Elektropneumatika Seminari

541090 EN 04/05

2 © Festo Didactic GmbH & Co. KG • 541090

The Festo Didactic Learning System has been developed and produced solely for

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

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

precautions specified in this workbook..

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

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

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

such damages are caused by intention or gross negligence on the part of Festo

Didactic.

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

541090 04/2005 M. Pany, S. Scharf Frank Ebel Doris Schwarzenberger 09/2005

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

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

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

Intended use

© Festo Didactic GmbH & Co. KG • 541090 3

Preface______________________________________________________________ 5

Introduction__________________________________________________________ 7

Notes on safety and operation ___________________________________________ 9

Technology package for electropneumatics (TP200) ________________________ 11

Training aims of Basic Level (TP201) _____________________________________ 13

Allocation of training aims and exercises _________________________________ 15

Equipment set – Basic Level (TP201) _____________________________________ 17

Allocation of equipment and exercises ___________________________________ 21

Methodological help for the trainer ______________________________________ 23

Methodological structure of the exercises_________________________________ 25

Designation of equipment _____________________________________________ 26

Contents of the CD-ROM _______________________________________________ 27

Equipment set – Advanced Level (TP202) _________________________________ 29

Training aims – Advanced Level (TP202) __________________________________ 30

Part A – Exercises

Exercise 1: Realising a sorting device ____________________________________A-3

Exercise 2: Realising a shut-off device___________________________________A-15

Exercise 3: Realising a lid press ________________________________________A-25

Exercise 4: Realising the operation of a hinged lid _________________________A-35

Exercise 5: Realising a diverting device __________________________________A-43

Exercise 6: Actuation of a stacking magazine _____________________________A-53

Exercise 7: Sorting of packages ________________________________________A-65

Exercise 8: Actuation of a sliding platform _______________________________A-73

Exercise 9: Expanding a diverting device_________________________________A-81

Exercise 10: Designing a stamping device________________________________A-91

Exercise 11: Realising a pallet loading station __________________________ A-101

Exercise 12: Eliminating a fault on the pallet loading station_______________ A-107

Contents

Contents


Part B – Fundamentals

Part C – Solutions

Exercise 1: Realising of a sorting device __________________________________C-3

Exercise 2: Realising a shut-off device___________________________________C-15

Exercise 3: Realising a lid press ________________________________________C-23

Exercise 4: Realising the operation of a hinged lid _________________________C-33

Exercise 5: Realising a diverting device __________________________________C-41

Exercise 6: Actuation of a stacking magazine _____________________________C-49

Exercise 7: Sorting of packages ________________________________________C-59

Exercise 8: Actuation of a sliding platform _______________________________C-67

Exercise 9: Expanding a diverting device_________________________________C-75

Exercise 10: Designing a stamping device________________________________C-85

Exercise 11: Realising a pallet loading station ____________________________C-95

Exercise 12: Eliminating a fault on the pallet loading station _______________C-101

Part D – Appendix

Organiser __________________________________________________________ D-2

Assembly technology ________________________________________________ D-3

Plastic tubing_______________________________________________________ D-4

Data sheets


Festo Didactic’s Learning System for Automation and Technology is orientated

towards different training and vocational requirements and is therefore structured

into the following training packages:

• Basic packages to provide technology-spanning basic knowledge

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

technology

• Function packages to explain the basic functions of automated systems

• Application packages to facilitate vocational and further training based on actual

industrial applications

The technology packages deal with the following technologies: Pneumatics,

electropneumatics, programmable logic controllers, automation using a personal

computer, hydraulics, electrohydraulics, proportional hydraulics and handling

technology.

Preface

Preface


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

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

hydraulic and electrical drives.

All the training packages are of identical structure:

• Hardware

• Teachware

• Software

• Seminars

The hardware consists of didactically designed industrial components and systems.

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

training hardware and comprises:

• Textbooks (with exercises and examples)

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

sheets)

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

environment)

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

use both in the classroom and for self-tuition.

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

software for programmable logic controllers.

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

packages completes the range of vocational and further training available.


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

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

practice-oriented vocational and further training. Technology package TP200 is

comprised exclusively of electropneumatic control systems.

Basic Level TP201 is suitable for basic training in electropneumatic control

technology and provides knowledge regarding the physical fundamentals of

electropneumatics and the function and use of electropneumatic equipment. The

equipment set enables you to construct simple electropneumatic control systems.

Advanced Level TP202 focuses on further training in electropneumatic control

technology. The two equipment sets enable you to construct complex combinational

circuits with logic operations of input and output signals and program controls.

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

Didactic profile plate, consisting of 14 parallel T-slots with 50 mm spacing. A short-

circuit protected power supply unit (input: 230 V, 50 Hz, output: 24 V, max. 5 A) is

used for DC voltage supply. A mobile, silenced compressor (230 V, maximum 8 bar =

800 kPa) can be used for compressed air supply.

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

Optimum operational reliability is achieved if the control system is operated

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

The equipment set of Basic Level TP201 is used to construct all of the complete

control systems of the 12 problem definitions. The theoretical fundamentals to help

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

• Electropneumatics

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

measuring devices, etc.).

Introduction

Introduction



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

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

supply immediately.

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

• Caution!

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

on.

• Do not operate an electrical limit switch manually during fault finding (use a

tool).

• Observe general safety regulations.

• With electrical limit switches you need to distinguish between two designs

– Actuation from the left

– Actuation from the right.

• At high piston speeds, limit switches must be approached only in the designated

direction of the trip cam of the cylinder. Limit switches must not be actuated from

the front.

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

• Only use extra-low voltage ≤ 24 V DC.

• All components are equipped with 4 mm safety sockets, i.e. jack plugs. Only use

cables with jack plugs for the electrical connections.

• Pneumatic circuit assembly:

Connect devices using the silver-metallic plastic tubing of 4mm outer diameter,

plugging the tubing into the push-in fitting up to the stop; no need for securing!

• Releasing of push-in fitting:

The tubing can be released by pressing down the releasing ring (disconnection

under pressure is not possible!)

• Switch off compressed air supply and power supply prior to dismantling the

circuit.

Notes on safety and operation

Notes on safety and operation


• The mounting plates of the devices are equipped with mounting variants A to D:

Variant A, latching system

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

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

the blue lever.

Variant B, rotary system

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

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

effected by means of the blue knurled nut.

Variant C, screw system

For heavy loadable devices rarely removed from the profile plate (e.g. Start-up

valve with filter control valve). These devices are mounted by means of socket

head screws and T-head bolts.

Variant D, plug-in system

Lightweight non loadable devices with locking pins (e.g. indicating devices).

These devices are attached by means of plug-in adapters.

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

be observed.


The technology package TP200 consists of numerous individual training media as

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

control systems. Individual components from the technology package TP200 may

also form a component part of other packages.

• Fixed workstation with Festo Didactic profile plate

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

• Equipment sets or individual components

• Optional training aids

• Practical training models

• Complete laboratory setups

Training documentation

Textbooks Basic Level TP201

Fundamentals of pneumatic control technology

Maintenance of pneumatic devices and systems

Workbooks Basic Lvel TP201

Advanced Level TP202

Optional Teachware Sets of overhead transparencies and overhead projector

Magnetic symbols, drawing template

WBT Fluid Studio Electropneumatics

Cutaway model sets 1 + 2 with storage case

Simulation software FluidSIM®

Pneumatic

Technology package for electropneumatics (TP200)

Important elements of

TP200

Technology package for electropneumatics (TP200)


Seminars

P111 Fundamentals of pneumatics and electropneumatics

P121 Maintenance of and fault finding on pneumatic and electropneumatic systems

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

control systems

EP-AL Electropneumatics for vocational training

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

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

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

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

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


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

single-acting cylinder.

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

double-acting cylinder.

• To be able to calculate piston forces according to specified values.

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

solenoid valve.

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

solenoid valve.

• To be able to select solenoid valves according to requirements.

• To be able to identify and draw the various types of actuation of directional

control valves.

• To be able to convert solenoid valves.

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

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

• To familiarise yourself with logic functions and to design these.

• To familiarise yourself with different types of end position control and to be able

to select a suitable type.

• To be able to calculate electrical characteristic values.

• To familiarise yourself with latching circuits with different characteristics.

• To be able to explain and design an electrical latching circuit with dominant

switch-off signal.

• To be able to design a pressure-dependent control system.

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

proximity sensors.

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

these for specified problem definitions.

• To be able to realise a sequence control using two cylinders.

• To be able to identify and eliminate errors in simple electropneumatic control

systems.

Training aims of Basic Level (TP201)

Training aims of Basic Level (TP201)



Exercise 1 2 3 4 5 6 7 8 9 10 11 12

Training aims

To familiarise yourself with the design

and mode of operation of a single-

acting cylinder.

•


and mode of operation of a double-

acting cylinder.

• • •

To be able to calculate piston forces

according to specified values.

•


and mode of operation of a 3/2-way

solenoid valve.

•


and mode of operation of a double

solenoid valve.

• •

To be able to select a solenoid valve

according to requirements.

•

To be able to identifiy and draw the

various types of actuation of

directional control valves.

•

To be able to convert solenoid valves. •

To be able to explain and design an

example of direct actuation.

• •


example of indirect actuation.

• • •

To familiarise yourself with different

types of end position control and to be

able to select a suitable type.

• •

To familiarise yourself with logic

functions and to be able to design

these.

• •

To be able to calculate electrical

characteristic values

•

Allocation of training aims and exercises

Allocation of training aims and exercises


Exercise 1 2 3 4 5 6 7 8 9 10 11 12

Training aims

To familiarise yourself with latching

circuits with different characteristics.

• •


electrical latching circuit with

dominant switch-off signal.

•

To be able to design a pressure-

dependent control system.

