing must be removed. Without this, it will no longer be possible to start the installation (see current path 1, 4, 34).

Components list

Quantity

Designation

6

Relay, 3-off

2


2


1


2


1


1

Manifold

1


1


2


1


1


1


3


1


1



C-87 Solution 16

Galvanising process

1B1

1B3

1B2

1A

4

2

1Y 5

0B

1

3

P1 0Z2

0Z1

1 3


2


1B1

BU

BN

K21

BK

K2

22 3 4 26

A1

42

41

14

14 13

11

14

14 11

11

2

K1

S

K21

K15

K13

2

A2

0B

1.2

A2

A1

1.1 K1 14

13

3

K2

5 6 42

A2

A1

42

41

24

24 23

21

1A+

2

K5

K1

K15

4 K2 14

13

5

Bad 1

H1

6

K3

K2

8

A2

A1

24

23

7

K4

9 10

A2

A1

12

11

14

14 13

11

1A-

K7

K3

K18

8 K4 14

13

9

K5 A2

A1

24

23

4 11 27

K4

10


24 V- 1.0

C-88

Solution 16

S = START-button



12 14 44

A2

A1

12

11

14

34 13

1A+

K9

K5

K15

31

24 V- 11 K6 14

13

12

H2

13

K7 A2

K8

A1

24

1A-

16 17

A2

A1

12

11 18 28

A2

K10

44 21

19 21 43

A2

A1

22

1A+

K13

K9

K15

21

K9

K8

41

18

11

14

21

17

24

K8

11

16

24

36 21

35

15

K11

K7

K19

A1

24

8 15 36

K6

23

14 K10 14

11

19

H3

20

C-89

Solution 16


Bath 3

Bath 2

1A-

23 25 29 45

A1

42

41

24

24 21

21

15 22

K12

K1

K11

K18

A2

A1

24

21

A2

K11

K10

22

K12 14

11

23 S1 14

13

24

A2

A1

24

21

18 2 37

K13

K12

25

K14 A2

A1

34

33

t1

34 30 45

K1

26 K5 24

23

27 K9 34

31

28 K12 34

K15

K14

31

29

2 4 11 18

A2

A1

18

17

30 1B3

K16

BK BU

BN

31

33 37

A2

A1

32


24 V- 21

C-90

Solution 16

S1 = SET-button



K14

Z

35

A2

A1

14

11

R2

R1

36

35

34

K18

A2

A1

14

11

40 8 22

K17

35

K19 A2

A1

32

t2

15

K7

31

36

K20 A2

A1

12

11

32

31

24

21

42 38

K22

K13

K16

37 K20 14

11

38

3

1B2 1

39

37

K18

K22

4

S2

A2

A1

32

31

40

1Y

S2 = Up/Down

K17

K16

24 V- 33

1A+

14

13

41

K20

K2

22

21

34

33

42 K10 34

31

43 K6

K12

H4

K14

34

33

44

28

44 27

41

45

C-91

Solution 16

Work surface

t1 > tReturn stroke

oscillate


C-92 Solution 16


Initial position: Cylinder 1A is retracted and is located above the work surface and lamp H4 is illuminated. Cylinder 1A can be extended via the up/down switch (current path 41). Once the initial start position has been regained, the cycle is started with the start button. Then lamp H4 is switched off and the time t1 expires. This switches lamp H1 (bath 1 reached) and allows cylinder 1A to extend via relay K2. Counting pulses are passed on to the counter via 1B3 (current paths 31-34). Additionally, 1B3 reverses the valve so that cylinder 1A retracts as far as 1B2. As a result, cylinder 1A is switched back to “Extend” (current paths 37-40). This oscillating movement of cylinder 1A is repeated until the counter switches and interrupts the signal of sensor 1B2. When the cylinder has retracted, time delay t1 is activated once again by relay K5, which switches relay K6 when it has completed its cycle. Lamp H2 is illuminated and cylinder 1A extends. Next, the delay period t2 of the basket in bath 2 is switched via K7. Then, relay K8 switches, cylinder 1A retracts once again and the time t1 is repeated. When the time relay has switched, the cylinder enters bath 3 and the motion sequence carried out for bath 1 is repeated. Time period t1 is then activated a final time and signals the initial start position via lamp H4. The time t1 must be longer than the time which the cylinder requires for its return stroke.