•

To familiarise yourself with the mode

of operation of magnetic proximity

sensors.

•

To familiarise yourself with

displacement step diagrams and to be

able to create these for specified

problem definitions.

•

To be able to realise a sequence

control using two cylinders.

•

To be able to detect and eliminate

errors in simple electropneumatic

control systems.

•


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

technology. It contains all the components required to meet the specifed training

aims and can be expanded in any way with other equipment sets. The profile plate

and a compressed air supply are required in addition.

Description Order No. Quantity

2 x 3/2-way solenoid valve, normally closed 539776 1

5/2-way double solenoid valve 539778 2

5/2-way solenoid valve 539777 1

Blanking plug 153267 10

Double-acting cylinder 152888 2

Limit switch, electrical, actuated from the left 183322 1

Limit switch, electrical, actuated from the right 183322 1

Manifold 152896 1

One-way flow control valve 539773 4

Plastic tubing 4 x 0.75, 10 m 151496 2

Pressure sensor 539757 1

Proximity sensor, electronic 540695 2

Proximity sensor, optical 178577 1

Push-in sleeve 153251 10

Push-in T-connector 153128 20

Relay, 3-off 162241 2

Signal input, electrical 162242 1

Single-acting cylinder 152887 1

Start-up valve with filter control valve 540691 1

Equipment set – Basic Level (TP201)

Equipment set – Basic Level

(TP201

Order No.: 540712)



Description Symbol

Relay, 3-off

1412 2422 3432

32

4442

11 21 31 41

A1

A2

1412 2422 34 4442

11 21 41

A1

A231

1412 2422 3432 4442

11 21 31 41

A1

A2

Signal input, electrical 13

13

13

23

23

23

14

14

14

24

24

24

31

31

31

41

41

41

32

32

32

42

42

42

3/2-way solenoid valve,

normally closed 2

1M1

31

1M1

Equipment set symbols



Description Symbol

5/2-way solenoid valve

1M1

24

35 1

1M1

5/2-way double solenoid valve

1M1 1M2

24

35 1

1M1 1M2

Proximity sensor, electronic

Pressure sensor

p

Proximity sensor, optical

Limit switch, electrical 42

1

One-way flow control valve 21



Description Symbol

Single-acting cylinder

Double-acting cylinder

Start-up valve with filter control valve

2

31

Manifold

Connection elements


Exercise 1 2 3 4 5 6 7 8 9 10 11 12

Equipment

Cylinder, single-acting 1 1 1 1

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

One-way flow control valve 1 2 2 1 2 2 2 2 2 2 3 3

3/2-way double solenoid valve,

normally closed

1 (1) 1 1

5/2-way solenoid valve 1 1 1 1

5/2-way double solenoid valve 1 1 1 1 1 1 1

Pressure sensor 1

Limit switch, electrical 1 2

Proximity sensor, normally open

conact

2 2 2 2

Pushbutton, electrical, normally open

contact

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

Pushbutton, electrical, normally

closed button

1 1

Relay 1 1 2 2 3 1 3 3 3 3

Manifold 1 1 1 1 1 1 1 1 1 1 1 1

Start-up valve with filter control valve 1 1 1 1 1 1 1 1 1 1 1 1

Power supply unit 24 V DC 1 1 1 1 1 1 1 1 1 1 1 1

Allocation of equipment and exercises

Allocation of equipment and exercises



• Training aims

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

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

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

The detailed training aims are documented in the table. Actual individual training

aims are allocated to each problem and major training aims are shown in

brackets.

• Time required

The time required to work through a problem depends on the trainee’s prior

knowledge. Skilled workers in the engineering and electrical fields require

approximately 2 weeks. Technicians or engineers require approximately 1 week.

• Components of the equipment set

The book of exercises and equipment set are harmonised. For all 18 exercises

you only require the components of the equipment set of Basic Level TP201.

Each of the Basic Level exercises can be assembled on a profile plate.

• Representation

Abbreviated notation and motion diagrams are used for the representation of

motion sequences and switching statuses.

Methodological help for the trainer

Methodological help for the trainer



All 12 exercises in Part A are of identical methodological structure.

The exercises are divided into:

• Title

• Training aims

• Problem definition

• Parameters

as well as

• Project task

• Positional sketch

• Worksheets

The proposed solutions in Part C are divided into:

• Circuit diagram

• Solution description

as well as

• Circuit assembly

• Equipment list

Methodological structure of the exercises


The designation of components in the circuit diagrams is effected in accordance with

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

number. Letters are assigned depending on components. Several components

within a circuit are numbered consecutively. The designation of pressure ports is P

and these are separately consecutively numbered.

Drives: 1A1, 2A1, 2A2, ...

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

Sensors: 1B1, 1B2, ...

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

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

Pressure strings: P1, P2, ...

Designation of equipment


The CD-ROM supplied provides you with additional media. The contents of Part A –

Exercises and Part C – Solutions are stored in the form of pdf files.

The structure of the CD-ROM is as follows:

• Operating instructions

• Data sheets

• Demo

• Festo catalogue

• FluidSIM®

circuit diagrams

• Industrial applications

• Presentations

• Product information

• Videos

Operating instructions are available for the various pieces of equipment of the

technology package to assist you in the use and commissioning of the equipment.

The data sheets for the equipment of the technology package are available in the

form of pdf files.

A demo version of the software package FluidSIM®

Pneumatic is stored on the CD-

ROM. This version is suitable for the testing of the control systems developed.

Pages from the Festo AG & Co. KG catalogue are provided for selected pieces of

equipment. The representation and description of equipment in this form is intended

to illustrate how such equipment is represented in an industrial catalogue. You will

also find additional information here regarding the equipment.

FluidSIM®

circuit diagrams are stored in this directory for all of the 12 exercises in

the technology package.

Contents of the CD-ROM

Operating instructions

Data sheets

Demo

Festo catalogue

FluidSIM® circuit diagrams

Contents of the CD-ROM


Photos and pictures are provided of industrial applications to enable you to

illustrate your own problem definitions. These can also be added to project

presentations.

Brief presentations are stored in this directory regarding the equipment of this

technology package. These presentations can for instance be used to create project

presentations.

This directory provides you with the product information and data sheets of Festo

AG & Co. KG regarding the equipment of the technology package and is intended to

explain what information and data are provided for an industrial component.

A number of videos of industrial applications complete the media for the training

package. Short sequences are shown of practice-related applications.

Industrial applications

Presentations

Product information

Videos


This Advanced Level equipment set has been compiled for further training in

pneumatic control technology. The two equipment sets (TP201 and TP202) comprise

the components required for the specified training aims and can expanded in any

way with other equipments sets of the Learning System for Automation and

Technology.

Description Order No. Quantity

Relay, 3 off 162241 2

Signal input, electrical 162242 1

Time relay, 2 off 162243 1

Predetermining counter 162355 1

Proximity sensor, inductive 178574 1

Proximity sensor, capacitive 178575 1

EMERGENCY-STOP button 183347 1

Valve terminal with 4 valve slices (MMJJ) 540696 1

Non-return valve, piloted 540715 2

Equipment set – Advanced Level (TP202)

Equipment set – Advanced

Level (TP202

Order No.: 540713)


• To describe the design and use of valve terminals

• To solve sequence controls with signal overlap – solution according to group

method

• To solve sequence controls with signal overlap – solution with sequence chain

using spring-return valves

• To solve sequence control with signal overlap – solution with sequence chain

using double solenoid valves (with control step)

• To be able to describe and configure modes of operation (single cycle,

continuous cycle, , ...)

• To describe the function and use of a predetermining counter

• To explain and realise an EMERGENCY-STOP FUNCTION using spring-return

valves

• To realise special EMERGENCY-STOP conditions: Actuators must stop during

EMERGENCY-STOP

• To explain the function and use of a 5/3-way solenoid valve

• To describe and configure the Reset mode of operation

• To carry out fault finding in complex electropneumatic circuits

Training aims of Advanced Level (TP202)

© Festo Didactic GmbH & Co. KG • 541090 A-1

Part A – Exercises

Exercise 1: Realising a sorting device ____________________________________A-3

Exercise 2: Realising a shut-off device___________________________________A-15

Exercise 3: Realising a lid press ________________________________________A-25

Exercise 4: Realising the operation of a hinged lid _________________________A-35

Exercise 5: Realising a diverting device __________________________________A-43

Exercise 6: Actuation of a stacking magazine _____________________________A-53

Exercise 7: Sorting of packages ________________________________________A-65

Exercise 8: Actuation of a sliding platform _______________________________A-73

Exercise 9: Expanding a diverting device_________________________________A-81

Exercise 10: Designing a stamping device________________________________A-91

Exercise 11: Realising a pallet loading station __________________________ A-101

Exercise 12: Eliminating a fault on the pallet loading station_______________ A-107

Contents

Contents

A-2 © Festo Didactic GmbH & Co. KG • 541090


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

cylinder.

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

solenoid valve.

• To be able to identify and draw various types of actuation of directional control

valves.


A sorting device is to be used to sort water samples according to the size of the

sample bottle. Design a control system whereby this process can be carried out.

• A single-acting cylinder is to be used.

• The control of the cylinder is to be effected by means of a pushbutton.

• In the event of a power failure the cylinder piston rod is to return into the

retracted end position.

1. Answer the questions or carry out the exercises regarding the fundamentals of

the training contents listed.

2. Draw the pneumatic and electrical circuit diagram.

3. Simulate the electropneumatic circuit diagram and check its correct functioning.

4. Compile an equipment list.

5. Carry out the pneumatic and electrical circuit assembly.

6. Check the circuit operation.

Exercise 1: Realising a sorting device

Training aims

Problem definition

Parameters

Project task



Sorting device

1. Pressing of a pushbutton causes the piston rod of a single-acting cylinder to

push the sample bottle off the conveyor.

2. When the pushbutton is released, the piston rod is to return into the retracted

end position.

Positional sketch



Exercise 1: Realising the operation of a sorting device

Name: Date:

Fundamentals: Function of pneumatic working components Sheet 1 of 7

Pneumatic working components can be divided into two groups:

• Working components using linear movement

• Working components using rotary movement

– Describe the function of the working components shown.

Symbol 1 Symbol 2 Symbol 3

Description of function

Symbol 1:

Symbol 2:

Symbol 3:




Name: Date:

Fundamentals: Completing solenoid valve symbols Sheet 2 of 7

– Complete the individual symbols with the help of the corresponding component

descriptions.

Description Symbol

Directly actuated 3/2-way

solenoid valve, normally open,

with manual override, with

spring return

2

31 Pilot actuated 3/2-way solenoid

valve, normally closed, with

manual override, with spring

return

2

31




Name: Date:

Fundamentals: Normal positions of directional control valves Sheet 3 of 7

An electrically actuated 3/2-way solenoid valve has two switching positions. It can

be in the normal position (unactuated) or in the switching position (actuated). In the

normal position the valve can be open or closed.

– Describe the effects on the motion sequence of the following application arising

as a result of the different normal positions. The single-acting cylinder shown is

controlled by an electrically actuated 3/2-way solenoid valve.

2

1M1

31

2

1M1

31

Description: Normal position closed Description: Normal position open




Name: Date:

Fundamentals: Direct and indirect actuation Sheet 4 of 7

An electrically actuated solenoid valve can be actuated either directly or indirectly.

– Describe the difference with the help of the following application: Electrical

actuation of a spring-returned 3/2-way solenoid valve using a pushbutton.

Description: Direct actuation Description: Indirect actuation




Name: Date:

Design and function of an electrical switch Sheet 5 of 7

Switches are basically divided into pushbutton and control switch designs and

perform the function of a normally open or normally closed contact or changeover

switch.

– Describe the design and function of the switches shown.


3

4

2

1

42

1

Description: Design/Function




Name: Date:

Fundamentals: Mode of operation of different valve types Sheet 6 of 7

Electrically actuated directional control valves are switches with the help of

solenoids. Basically, these can be divided into two groups:

• Spring-return solenoid valves

• Double solenoid valves

– Describe the differences between the two groups with regard to function and

behaviour in the event of power failure.

Valve type Mode of operation

Spring-return valve

Double solenoid valve




Name: Date:

Fundamentals: Port designations of valves Sheet 7 of 7

In order to prevent incorrect tubing up of directional control valves, the valve ports

(working and pilot lines) are identified in accordance with ISO 5599, both on the

valve itself and in the circuit diagram.

– Describe the meaning and function of the designations below.

Designation Meaning, function

3

12

10




Name: Date:

Completing the pneumatic and electrical circuit diagram Sheet 1 of 1

– Complete the pneumatic and electrical circuit diagram for the sorting device.

2

31

Pneumatic circuit diagram

1+24 V

0 V

Electrical circuit diagram




Name: Date:

Compiling the equipment list Sheet 1 of 1

Apart from the circuit diagram, comprehensive project documentation also requires

an equipment list.

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

below.

Quantity Description

Equipment list




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

cylinder.


In a water treatment system numerous pipes need to be opened or and closed by

means of shut-off devices. A test setup is to be used to find a possible means of

actuating the shut-off valve.

• A double-acting cylinder is to be used.

• The cylinder control is to be effected by means of a pushbutton.

• In the event of power failure the cylinder piston rod is to return into the retracted

end position.



2. Design the pneumatic and electrical circuit diagrams.





Exercise 2: Realising a shut-off device

Training aims

Problem definition

Parameters

Project task



Shut-off device

1. Pressing of a pushbutton is to cause the valve to open the slide

2. Releasing of the pushbutton is to cause the slide to close.

Positional sketch




Name: Date:

Fundamentals: Comparison of directly actuated and pilot actuated valves Sheet 1 of 5

Differentiation is made between directly actuated and pilot actuated solenoid valves

with regard to the type of actuation of the valve piston.

– Compare these two valve types and describe the respective advantages and

disadvantages.

Directly actuated valve Pilot actuated valve




Name: Date:

Port designations of valves Sheet 2 of 5

In order to prevent incorrect tubing up of directional control valves, valve ports

(working and pilot lines) are identified in accordance with ISO 5599-3, both on the


– Describe the meaning and function of the designations below.


4

14

82/84




Name: Date:

Fundamentals: Mode of operation of a solenoid valve Sheet 3 of 5

A valve symbol provides information regarding the function of the valve, i.e. the

number of ports, switching positions and type of actuation, but not about the

constructional design.

– Describe the mode of operation of the directional control valve shown.

1M1

24

35

1

Description: Mode of operation of a directional control valve




Name: Date:

Fundamentals: IP classification Sheet 4 of 5

Depending on the installation and ambient conditions, electrical equipment is

protected by means of a housing or cover. The required protection class against

dust, humidity and foreign objects is to be identified.

The classification IP 65 is shown on a valve

– Describe the meaning of this classification.

Description of IP 65 classification




Name: Date:

Fundamentals: Symbols of pneumatic cylinders Sheet 5 of 5

Piston rod cylinders with linear action can be divided into two groups:

• Single-acting cylinders

• Double-acting cylinders

– Describe the meaning of the cylinder symbol shown.

Symbol 1 Symbol 2

Description of symbolic representation




Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 1

– Complete the pneumatic and electrical circuit diagrams for the sorting device.

24

35

1


1+24 V

0 V





Name: Date:



an equipment list.


below.


Equipment list





cylinder.

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

In a filling plant, wall or ceiling paints are filled into plastic pots. Once filled, slip-lids

are to be pressed onto the plastic pots.


• The cylinder control is to be effected indirectly and by means of a pushbutton. In

the event of power failure the cylinder piston rod is to return into the retracted

end position.








Exercise 3: Realising a lid press

Training aims

Problem definition

Parameters

Project task



Filling of pots of paint

1. Pressing of a pushbutton is to cause the pressing ram to advance and the slip-lid

to be pressed on.

2. Once the pushbutton is released, the pressing ram is to be returned into the

initial position.

Positional sketch



Exercise 3: Realising of a lid press

Name: Date:

Fundamentals: Mode of operation of relays Sheet 1 of 4

A relay is a remotely controlled electromagnetically actuated switch with several

contacts.

The main components are:

• Coil with core

• Winding of coil

• Contact set

• Return spring

• Armature

• Terminal lugs

The following illustration shows a sectional representation of a relay.

– Allocate the component designations.

124A1 A2

2 3

1

5

67

4




Name: Date:

Fundamentals: Design and mode of operation of relays Sheet 2 of 4

– Describe the mode of operation of a relay.

Description of mode of operation of a relay




Name: Date:


One or several contacts can be switched by a relay coil. Relays with normally closed,

normally open or changeover contact(s) are used depending on the function

required.

Additional designs of electromagnetically actuated switches are for instance a

remanence relay, the time relay with switch-on delay, the time relay with switch-off

delay and the contactor.

– Describe the design and contact alignment of the relays shown.

Description of design/contact alignment Symbol

13 23 31 41

14 24 32 42

A1

A2

1412 2422 3432 4442

11 21 31 41

A1

A2




Name: Date:


– List the possible applications of relays in electrical or electropneumatic control

systems.

Description: Possible applications




Name: Date:


– Design the pneumatic and electrical circuit diagrams for the lid press.





Name: Date:


1+24 V

0 V

2

12

22

32

42

14

24

34

44

11

21

31

41





Name: Date:



an equipment list.


below.


Equipment list




• To be able to design an example of indirect actuation

• To familiarise yourself with logic operations

• To be able to select solenoid valve according to requirements

Plastic granulate is to be filled from a storage silo. The silo is to be opened or closed using a hinged lid. The process is to be effected from two points.

• A single-acting cylinder is to be used.

• The cylinder control is to be indirect and via hand levers.

In the event of power failure, the cylinder piston rod is to advance into the

forward end position.








Exercise 4: Realising the operation of a hinged lid

Training aims

Problem definition

Parameters

Project task



Filling of plastic granulate

1. Pressing of either one of the pushbuttons is to cause the hinged lid to open and

to empty the bulk material from the container.

2. Once the pusbutton is released, the hinged lid closes.

Positional sketch




Name: Date:

Fundamentals: Converting solenoid valves Sheet 1 of 3

In industrial practice, there are numerous different requirements with regard to a

valve. If a valve with all the required features is not available, it is often possible to

use a valve with a different number of ports. The table below lists a selection of

directional control valves frequently in use in industrial applications.

– Describe the valve types shown.

– Identify all solenoid valves that can be replaced by a 5/2-way solenoid valve of

the type shown..

– If measures are required to convert the valve, describe these.

Note

By „conversion measures“ we understand the simplest of conversions such as the

sealing of working ports 2 or 4 using a blanking plug.

1M1

24

35

1

14

Symbol Description of valve type Replacement

possible

Description of necessary conversions

2

1M1

1

12

2

1M1

31

12

2

1M1

31

10

4

1M1

31

14

2




Name: Date:

Fundamentals: Selecting solenoid valves Sheet 2 of 3

Valves are selected according to the following criteria:

• Exercise definition,

• Required behaviour in the event of power failure,

• Minimum possible overall costs

The following valves are available for selection for the actuation of a single-acting

cylinder:

• A pilot actuated, spring return 3/2way solenoid valve with manual override,

• A pilot actuated, spring-return 5/2-way solenoid valve with manual override

– Select a valve and explain the reasons for your decision.

Note

Apart from the cost of the valve, the above overall costs also include the cost of

installation, maintenance and storage for replacement parts.