C-93 Solution 16

Quantity

Designation

6

Relay, 3-off

1


1

Time relay, 2-off

1


1


1


1


1

Manifold

1


1


2


1


1


1


1



Components list

C-94 Solution 16


C-95 Solution 17

Loading station

Fig. 17/4: Circuit diagram, pneumatic 1B 1

*

1A1

1B2

1A2

2B1

2B2

2A

1V1

1Y1

4

2

5

3

1V2

1Y2

4

2

5

3

2V

2Y1

4

2

5

3

2Y2 1

3A

3S1

1

1

3S2

*

4S

4M

3V

3Y1

4

5

2

1

4V

3Y2

4Y

3

4

5

2

1

4B

3

0Z2

* For the purposes of this exercise, the rotary actuator (4M) is replaced by a singleacting cylinder, and the rodless cylinder (1A) by a double-acting cylinder.


0Z1 1 3

2

1B1

24 V- 1

3A+

24 A1

21

14

11

1A+

K2

K1

K2

35 5 6 39

1B2

5

3 5 35 36

14

11

4

A2

42 A1

41

14

K1

3

A2

K7

K1

S

13

2

K3

K2

K9

7 8 20

A2

24 A1

21

14

13

6 K3 14

11

7 11

K4 A2

24 A1

21

14

11

4M+

20 9 10 44

K3

K18

14

K19

8

12

K4 14

11

9

K5 A2

24 A1

21

14

13

4M-

44 11 12 34

K4

K11

10 K5

14

11

11

C-96

Solution 17


S = START-button



K7

K6

K8

A2

24 A1

23

14

13

1A-

14

13

3A-

K6

14

2

A2

24 A1

21

14

13

13

39 13 14 42

K6

K5

K10

24 V- 12

K8

3S1

14 28

A2

A1

4

1

15

K9

3S2

6 20

A2

A1

4

1

16

K10

4S

12 24

A2

A1

4

1

17 4B

18

K11

10 22

A2

A1

19

K12

21 22 33 43

A2

34 A1

22 31

32 21

31

24

23

4M+

K3

K18

K4

K9

20 K12 14

11

21

K13 A2

24 A1

21

24

23

4M-

33 23 43 24

K12

K11

22 K13 14

11

23

C-97

Solution 17


K14

24 A1

21

14

11

3A-

K15

K14

K15

2A-

2B1

39 27 28 41

14

11

25 27 37

K14

27

A2

24 A1

21

24

23

26

A2

K13

K10

25

A2

24 A1

21

24

23

2A+

37 29 31 38

K16

K15

K8

28 K16 14

11

29 2B2

30

K17 A2

24 A1

21

14

11

3A+

41 31 32 40

K16

K17

31

K18 A2

A1

24

21

20 8

K17

32

K19

8

K13

K12

8

A2

32 A1

31

34

31

33 K5

R2

R1

34

31

34


24 V- 24

C-98

Solution 17



1Y1

32

31

34

1A+

K2

K1

31

24 V- 35

1Y2

44

1A+

K1

41

36

2Y1

32

31

34

2A-

K16

K14

31

37

2Y2

44

2A+

K16

41

38

3Y1

42

41

32

44 31

3A+

K6

K15

K2

41

39 K17 34

31

40

3Y2

42

44 41

3A-

K17

K15

41

41 K6 34

33

42

4Y

42

44 41

4M+

K13

K12

41

43

H1

K5

K4

42

44 41

41

44

C-99

Solution 17

Suction cups Fig. 17/8: Circuit diagram, electrical (4)

C-100 Solution 17

Solution description Main program

The loading station is located in step 21 of the subroutine. When the START button has been pressed, K1 causes cylinder 1A to extend. Then cylinder 3A is extended via K2 and cylinder 3A is switched to the unpressurised condition. Next, the jump from K3 to K12 into the subroutine takes place. When the subroutine has run through, the return jump through K18 and K19 to K4 in the main program takes place. Cylinder 4M advances and is retracted by K5. The, cylinder 3A is retracted by K6 and cylinder 1A by K7.

Subroutine

Movements 4M+, 4M-, 2A- (with every 2A- movement, cylinder 1A which has been switched unpressurised, is pushed back by a partial stroke), 3A-, 2A+, 3A+ are executed in the subroutine and repeated three times via a counter. When the counter has reached the preselected figure, the return jump to the main program is carried out.

Comment

In the case of this motion sequence, costs make it necessary to realise this by means of a repetition of a program section (subroutine). Increased expenditure on planning is justified here by a considerable saving on relays and very much simpler circuitry, so that in this case, the solution shown is more economical than a solution with the full sequence which requires less planning.