Valve type Reason




Name: Date:

Fundamentals: Logic operations: The OR function Sheet 3 of 3

Triggering the advancing of a cylinder piston rod is to be possible using two

pushbuttons S1 and S2. If at least one of the two pushbuttons is actuated, the valve

coil 1M1 is energised, the solenoid valve 1V1 switches into the actuated position

and the piston rod advances. If both pushbuttons are released, the valve switches

into the initial position and the piston rod retracts.

– Create the appropriate function table and the logic symbol.

Note

0 means: Pushbutton not actuated, i.e. piston rod does not advance

1 means: Pushbutton actuated, i.e. piston rod advances

S1 S2 1M1 1V1

Function table

Logic symbol




Name: Date:


– Design the pneumatic and electrical circuit diagrams for the operation of the

hinged lid.





Name: Date:


K1

1412

11

1

K1 1M1

+24 V 32

0 V

A1

A2

K1

12

22

32

42

14

24

34

44

11

21

31

41





Name: Date:



an equipment list.


below.


Equipment list



cylinder.


solenoid valve.

Packages are to be pushed from one conveyor to another via a diverting device.


• The cylinder control is to be effected indirectly and via a pushbutton. In the event

of power failure the cylinder piston rod is to remain in the current position.

1. Answer the questions and carry out the exercises regarding the training contents

listed.






Exercise 5: Realising a diverting device

Training aims

Problem definition

Parameters

Project task



Diverting device

1. Pressing of a pushbutton is to cause the frame of the diverting device to be

advanced. The package is transferred and transported away.

2. Pressing of another pushbutton causes the frame to be moved into the initial

position.

Positional sketch




Name: Date:

Fundamentals: Use of solenoid valves Sheet 1 of 4

Two factors are to be considered regarding the question as to which valve type is to

be used for a particular application:

• Duration, i.e. time frame,

• Quantity or frequency

of required switching operations.

In order to utilise a directional control valve as efficiently as possible, you will need

to decide in each case whether the use

• of a double solenoid valve or

• a spring-return directional control valve

is more cost effective for the required application.

– Decide whether a double solenoid or a spring-return solenoid valve seems more

cost effective for the applications listed and explain the reasons for your choice.

Application 1

The clamping cylinder of a milling device is to firmly hold in position a workpiece for

the duration of a milling operation (duration of approx. 10 min, 60 clamping

operations per day).

Valve type Reason

Application 2

The ejecting cylinder of a sorting device is to push defective workpieces from a

conveyor (duration of approx.1s, 600 ejecting operations per day).

Valve type Reason




Name: Date:



1M1 1M2

24

35

1

Description of mode of operation of a directional control valve




Name: Date:

Fundamentals: Calculating the current consumption of a valve coil Sheet 3 of 4

A spring-return solenoid valve is to be switched via pushbutton S1.

– Calculate the current consumption of the valve coil 1M1 at a voltage supply of

24 V DC and a coil resistance of 48 Ω (Ohm).

1M1

1

S1

13

14

+24 V

0 V

Current consumption in 1M1 Power rating of 1M1




Name: Date:

Fundamentals: Calculate the current consumption of a valve coil Sheet 4 of 4

– Would the current consumption in 1M1 be the same, higher or lower if the above

valve coil is connected to a 24V AC voltage? Explain the reasons for your answer.

Identical Higher Lower Reason




Name: Date:


– Design the pneumatic and electrical circuit diagrams for the diverting device.

1





Name: Date:


1 2+24 V

0 V

3 4

1212

2222

3232

4242

1414

2424

3434

4444

1111

2121

3131

4141





Name: Date:



an equipment list.


below.


Equipment list




• To be able to use a double-acting cylinder.


solenoid valve.

• To familiarise yourself with the option of sensing the end positions of cylinders.

Wooden boards are to be pushed from a stacking magazine into an assembly device.

• The forward end position of the cylinder is to be sensed.








Exercise 6: Actuation of a stacking magazine

Training aims

Problem definition

Parameters

Project task



Stacking magazine

1. Pressing of a pushbutton causes a wooden board to be pushed out of the

stacking magazine.

2. Once the forward end position is reached, the slide is moved into the initial

position.

Positional sketch




Name: Date:

Fundamentals: Components of an electropneumatic system Sheet 1 of 6

The components of an electropneumatic system are represented in a pneumatic

circuit diagram and/or in an electrical circuit diagram.

– Determine where the components below are to be represented.

Component Pneumatic circuit

diagram

Electrical circuit

diagram

Manually operated pushbutton

Cylinder

Valves

Valve coils

Relay

Electromechanical limit switch

Electronic proximity sensor

Indicating devices




Name: Date:


The function of sensors in electropneumatic control systems is to acquire

information and to transmit this for signal processing.

– What function(s) can an electromechanical limit switch fulfill in an

electropneumatic control system?

Description: Function(s) of electromechanical limit switches




Name: Date:

Fundamentals: Representation of limit switches Sheet 3 of 6

Limit switches can be actuated in different ways, via the function of a normally

closed or normally open contact or changeover switch and, in the normal position of

the system, can be either actuated or unactuated.

– Describe the appropriate design or function of the symbols shown.

Description: Design/function Symbol

2

1

4

1




Name: Date:

Fundamentals: Creating a logic element table Sheet 4 of 6

One possibility of recording the allocated contacts of a relay is by means of listing

these in a logic element table.

– Create the logic element tables for relays K6 and K9.

K1

1412

11

K5

1412

11

K6 K7 K8 K9

10

A1 A1 A1 A1

A2 A2 A2 A2

K6 K7 K8 K9 K6 K7

14 14 14 14 34 3414 14 14

24 24 34 3424

12 12 12 12 32 3212 12 12

22 22 32 3222

11 11 11 11 31 3111 11 11

21 21 31 3121

1M1 2M1

12 14 16 18 1913 15 1711

K2 K4 K3

K6 K7 K9 K8K9

+24 V

...

...

0 V

2422

21

K8


Logic element

table

Description: Logic element table

K6

K9




Name: Date:


Another method of recording the allocated contact sets of a relay can be seen in the

electrical circuit diagram below.

NA

EMERGENCY

STOP

K1

1412

11

K5

K11 K11 K11

14

14 24 34

12

12 22 32

11

11 21 31

K6 K7 K8 K9

11 25 27

A1 A1 A1 A1

A2 A2 A2 A2

12 12 12 12

22 22 22 22

32 32 32 32

42 42 42 42

.13 .15 .17 .19

.20

.26

.24

.14 .16 .18

.24

.23

.22 .23

.22

14 14 14 14

24 24 24 24

34 34 34 34

44 44 44 44

11 11 11 11

21 21 21 21

31 31 31 31

41 41 41 41

K6 K7 K8 K9

14 14 14 1414 14 14

2424 24 24

12 12 12 1212 12 12

2222 22 22

11 11 11 1111 11 11

2121 21 21

16 1817 191312

K4 K3

K6K10 K7 K8

S1

Start

K1 K2 K3 K4 K5K11

+24 V 2 4 6 8 101 3 5 7 9

0 V

1B1 1B2 2B1 2B2

A1 A1 A1 A1 A1A1

A2 A2 A2 A2 A2A2

13

21

14

22

12 12 12 1212 12

22 22 22 2222 22

32 32 32 3232 32

42 42 42 4242 42

.12

.20

.14 .18

.27

.12.11

.25

.27

.1614 14 14 1414 14

24 24 24 2424 24

34 34 34 3434 34

44 44 44 4444 44

11 11 11 1111 11

21 21 21 2121 21

31 31 31 3131 31

41 41 41 4141 41

2M1

1A1+ 2A1-2A1+ 1A1-

K6 K8K7 K9 K3

34 3434 34 2432 3232 32 22

31 3131 31 21

22 2423 26

44 4444 3442 4242 32

41 4141 31

K7 K9K8 K10

K10

A1

A2

12

22

32

42

.21

.12

.26

14

24

34

44

11

21

31

41

K10

1424

24

1222

22

1121

21

20 21

K1

K9

1M1 1M22M2





Name: Date:


– Complete the information regarding the relays shown by:

Indicating the current path in which the respective contact is used and

specifying the function fulfilled by the contact set (normally open or normally

closed contact).

Relay Current path Function:

Normally

open contact

Function:

Normally

closed

contact

Relay K9

Relay K10




Name: Date:


– Design the pneumatic and electrical circuit diagrams for the stacking magazine.

1A1

1V1 24

35

1

1V2 1V31 1

2 2





Name: Date:


K1 K2

14 1412 12

11 11

1 2+24 V

0 V

K1 K2

3 4

A1 A1

A2 A2

1212

2222

3232

4242

1414

2424

3434

4444

1111

2121

3131

4141





Name: Date:



an equipment list.


below.


Equipment list




• To be able to calculate piston forces according to specific values

• To be able to calculate electrical characteristic values

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

• To familiarise yourself with logic functions and to be able to design these

Packages are to be transported on a conveyor past workstations. The packages can

be diverted by means of deflectors.


• The cylinder control is to be effected indirectly via pushbuttons and

electromechanical limit switches.

• Triggering of the advancing movement is to be possible only if the piston rod is in

the retracted end position.








Exercise 7: Sorting of packages

Training aims

Problem definition

Parameters

Project task



Conveyor belt for packages

1. The piston rod of a cylinder is to advance automatically as soon as pushbutton

S1 is actuated.

2. If the pushbutton is no longer actuated, the piston rod is to assume the retracted

end position.

Positional sketch




Name: Date:

Fundamentals: Calculation of piston force Sheet 1 of 3

The piston of a double-acting cylinder has a diameter of 16 mm and the piston rod a

diameter of 8 mm. The frictional losses within the cylinder are 10 %.

The following applies for double-acting cylinders:

Advance stroke Feff = (A • p) – FF

Return stroke Feff = (A' • p) – FF

Feff = Effective piston force (N)

A = Effective piston surface (m2)

= )4

D(

2π•

A' = Effective annular surface (m2)

= 4)d(D 22 π

−

p = Working pressure (Pa) FF = Friction force (approx. 10% of Fth

) (N)

D = Cylinder diameter (m) d = Piston rod diameter (m)

– Calculate the effective piston force in the advance and return stroke at an

operating pressure of 6 bar (600 kPa).

To be calculated Solution approach

Advance stroke

Return stroke




Name: Date:

Fundamentals: Calculation of electrical characteristic values Sheet 2 of 3

A relay in an electropneumatic circuit is designated as follows: 580 Ω, 1 W.

– Calculate the permissible operating voltage which ensures that no overload

occurs on the relay.


Max. Operating

voltage




Name: Date:

Fundamentals: Sheet 3 of 3

Triggering of the advancing movement of the piston rod of a cylinder is to be

achieved by means of two pushbuttons S1 and S2. The valve coil 1M1 is energised if

both pushbuttons are actuated simultaneously and the solenoid valve 1V1 switches

into the actuated position causing the piston rod to advance. If at least one of the

two pushbuttons is released, the valve switches into the initial position and the

piston rod retracts.

– Create an appropriate function table and the logic symbol.

Note

0 means: Pushbutton not actuated, i.e. piston rod not advancing


S1 S2 1M1 1V1

Function table

Logic symbol




Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 vof 2

– Configure the pneumatic circuit diagram and design the electrical circuit diagram

for the feeding device.

1M1 1M2

1A1

1V1 24

35

1

1V2 1V3

1B1 1B2

1 1

2 2





Name: Date:


K3 1M2

1 2+24 V

0 V

K1 K2

3 4

A1 A1

A2 A2

12

22

32

42

14

24

34

44

11

21

31

41

12

22

32

42

14

24

34

44

11

21

31

41

12

22

32

42

14

24

34

44

11

21

31

41

5

1M1





Name: Date:



an equipment list.


below.


Equipment list


• To familiarise yourself with logic functions and to be able to design these

• To be able to explain and design electrical latching circuits with dominant switch-

off signal

Wooden boards are to be manually placed onto a sliding platform. The boards are to

be pushed under a belt sanding machine by means of a pneumatic drive.


• The cylinder control is to be effected indirectly.





4. Compile the equipment list.



Exercise 8: Actuation of a sliding platform

Training aims

Problem definition

Parameters

Project task



Sliding platform

1. The piston rod of a cylinder is to advance if pushbutton S1 is actuated.

2. Actuation of pushbutton S2 is to cause the piston rod to retract.

Positional sketch




Name: Date:

Fundamentals: Signal storage Sheet 1 of 3

The actuation of the pushbutton must be stored if the piston rod of a cylinder is to

also advance if the pushbutton is only briefly actuated. This signal storage can be

effected either in the power section or in the signal control section of a circuit.

– Describe how signal storage is devised in the power section or in the signal

control section respectively.

Place of signal storage Description: Signal storage

Signal storage in the

power section


signal control section




Name: Date:

Fundamentals: Analysing circuits Sheet 2 of 3

– Describe the behaviour of the circuit specified (pilot actuated, spring-return

5/2-way solenoid valve with manual override, double-acting cylinder) in the

event of

– Power failure

– Pressure failure.

Power failure Pressure failure




Name: Date:

Fundamentals: Logic functions Sheet 3 of 3

The lamp P1 is to be illuminated whenever pushbutton S1 is not actuated.

– Draw up the appropriate function table and the logic symbol(s).

0 means: Pushbutton S1 not actuated, i.e. lamp P1 off

1 means: Pushbutton S1 actuated, i.e. P1 illuminated

S1 P1

Function table

Logic symbol




Name: Date:


– Design the pneumatic and electrical circuit diagrams for the sliding platform.

24

35

1





Name: Date:


12

22

32

42

14

24

34

44

11

21

31

41

1

K1 1M1

+24 V 32

0 V

A1

A2




Exercise 8: Actuation of a diverting device

Name: Date:



an equipment list.


below.


Equipment list


• To familiarise yourself with different types of end position control and to be able

to select a suitable type.

• To familiarise yourself with latching circuits of different characteristics.

Packages are to be transferred from one conveyor belt to another via a diverting

device using reciprocating strokes. Once switched on, the device is to run

continuously and only be switched off via a stop signal.

• The latching circuit used is to exhibit a dominant „Off“ behaviour.



2. Design the pneumatic and electrical circuit diagram.


4. Compile the equipment list.



Exercise 9: Expanding a diverting device

Training aims

Problem definition

Parameters

Project task



Diverting device for packages

1. Actuation of the pushbutton is to cause a reciprocating movement of the cylinder

piston rod to drive the diverting device via a latching drive.

2. The packages are to be deflected and transported in the opposite direction.

3. Pressing of a second pushbutton is to switch off the drive.

Positional sketch




Name: Date:

Fundamentals: Latching circuits Sheet 1 of 4

A latching relay circuit is required in order to store a signal in the signal control

section.

– The relay K1 is energised by actuating pushbutton S1. Complete the electrical

circuit diagram below so that the relay latches after the pushbutton S1 is

released.

12

22

32

42

14

24

34

44

11

21

31

41

1

S1

K1

+24 V

0 V

A1

A2

13

14





Name: Date:


An additional normally closed contact is required in order to cancel a set self-

latching loop.

Differentiation is made between two groups depending on the configuration of this

normally closed contact:

• Dominant setting self-latching loop

• Dominant resetting self-latching loop

– Complete the electrical circuit diagram below so that the self-latching loop is

reliably cancelled via the actuation of a pushbutton S2.

12

22

32

42

14

24

34

44

11

21

31

41

1

S1

K1

+24 V

0 V

A1

A2

13

14





Name: Date:


The various circuits for signal storage exhibit different behaviour:

• with simultaneously applicable set and reset conditions

• in the event of power failure or cable fracture

– Complete the table and enter the behaviour of the respective valve.

Valve position unchanged/valve is actuated/valve switches to normal position

Signal storage via electrical latching circuit

combined with spring-return valve

Signal storage via

double solenoid

valve Dominant setting Dominant resetting

Set and reset signal shared

Power failure




Name: Date:

Fundamentals: Limit switches and proximity sensors Sheet 4 of 4

The function of limit switches and proximity sensors is to acquire information and to

transmit this for signal processing.

These include:

Mechanical position switches (limit switches), magnetic proximity sensors (reed

switches), optical proximity sensors, capacitive proximity sensors, inductive

proximity sensors

– Allocate the designations to the corresponding symbols in the table.

Designation Symbol

BN

BU

BK

BN

BU

BK

BN

BU

BK

42

1

BN

BU

BK




Name: Date:


– Design the pneumatic and electrical circuit diagram for the diverting device.

1M1 1M2

1V1 24

35

1

1V2 1V3

1A1

1 1

2 2





Name: Date:


12

22

32

42

14

24

34

44

11

21

31

41

K1

1412

11

1

S1

K1 1M1 1M2

+24 V 3 5 7 82 4 6

0 V

A1

A2

S2

31

13

32

14





Name: Date:



an equipment list.


below.


Equipment list




• To be able to design a pressure-dependent reversal control.

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

proximity sensors.

Small mounting blocks are to be stamped during the production of door frames.

These blocks are to be stamped by means of a stamping device.

• The stamping pressure is to be 5.5 bar (550 kPa).








Exercise 10: Designing a stamping device

Training aims

Problem definition

Parameters

Project task



Stamping device

1. The pressing of a pushbutton is to cause the stamping device to advance and the

workpiece to be stamped.

2. The stamping tool is to return into the initial position once the stamping pressure

is obtained.

Positional sketch




Name: Date:

Fundamentals: Magnetic proximity sensor Sheet 1 of 5

In contrast with limit switches proximity sensors are switched contactlessly and

without an external mechanical actuating force.

– Describe the design and function of a magnetic proximity sensor (reed switch).

Description: Design and function Symbol Schematic representation

BN

BU

BK




Name: Date:

Fundamentals: Magnetic proximity sensors Sheet 2 of 5

As regards polarity there are two different designs of electronic proximity sensors,

i.e. PNP or NPN.

– Describe the differences between these two types.

PNP NPN




Name: Date:

Fundamentals: Pressure switches Sheet 3 of 5

Pressure sensitive sensors, so-called PE converters, are used to monitor the

pressure in a system.

– Describe the mode of operation of PE converter.

Description of mode of operation




Name: Date:

Fundamentals: Pressure sensors Sheet 4 of 5

Pressure sensors can be divided into two groups whereby differentiation is made

between:

• Pressure sensors with mechanical contact (mechanical principle of action)

• Pressure sensors with electronic switching

(electronic principle of action)

– Describe the purpose and function of the pressure sensor shown below.

Description: Purpose and function Symbol Schematic representation




Name: Date:

Fundamentals: Choice of proximity sensors Sheet 5 of 5

The end positions of a drive cylinder are to be sensed by means of proximity

sensors. The following requirements apply regarding the proximity sensors:

• The end positions of the piston rod are to be sensed contactlessly

• The proximity sensors are to be insensitive to dust

• The piston rod and trip cam of the cylinder are made of metal

– Choose which proximity sensors meet the specified requirements and explain

your reasons for this.

Proximity sensor Reason




Name: Date:


– Design the pneumatic and electrical circuit diagrams for the stamping device.

1M1 1M2

1V1 24

35

1

1V2 1V3

1A1

1 1

2 2





Name: Date:


7

K2 K3K1 1M1 1M2

+24 V 1 3 5 82 4 6

0 V

1B1 1B2 1B3

A1 A1A1

A2 A2 A2

p

12 1212

22 2222

32 3232

42 4242

14 1414

24 2424

34 3434

44 4444

11 1111

21 2121

31 3131

41 4141





Name: Date:



an equipment list.


below.