C-101 Solution 17

Quantity

Designation

6

Relay, 3-off

1


1


2


1


3


1


1

Manifold

1


1


1


2


1


1


1


2


2


1


1



Components list

C-102 Solution 17


C-103 Solution 18


3 5

1

2 4

8Y

8A

3 5

7Y

7A

1

2 4

7S2 7S1

2Y1 3 1 5

1Y2 1Y1

3 1

3

8S1

3 5

1

2 4

2Y2

8S2

9Y

9A

5

4

1

2

9S1

3 1 5

3Y1 2A 2 4

5

4

10Y

10A 9S2

4Y1 3Y2 2 4

2S2 2S1

(2B1) (2B2) 1A

3

3 5

2

10S1 10S2

5

4A

4

1

3

4Y2 2

11Y

4

1

2

11S1 11S2 11A

5Y1

4S2 4S1 3S2 3S1 3A 1S2 1S1

(1B1) (1B2)

5

12Y

4

1

2

3 5

3 5

5A

4

1

2

5S1

5Y2

5S2

6Y

6A

4

1

2

(6S) 6S1

(6B) 6S2


For the purposes of this exercise, cylinders 3A and 4A are not constructed. Feed units 6A to 11A are represented in the construction by a single-acting cylinder. The on/off valve with filter regulator and manifold are not represented.


24 V-

36

35

K1

1 3 6

A2

A1

32

31

24

18

17

3

4 2B1

H2

S1 = ON S3 = Sensing of parts S2 = AUTO/MANUELL S4 = OFF

H1

K1

S4

23

13

14

32

14

K1

31

5

K2

K1

A2

28 A1

42 27

41

14

14 11

4 13

36 7 8 34

K6

K16

S3

6S

1

6 K2 14

13

7

K3 A2

A1

24

23

28 11 44 57

K2

8 1B2

9

K4

11 24 34

A2

A1

10

K5

K9

K3

K4

13 14

A2

12 A1

11

14

13

14

13

11 K17 14

11

12 K5

14

13

13

K6 A2

A1

24

23

6 17 46

K5

14


S1

S2

2

13

1

C-104

Solution 18

START

Pump


1B1

24 V-

15

K7


18 19 52

17 28 51

12 A1

11

14

13

14

13

A2

K8

K11

K6

K7

17

A2

A1

16

K8 14

11

18

K9 A2

A1

24

21

11 21 36 49

K8

19 2B2

22 23

A2

12 A1

11

24

4 21

1

21

K13

K9

5S2

BK

K10

BU

BN

20 K10 14

11

22

K11 A2

A1

24

21

17 24 45 53

K10

23

K12 A2

22 A1

21

24

4 21

1

24

23

34 25 26

K16

K11

5S1

K4

24 K12 14

11

25

K13 A2

A1

24

21

21 28 47 55

K12

26 6B

27

K14

K3

K13

K7

29 31 33

A2

42 A1

41

24

24 21

23

28

C-105 Solution 18


K14

14

11

29

24 V-

K15

12

11

30

K15

S5 = EMERGENCY-Stop S6 = RESET K16

K14

A1

34

24 6 50

24

30 32

K15

31

33

A2

A1

24

21

32

A2

K14

21

31

K17 A2

32 A1

31

34

33

34

44 12 35 43

K12

K4

K2

33

K17 24

21

35

K18

K2

K9

37 56

A2

42 A1

41

34

31

36

K18 14

11

37

K19

S6

48 51 54

A2

A1

14

13

38

K20

56

A2

A1

24

23

39

S5 22

21

40

K21

50 42

A2

A1

32

31

14

13

41 K21

14

11

42


34

C-106

Solution 18



H3

K17

24 V-

34

31

43

1Y1

42

41

24

23

1A+

K17

K3

44

K11

24

23

46

1A-

K6

1Y2

34

31

45

K13 34

31

47

K19

44

41

49

2A+

K9

2Y1

14

11

48

2Y2

22

21

34

31

2A-

K21

K16

50 K7

K19

34

31

52

5A+

K8

5Y1

34

33

24

21

51

5Y2

44

41

5A-

K11

53

K19 34

31

54

6Y

K18

K20

44

41

6A+

K13

55 K3

12Y

18

17

24

21

56

34

33

57

C-107 Solution 18

Air blast Fig. 18/7: Circuit diagram, electrical (4)

Vacuum generator

C-108 Solution 18


Current paths 1 to 3 fulfill the following functions: START and STOP via push buttons, display of the start signal and simulation of the central lubrication system. Power to the installation is switched off with the EMERGENCY-STOP in order to add a memory and secure the movement 2A-. Otherwise, cylinder 2A would retract as a result of the automatic setting condition if cylinder 1A is already located in its initial start position. The status of the vacuum generator is stored by current paths 33 and 34. After EMERGENCY-STOP, the unit is reset and a restart can be made. If the fact that the vacuum generator is active has now been stored, steps 1 and 2 (1A+, 1A-) are now skipped because a workpiece has already been collected. In manual mode, the initial start position of the machining station can be achieved via the RESET button, cylinder 2A only being able to retract when cylinder 1A is in its initial position. In addition, processing is started via the RESET key if memory K18 reports that no processing has yet been carried out. Memory K21 (EMERGENCY-STOP actuated) is reset. In order to limit the cost incurred through additional equipment, relay K21 can be replaced by the counter (preselected figure 1).


C-109 Solution 18

40

Fig. 18/8: Circuit diagram, electrical (3) Addition with counter

41

21

13

22

14

S5

38

39

13

23

31

14

24

32

S6

A1

K19

A1

K20 A2

A2

S5 = EMERGENCY-STOP S6 = RESET


A1

R1

A2

R2

K21

C-110 Solution 18

Components list

Quantity

Designation

6

Relay, 3-off

2


1

Time relay, 2-off

2


1


3


1


1

Manifold

1


1


1


1


2


2


1


2


3


1


1



C-111 Solution 19

Checking station

Fig. 19/3: Circuit diagram, pneumatic 2A 1B1

2B1

*

2B2

1B2

4A 3A

3S

4S1

3B

1A

4

2

5

3

4

2Y 4

2

5

3

4Y 1

4

2

3Y 1Y1

1

5

1Y2

1

3

0Z2

0Z1

1

2

3

* For the purposes of this exercise, cylinder 4A is to be replaced by a single-acting cylinder.


2

5

1

3

4S2

S1 = START-button

K1

S2

K3

K2

S1

A1

4

1 5

K2

3S

2 5

14

1

A2

K1

13

3

A2

32 A1

31

14

14 13

14 13

13

2

K3

4S1

1 5

A2

K3

K2

K1

K4

K19 A1

4

1

4

6 9 37 39

A2

18 A1

17

24

24 23

24 23

23

5 K4 14

11

6

BU

1B2 BN

7

K5

BK

9

A2

A1

8

A2

24 A1

21

14

37 10 16 38

K6

K4

K5

11

9 K6 14

11

10

BU

1B1 BN

11

K7

BK

15

A2

A1

12


24 V- 1

C-112

Solution 19

S2 = STOP-button


2B1

24 V- 13

K8

S3 = Tolerance check

TP202 • Festo Didactic 16

15

A1

K9

K6

K10

= 3s

14

14 13

13

A2

K9

K8

K7

15

A2

A1

14

17 21 23 33

A2

A1

24

21

18

17

16 K10 14

11

17

39

K10' A2

A1

18 2B2

19

K11

23

A2

A2

A1

24

21

14

13

21

41 22 40

K12

K10

S3

A1

20 K12 14

11

22

C-113 Solution 19


K13

K10

K11

31

K15

A1

14

13

28 29

K14

A1

4S2

24 29 40 41

3B

27

A2

14

11

26

A2

K13

25

A2

A1

34

31

14

11

24

K16

K14

A2

A1

14

11

28

K17 A2

A1

24

21

24

21

40 32 33 36

K13

K14

29

K17'

41

A2

A1

30 K15 14

11

31 K17

14

11

32


24 V- 23

C-114

Solution 19


S4

K17


= Interrogate container

K18

5

A1

22

21

35 34

K19

14

11

35

A2

44 A1

41

K18

34

A2

K18

K10

14

24 13

21

24 V- 33

H1

K17 34

31

36

1Y1

32

31

34

31

1A+

K6

K4

37

1Y2

44

41

1A-

K6

38

2Y

12

11

44

41

2A-

K10'

K4

39

3Y

42

41

24

34 21

31

3A+

K17

K12

K13

40

4Y

12

11

32

44 31

41

4A+

K17'

K12

K13

41

C-115 Solution 19


Conveyor belt

C-116 Solution 19


In this solution, end position sensing is indirectly interconnected. The START and STOP conditions for continuous cycle using one push button each, are both realised by means of relay K1. Selection between tolerance conditions Good/Reject is made with the switch S4 (K12), with the result that either cylinder 3A or 4A extends. Parts are counted by 3B (position C+) indirectly via K14. The conveyor belt is started by the final step (K17) and does not stop until the timer which resets the sequence has run through. The time delay is not started until the control is in the final step and a container (S4) has been signalled as being present. The time element with switch-on delay is activated immediately after power supply has been switched on, meaning that interruption of this causes delayed start-up behaviour. That is, the time element switches to its normal position when the time has expired. However, for this purpose it is necessary to store the interruption signal (see K18).