Equipment list


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

these for specified problem definitions.

• To be able to realise a sequence control using two cylinders.

Stacks of roof tiles are to be strapped with a band and then transported to a pallet

loading station, where they are to be transferred onto Euro pallets.

• Adjust the one-way flow control valve so that both cylinders retract at identical

speed.

1. Design the displacement-step diagram.

2. Draw up the corresponding function diagram and function chart.






Exercise 11: Realising a pallet loading station

Training aims

Problem definition

Parameters

Project task



Pallet loading station

1. Cylinder 1A1 is to advance when pushbutton S1 is pressed, whereby a single

package arrives at the loading point and sensor 1B2 is actuated.

2. Cylinder 2A1 advances, actuates sensor 2B2, and pushes the package onto the

pallet.

3. If 2B2 is actuated and S1 is unactuated, cylinder 1A1 retracts. 1B2 is therefore no

longer actuated and cylinder 2A1 retracts. Consequently, the overall sequence is:

1A1+ 2A1+ 1A1–

2A1–

Positional sketch




Name: Date:

Fundamentals: Designing the displacement-step diagram Sheet 1 of 3

If pushbutton S1 is actuated, cylinder 1A1 advances whereby the package reaches

its loading point and sensor 1B2 is actuated. Cylinder 2A1 advances, actuates

sensor 2B2 and pushes the package onto the pallet. If 2B2 is actuated and S1

unactuated, cylinder 1A1 retracts. 1B2 is no longer actuated and cylinder 2A1

retracts. Consequently the overall sequence is:

1A1+ 2A1+ 1A1–

2A1–

– Design the displacement-step diagram for the problem definition described.

1A1

0

1

2A1

0

1

1 2 3 4=1

Displacement-step diagram




Name: Date:


– Design the pneumatic and electrical circuit diagrams for the pallet loading

station.

1V1 24

35

1

1V2 1V3

1A1

2V2

2

31

2A1

2V1

1 1

2 2

2

1





Name: Date:


1M1 1M2 2M1

+24 V 1 3 5 6 7 82 4

0 V

1B2 2B2

A1A1 A1

A2 A2 A2

12 12 12

22 22 22

32 32 32

42 42 42

14 14 14

24 24 24

34 34 34

44 44 44

11 11 11

21 21 21

31 31 31

41 41 41

BN

BU

BK

BN

BU

BK





Name: Date:



an equipment list.


below.


Equipment list


• To be able to identify and eliminate faults in simple electropneumatic control

systems.

The pallet loading station stops during continuous operation. A fault has occurred

and must be eliminated. Thereafter the pallet loading station is to be re-started.

• Only one fault has occurred.

1. Describe the behaviour of the control system. Compare this with the correct

control system behaviour. Use the displacement-step diagram to assist you.

2. Localise potential causes of the fault with the help of the pneumatic and

electrical circuit diagrams.

3. Find the fault in the control system and eliminate it.

4. Re-start the control system.

Exercise 12: Eliminating a fault on the pallet loading station

Training aims

Problem definition

Parameters

Project task



Pallet loading station

1. Cylinder 1A1 is to advance if pushbutton S1 is pressed. This causes a single

package to reach its loading point thereby actuating sensor 1B2.

2. Cylinder 2A1 advances, actuates sensor 2B2 and pushes the package onto the

pallet.

3. If 2B2 is actuated and S1 unactuated, cylinder 1A1 retracts, 1B2 is no longer

actuated and cylinder 2A1 retracts. Consequently the overall sequence is:

1A1+ 2A1+ 1A1–

2A1–

Positional sketch




Name: Date:

Fault finding in simple electropneumatic circuits Sheet 1 of 4

The following fault occurs in the circuit shown below:

The piston rod of cylinder 1A1 and the piston rod of cylinder 2A1 advance and

remain in the forward end position.

– Describe what the potential causes of the fault could be.

1M1 1M2

1V1 24

35

1

1V2 1V3

1A1

1B2 2B2

2V2

2

2M1

31

2A1

2V1

1 1

2 2

2

1





Name: Date:


K3

1412

11

K2

1412

11

K1

1412

11

K2K1 K3 1M1 1M2 2M1

+24 V 1 3 5 6 7 82 4

0 V

1B2 2B2

A1A1 A1

A2 A2 A2

S1

13

14

12 12 12

22 22 22

32 32 32

42 42 42

.8 .7 .614 14 14

24 24 24

34 34 34

44 44 44

11 11 11

21 21 21

31 31 31

41 41 41

BN

BU

BK

BN

BU

BK


List of potential causes of faults




Name: Date:


A cable break occurs at the areas marked in the circuit shown below.

– Describe what the effects of a cable break at these respective points are on the

functioning of the circuit.

K3

1412

11

K2

1412

11

K1

1412

11

K2K1 K3 1M1 1M2 2M1

+24 V 1 3 5 6 7 82 4

0 V

1B2 2B2

A1A1 A1

A2 A2 A2

S1

13

14

12 12 12

22 22 22

32 32 32

42 42 42

.8 .7 .614 14 14

24 24 24

34 34 34

44 44 44

11 11 11

21 21 21

31 31 31

41 41 41

BN

BU

BK

BN

BU

BK





Name: Date:


Fault Effect of fault

Break in earthing wire of

relay K1 (current path 2)

Break in signal line of

sensor 2B2 (current path 4)

Break in supply line of relay

K3 (current path 5)


contact 14 at K2 (current

path 7)

Break in earthing wire 2M1

(current path 8)




Name: Date:

Fault finding: Determining the required status Sheet 1 of 9

– Create the displacement-step diagram with the help of the documentation given

out.

Time

Designation SignalIdentification

Components

Step

1 2 3 4 5 6 7 8 9 10




Exercise 12: Eliminating a fault in the pallet loading station

Name: Date:

Fault finding: Setpoint/actual comparison Sheet 2 of 9

Determine the ACTUAL status of the system with the help of the following

documentation:

• Positional sketch with problem description

• Graphic representation

– If the correct function is not given (REFERENCE/ACTUAL comparison), clearly

mark the area in the diagram where the fault occurs.

Time

Designation SignalIdentification

Components

Step

1 2 3 4 5 6 7 8 9 10





Name: Date:

Fault finding: Description of faults Sheet 3 of 9

You have marked the area where a fault occurs in the diagram of the worksheet

‘REFERENCE/ACTUAL comparison.

– Describe the process up the point where the station or system stops.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________




Name: Date:

Fault finding: Definition of faults - pneumatics Sheet 4 of 9

Once you have established the ACTUAL status of the system, consider what the

causes of the faults could be.

In which pneumatic tubing connections could the fault occur?

– Enter all the possibilities and indicate components at the start and end of the

tubing connection in order to ensure clear identification.

Potential fault

No.

Tubing connection

Start

End

Potential faults




Name: Date:

Fault finding: Definition of faults – electrics Sheet 5 of 9

Once you have established the ACTUAL status of the system, consider what the

causes of the faults could be.

• In which current paths could the fault be located?

• What is the function of the current path?

– Enter all the possibilities.

Potential fault

No.

Current path No. Function of current path

Potential faults




Name: Date:

Fault finding: Localisation of faults - pneumatics Sheet 6 of 9

Investigate the potential causes of errors you have found in the pneumatics.

• Use the same fault numbering that you have used for the worksheet ‘Definition

of faults – pneumatic.

• Document the procedure used to investigate the tubing connections.

– Enter the results of your investigation.

Measuring and test protocol

Potential fault

No.

Tubing connection

Start

End

Inspection Result





Name: Date:

Fault finding: Localisation of faults Sheet 7 of 9

Investigate the potential error causes you have found.

• Use the same fault numbering that you have used in the worksheet ‘Definition of

faults - electrics’.

• Document the procedure you have used to check the line connection.

– Enter the result of the investigation.


Potential fault

No.

Current path

No.

Measuring points

Inspection Result





Name: Date:

Fault finding: Elimination of fault Sheet 8 of 9

Once you have localised the failure location, your procedure for the elimination of

the fault must be documented on this worksheet.

– Describe each of the steps carried out in detail.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

Note

In the event of the system not fulfilling the intended function return to the first

worksheet and repeat the fault finding.

Ask for new worksheet s to do so.




Name: Date:

Fault finding: Re-starting Sheet 9 of 9

Once you have identified, localised and eliminated the fault, re-start the system in

accordance with the required status.

Reset the specified required times.

– Briefly document the procedure followed in note form.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________



© Festo Didactic GmbH & Co. KG • 541090 B-1

The theoretical fundamentals for the electropneumatics training package are

summarised in the textbook:

Electropneumatics, Basic Level

This textbook represents an impressive synthesis of years of experience gained in

Festo Didactic courses and the requirements of company and college training. It

explains basic equipment and modern installation-saving components that require

little maintenance. A comprehensive description of methods of representation

showing motion sequences and operating states makes complex circuits easy to

understand. A detailed example provides students with the necessary knowledge for

the planning and implementation of an electropneumatic circuit.