Components list

Quantity

Designation

6

Relay, 3-off

1


1

Time relay, 2-off

1


2


1


3


1


1

Manifold

1


1


1


2


2


1


1


2


1


1


1



C-117 Solution 20

Handling device

1A

1S1

2B1

1S2

2B2


2A

4

2

5

3

4

1Y

2

2Y 1

5

1

3

4M

* 3A

3B1

4S

3B2 4B

4

3Y

5

2

1

3

4

4Y1

5

2

1

3

4

4Y2

4Y3

0Z2

0Z1

1

2

3

* For the purposes of this exercise, cylinder 1A is replaced by a single-acting cylinder. Rotary actuator 4M is replaced by a double-acting cylinder.


5

2

1

3

4Y4

S6

S1 = START-button S2 = MAN/AUT S3 = Sensing of parts

S4 = STOP S5 = RESET S6 = EMERGENCY-STOP

3 12

46 2 48 45

6

A2

K2

12 A1

32 11

14 31

14 13

14 11

13

14

14 13

A2

K1

K3

S4

K18

S3

A1

K1

11

2

K2

14

13

32

31

3

H1

4

K3

2

K15

A2

A1

14

11

5

K2

R2

R1

42

24 41

23

6 K4

K4

14

S5

13

7

7 50

A2

A1

14

K5 A2

A1

12

11

18

17

9

22 10 30

K16

K10

13

8

K5 14

13

10

3B1

11

K6

1A+

A2

A1

24

23

24

2A+

K7

K6

K15 14

21

14

15 16 41

A2

A1

12

11

24

K6

13

13

13 14 42

K13

K2

23

12

K7

A2

A1

24

23

4

1

16

2A-

42 17 19

K7

K8

14

1S2

13

15

K8 14

13

17


S1

S2

22

21

24 V- 1

C-118

Solution 20

START


1B1


K9' A2

45

A2

20 24 30 44

K10

11

14

11

42

K16

41

9 24

A2

A1

A1

K11

K17

K5

22

A1

3A+ 4M+

K9

14

11

21

12

K9

20

24

23

19

BK

K8

BU

BN

18

24 V-

24

K11

A2

A1

24

21

28

27

24

1A-

22 25 41 26

K9

K11

K10

21

23 K12

A2

A1

34

31

4

1

26

30 27 44 29

K11

K12

24

1S1

21

25

K12'

14

11

27

45 47 49

A2

A1

28

12

K12

A2

31 43

A2

A1

32

31

22

24 21

34 23

K14

31

30

K17

K5

K9

K14

A1

24

21

24

21

3A- 4M-

K13

K12

K18

29

14

11

31 1B2

5 14

A2

A1

33

BK

K15

BU

BN

32

C-119 Solution 20


3B2

K16

4S

30 22

K18

9 23

K17

A1

37

A2

4B

36

A2

A1

35

2 29

A2

A1

4

1

38

H2

39

H3

40

1Y

42

2Y

2A+

42

41

41

K8

34

K6

33

42

34

1A+

K11

K7

33

41

3Y

24

3A+

K14

21

43

42

41

44

4M+

4Y1

K12

K9

41

44

4Y2

12

14 11

24 11

4M+

K12'

K9'

K1

21

45

K1

4Y3

24

21

47

4M-

K12'

32

31

46

K1

4Y4

34

31

49

4M-

K12'

42

41

48

K4 24

23

50


34

24 V-

C-120

Solution 20

MAN

AUTO


C-121 Solution 20

The continuous cycle is introduced via the START button. The handling device then runs until a STOP is actuated at the end of the cycle or until the counter has reached the preselected figure or no parts are reported as being present.


At this point, lamp H1 indicates whether the start signal is still stored. Memories K5 and K14 cause cylinder 3A to move every second cycle. Lamp H2 indicates that the installation is operating in AUTOMATIC mode. H3 lights up when MANUAL mode is operating (RESET). Quantity

Designation

6

Relay, 3-off

2


1

Time relay, 2-off

1


2


1


3


1


1

Manifold

1


1


1


1


2


2


1


2


2


1


1



Components list

C-122 Solution 20


[FESTO] Electropneumatics - Workbook Advanced Level.pdf

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