G. Prede, D. Scholz, 2001 edition,

296 pages, bound

Order No.: 091181

Part B – Fundamentals

B-2 © Festo Didactic GmbH & Co. KG • 541090

© Festo Didactic GmbH & Co. KG • 541090 C-1

Part C – Solutions

Exercise 1: Realising a sorting device ____________________________________C-3

Exercise 2: Realising a shut-off device___________________________________C-15

Exercise 3: Realising a lid press ________________________________________C-23

Exercise 4: Realising the operation of a hinged lid _________________________C-33

Exercise 5: Realising a diverting device __________________________________C-41

Exercise 6: Actuation of a stacking magazine _____________________________C-49

Exercise 7: Sorting of packages ________________________________________C-59

Exercise 8: Actuation of a sliding platform _______________________________C-67

Exercise 9: Expanding a diverting device ________________________________C-75

Exercise 10: Designing a stamping device________________________________C-85

Exercise 11: Realising a pallet loading station ____________________________C-95

Exercise 12: Eliminating a fault on the pallet loading station________________C-101

Contents

Contents

C-2 © Festo Didactic GmbH & Co. KG • 541090



Name: Date:

Fundamentals: Function of pneumatic working components Sheet 1 of 7

Pneumatic working components can be divided into two groups:

• Working components using linear movement

• Working components using rotary movement

– Describe the function of the working components shown.


Description: Function

Symbol 1

Single-acting cylinder, return spring in piston chamber, return stroke via compressed air, forward

stroke via return spring.

Function

The piston rod of this single-acting cylinder is moved into the retracted end position by means of

switching on the compressed air. Once the compressed air is switched off the piston reverses into the

forward end position via a return spring in the piston chamber (2 operating positions).

Symbol 2

Single-acting cylinder, return spring in piston chamber, forward stroke via compressed air, return

stroke via return spring

Function

The piston rod of the single-acting cylinder is moved into the forward end position by means of

switching on the compressed air. Once the compressed air is switched off the piston reverses into the

retracted end position (2 operating positions).

Symbol 3

Pneumatic semi-rotary drive (swivelling drive), with limited swivel range

Function

This semi-rotary drive is double-acting and is reversed by means of alternating connection of

compressed air (2 operating positions).


Solutions

Exercise 1: Realising a sorting device Solutions



Name: Date:

Fundamentals: Completing solenoid valve symbols Sheet 2 of 7

– Complete the individual symbols with the help of the corresponding component

descriptions.

Description Symbol

Pilot actuated 3/2-way solenoid

valve, normally open, with


return

2

1M1

31

10

Pilot actuated 3/2-way solenoid

valve, normally closed, with


return

2

1M1

31

12




Name: Date:

Fundamentals: Normal positions of directional control valves Sheet 3 of 7

An electrically actuated 3/2-way solenoid valve has two switching positions. It can

be in the normal position (unactuated), or in the switching position (actuated). In the

normal position the valve can be closed or open.

– Describe the effects on the motion sequence of the following application arising

as a result of the different normal positions: The single-acting cylinder shown is

controlled by one of the represented 3/2-way solenoid valves respectively.

2

1M1

31

12

2

1M1

31

10

Description:

3/2-way solenoid valve, normally closed

Description:

3/2-way solenoid valve, normally open

The solenoid valve used is reversed via the

application of voltage at the solenoid coil; flow is

released from pressure port 1 to working port 2.

When the signal is cancelled, the valve is

returned to the initial position via a return spring;

pressure port 1 (and consequently flow) is

closed. If the solenoid coil of the directional

control valve is de-energised, the cylinder

chamber is exhausted via the directional control

valve (exhaust port 3), and the piston rod is

retracted. If the solenoid coil is energised, the

directional control valve switches. The cylinder

chamber is pressurised and the piston is

advanced. If the solenoid coil is de-energised,

the valve reverses. The cylinder chamber is

exhausted and the piston rod retracts.

Consequently the motion sequence is: 1A1+ 1A1-

The solenoid valve used is reversed by applying

voltage at the solenoid coil; port 1 (and

consequently flow) is closed. If the signal is

cancelled the valve is returned to the initial

position via a return spring and flow is released

from pressure port 1 to working port 2. If the

solenoid coil of the directional control valve is

de-energised, the cylinder chamber is

pressurised via the directional control valve and

the piston rod is advanced. If the solenoid coil is

energised the directional control valve switches

and the cylinder chamber is exhausted via the

directional control valve (exhaust port 3),

causing the piston rod to retract. The valve

reverses if the solenoid coil is de-energised. The

cylinder chamber is pressurised and the piston

rod advances.

Consequently the motion sequence is: 1A1- 1A1+




Name: Date:

Fundamentals: Direct and indirect actuation Sheet 4 of 7

An electrically actuated solenoid valve can be actuated either directly or indirectly.

– Describe the difference with the help of the following application:

Electrical actuation of a spring returned 3/2-way solenoid valve using a

pushbutton.

Description: Direct actuation Description: Indirect actuation

Current flows through the solenoid coil of the

valve if the pushbutton is actuated. The solenoid

is energised and the valve switches into the

actuated position.

The current flow is interrupted if the pushbutton

is released. The solenoid is de-energised and the

directional control valve returns to the initial

position.

In the case of indirect control, current flows

through a relay coil if a pushbutton is actuated.

The relay contact closes and the valve switches.

The switching position is retained for as long as

current flows through the solenoid or relay coil

(in the case of self-latching loops also after the

pushbutton is released). The relay is de-

energised if the current flow is interrupted via

the relay coil and the valve switches into the

initial position.

More complex, indirect actuation is always used

if the control circuit and primary circuit operate

using different voltages, the current through the

coil of the directional control valve exceeds the

permissible current for the pushbutton, if several

valves are switched using one pushbutton or

extensive logic functions are required between

the signals of various pushbuttons.




Name: Date:

Design and function of an electrical switch Sheet 5 of 7

Switches are basically divided into pushbutton and control switch designs and

perform the function of a normally closed contact, normally open contact or

changeover switch.

– Describe the design and function of the switches shown.


3

4

2

1

42

1

Description: Design/function

Symbol

Pushbutton with normally open function

Function

With a pushbutton, the selected switching position is only retained for as long as it is actuated. The

pushbutton shown performs the function of a normally open contact. In the case of a normally open

contact, the circuit is interrupted in the normal position of the pushbutton, i.e. in the unactuated state.

Actuation of the switching stem causes the circuit to be closed and current to flow to the consuming

device. Once the switching stem is released, the pushbutton returns to the normal position as a result

of the spring force, thereby interrupting the circuit.

Symbol

Detent switch with normally closed contact

Function

In the case of a detent switch both switching positions are mechanically locked. A switching position is

therefore always retained until the switch is re-actuated. The detent switch shown performs the

function of a normally closed contact. With a normally closed contact the circuit is closed in the normal

position of the detent switch due to the spring force. Actuation of the detent switch causes the circuit

to be interrupted and renewed actuation closes the circuit again.

Symbol

Pushbutton with changeover function

Function

In the case of this pushbutton, the selected switching position is retained only for as long as this is

actuated. The pushbutton shown performs the function of a changeover switch, where the functions of

a normally closed and normally open contact are combined in one device. A switching action causes

one circuit to be closed and another circuit to be opened. Both circuits are briefly interrupted during

switching.




Name: Date:

Fundamentals: Mode of operation of different valve types Sheet 6 of 7

Electrically actuated directional control valves are switched with the help of

solenoids and can basically be divided into two groups:

• Spring return valves

• Double solenoid valves

– Describe how these two groups differ with regard to function and behaviour in

the event of a power failure.

Valve type Mode of operation

Spring return valve The actuated switching position is maintained only for as long as

current flows through the solenoid coil. The normal position is

clearly defined by the return spring. In the event of a power failure

the valve switches to the normal position via the spring and this

may trigger dangerous machine movements,

e.g. causes the piston rod of a pneumatic cylinder to move into

the initial position and release the clamping of a workpiece.

Double-solenoid valve Switching of the valve merely requires a brief signal; due to the

static friction, the last assumed switching position is retained

even in the de-energised state. All solenoid coils are de-energised

in the normal position and the normal position cannot be clearly

defined. In the event of a power failure, the valve retains its last

switching position; no dangerous movements are triggered,

e.g. the piston rod of a pneumatic cylinder maintains its operating

position and retains a workpiece.




Name: Date:

Fundamentals: Port designations of valves Sheet 7 of 7

In order to prevent incorrect tubing of directional control valves, valve ports

(working and pilot lines) are identified to ISO 5599 3, both on the valve itself and in

the circuit diagram.

– Describe the meaning or function of the designations below.

Designation Meaning or function

3 Working line, exhaust port

12 Pilot line, with pilot actuated or pneumatically actuated directional control valves;

Function on actuation: Connection of supply port 1 and working port 2

10 Pilot line, with pilot actuated or pneumatically actuated directional control valves;

Function on actuation: Closing of supply port 1




Name: Date:


– Design the pneumatic and electrical circuit diagrams for the sorting device.

1V2

2

31

0Z1

2

2

1

1M1

31

1A1

1V1

0Z2





Name: Date:


1M1

1

S1

13

14

+24 V

0 V





Name: Date:

Process description Sheet 1 of 1

Initial position

The cylinder is in the retracted end position.

Steps 1-2

Actuation of pushbutton S1 (normally open contact), causes the solenoid coil 1M1 of

the 3/2-way solenoid valve 1V1 to be energised. The valve 1V1 reverses and cylinder

1A1 advances.

Steps 2-3

As soon as pushbutton S1(normally open contact) is no longer actuated, the coil

1M1 is de-energised, the valve 1V1 is returned into the initial position via the return

spring, the cylinder 1A1 is exhausted and the spring returns the cylinder into the





Name: Date:



an equipment list.


below.


1 Cylinder, single-acting

1 One-way flow control valve

1 3/2-way solenoid valve, normally closed

1 Pushbutton (normally open contact)

1 Manifold

1 Start-up valve with filter control valve

1 Compressed air supply

1 Power supply unit 24 V DC

Equipment list





Name: Date:


Differentiation is made between directly actuated and pilot actuated directional

control valves with regard to the type of actuation.

– Compare these two valve types and describe the respective advantages and

disadvantages.

Directly actuated valve Pilot actuated valve

Flow is releases to the consuming device via

the armature of the solenoid. In order to obtain

a sufficient cross section of opening, a

comparably large armature is required. This

consequently requires a powerful return spring

and the solenoid to generate a high force. It is

therefore of a large design with high power

consumption.

Flow to the consuming device is switched via the

main stage. The valve piston is moved via an air

duct from pressure port 1.

This only requires a low flow so that a

comparatively small armature with minimal

actuating force can be used. A minimum supply

pressure is required in order to actuate the piston

against the spring force.

Compared to a directly actuated valve, the solenoid

can be configured in a small design and the power

consumption and heat emission is thus reduced.


Solutions

Exercise 2: Realising a shut-off device Solutions



Name: Date:


In order to prevent incorrect tubing up of directional control valves, valve ports

(working and pilot lines) are identified in accordance with ISO 5599-3, both on the


– Describe the meaning and function of the designations below


4 Working line, working port

14 Power line, with pilot actuated or pneumatically actuated directional control valves

Function on actuation: Connection of supply port 1 and working port 4

82/84 Pilot line, with pilot actuated or pneumatically actuated directional control valves

Function on actuation: Auxiliary pilot air exhausting




Name: Date:


A valve symbol provides information regarding the function of the valve, i.e. the

number of ports, switching positions and type of actuation, but not about the

constructional design.


1M1

24

35

1

Description: Mode of operation of directional control valve

Pilot actuated 5/2-way solenoid valve, with manual override, with spring return

Mode of operation:

In the normal position, the piston is positioned at the lefthand stop, the ports 1 (supply port) and 2

(working port), as well as the ports 4 (working port) and 5 (exhaust port) are connected. If the

solenoid coil is energised, the valve piston moves up to the righthand stop. In this position, ports 1

and 4 as well as 2 and 3 (exhaust port) are connected (the designation of the internal line of the pilot

control is 14; function on actuation: Connection of supply port 1 and working port 4).

If the solenoid is de-energised, the valve piston switches back into the normal position due to the

spring force and the pilot air is exhausted. In the de-energised state the valve can be switched by

means of a manual override.




Name: Date:

Fundamentals: IP classification Sheet 4 of 5

Depending on the installation and ambient conditions, electrical equipment is

protected by means of a housing or cover. The required protection class against

dust, humidity and foreign objects is to be identified.

Protection class IP 65 is shown on a valve.

– Describe the meaning of this classification.

Description: IP 65 classification

In accordance with DIN-VDE 470-1, the protection classification code is composed of the two letters IP

(for “International Protection”) and two digits.

The first digit indicates the scope of protection against the ingress of dust or foreign objects and the

second digit the scope of protection against the penetration of humidity or water.

Protection class IP 65 therefore means protection against the ingress of dust .

(i.e. complete protection against contact with energised or internally moving parts, protection against

the ingress of dust) and hose-water (i.e. strong jets of water aimed from any direction against the

housing/enclosure must not have any harmful effect).




Name: Date:

Fundamentals: Symbols of pneumatic cylinders Sheet 5 of 5

Piston rod cylinder with linear action can be divided into two groups:

• Single-acting cylinders

• Double-acting cylinders

– Describe the meaning of the cylinder symbols shown.

Symbol 1 Symbol 2

Description: Symbolic representation

Symbol 1

Double-acting multi-position cylinder; reversal via alternating supply of compressed air. By series

connecting two cylinders of identical piston diameter and different stroke length, it is possible to

approach three positions. The third position can be approached directly or via the second

intermediate position from the first position. However, to do so the subsequent cylinder stroke must

always be greater than the previous stroke. With the return stroke, an intermediate position is only

possible with the appropriate actuation (3 working positions). The shorter stroke length is half of the

longer one.

Symbol 2

Double-acting cylinder, reversal via alternating supply of compressed air, adjustable end position

cushioning (2 working positions)

Cushioning is used in the end position if large loads are to be moved by a cylinder. Prior to reaching

the end position, a cushioning piston interrupts the direct exhaust path of air to atmosphere. The

restricted exhaust air causes the piston speed to be reduced during the last part of the stroke travel.




Name: Date:


– Design the pneumatic and electrical circuit diagrams for the shut-off device.

1M1

1A1

1V1 24

35

1

1V2 1V31 1

2 2


1M1

1

S1

13

14

+24 V

0 V





Name: Date:


Initial position

The cylinder is in the retracted end position.

Steps 1-2

Actuation of pushbutton S1(normally open contact) causes the solenoid coil 1M1 of

the 5/2-way solenoid valve 1V1 to be energised and the valve 1V1 to reverse. The

piston side of cylinder 1A1 is now filled with compressed air whilst the piston rod

side is exhausted. Cylinder 1A1 advances.

Steps 2-3

As soon as pushbutton S1 (normally open contact) is no longer actuated, the coil

1M1 is de-energised and the valve 1V1 is returned to the initial position again via

the return spring. The piston side of cylinder 1A1 is exhausted whilst the piston rod

side is filled with compressed air. The cylinder returns into the retracted end

position.




Name: Date:



an equipment list.


below.


1 Cylinder, double-acting


1 5/2-way solenoid valve


1 Manifold




Equipment list



Name: Date:

Fundamentals: Mode of operation of relays Sheet 1 of 4

Relays form part of the components of the electrical signal control section. The main

components are:

• Coil with core

• Coil winding

• Contact set

• Return spring

• Armature

• Terminal lugs

The illustration below represents a sectional view of a relay.

– Allocate the component designations.

124A1 A2

2 3

1

5

67

4

The relay consists of

(1) Coil with core

(2) Return spring

(3) Coil winding

(4) Armature

(5) Contact set

(6) Terminal lugs

(7) Terminal lugs


Solutions

Exercise 3: Realising a lid press Solutions



Name: Date:


– Describe the mode of operation of a relay.

Description: Mode of operation of a relay

A relay is an electromagnetically operated switch. An electromagnetic field is created if voltage is

applied at the coil of the solenoid, which causes the movable armature to be attracted to the coil core.

The armature acts on the relay contacts which, depending on configuration either open or close. If the

current flow through the coil is interrupted, a spring causes the armature to return into the initial

position.




Name: Date:


One or several contacts can be switched by a relay coil. Depending on the required

function, a relay with normally open, normally closed or changeover contact(s) is

used.

Additional designs of electromagnetically operated switches are

for instance the remanence relay, time relay with switch-on delay and the contactor.

– Describe the design and contact line-up of the relays shown.

Description: Design/contact line-up Symbol

Design: Relay with two normally closed contacts

and two normally open contacts

Function: If the relay coil is energised, two of the

four contacts are opened and two contacts are

closed.

13 23 31 41

14 24 32 42

A1

A2

Design: Relay with four changeover contacts

Function: If the relay coil is energised, up to four

current paths are opened or closed via the four

relay contacts.

High flexibility, wide range of different contact

combinations possible.

1412 2422 3432 4442

11 21 31 41

A1

A2



Exercise 3: Realising a list press

Name: Date:


– Name possible applications of relays in electrical or electropneumatic control

systems.

Description: Possible applications

• Signal multiplication

• Voltage or current amplification

• Delaying or converting of signals

• Logic operations of information

• Isolation of control and primary circuits

• Isolation of DC and AC circuits in purely electrical control systems




Name: Date:


– Design the pneumatic and electrical circuit diagrams for the lid press.

1M1

1A1

1V1 24

35

1

1V2 1V31 1

2 2





Name: Date:


1M1

1

S1

13

14

+24 V

0 V

K1

2

A1

A2

K1

1412

11

12

22

32

42

.214

24

34

44

11

21

31

41





Name: Date:


Initial position

Cylinder 1A1 is in the retracted end position.

Steps 1-2

Actuation of pushbutton S1 (normally open contact) causes the relay K1 to be

energised, the changeover contact K1 (connected in the form of a normally open

contact) also closed and the solenoid coil 1M1 of the 5/2-way valve 1V1 is

energised. The valve 1V1 reverses and causes the rear chamber of cylinder 1A1 to be

filled with compressed air whilst the front chamber if exhausted. Cylinder 1A1

advances.

Steps 2-3

As soon as pushbutton S1 (normally open contact) is no longer actuated, relay K1 is

de-energised and the changeover contact K1(connected in the form of a normally

open contact) opens. This causes the coil 1M1 to be de-energised and the valve 1V1

to be returned into the initial position via the return spring. The rear chamber of

cylinder 1A1 is exhausted whilst the front chamber is filled with compressed air. the

cylinder returns into the retracted end position.




Name: Date:

Completing the pneumatic and electrical circuit diagrams, alternative solution Sheet 1 of 2

Indirect actuation does of course function equally with a 3/2-way solenoid valve and

single-acting cylinder.

1V2

2

1M1

31

1A1

1V1

2

1





Name: Date:

Completing the pneumatic and electrical circuit diagrams, alternative solution Sheet 2 of 2

1M1

1

S1

13

14

+24 V

0 V

K1

2

A1

A2

K1

1412

11

12

22

32

42

.214

24

34

44

11

21

31

41





Name: Date:



an equipment list.

– Create the equipment list by entering the required equipment in the table below.

Quantity Designation




1 Pushbutton (normally open)

1 Relay

1 Manifold




Equipment list



Name: Date:

Fundamentals: Converting solenoid valves Sheet 1 of 3

In industrial practice there are numerous different requirements placed on a valve. If

a valve with the desired characteristics is not available, it is often possible to use a

valve with a different number of ports to obtain the required function. The table

below lists a selection of directional control valves frequently in use in industrial

applications.

– Describe the valve types shown.

– Designate all the solenoid valves that can be replaced by using a 5/2-way

solenoid valve of the type shown.

– If conversion measures need to be taken in order to obtain the desired function,

then please describe thee.

Note

By the term „conversion measures“ we understand the simplest of conversions,

such as the closing of working ports 2 or 4 using a blanking plug.

1M1

24

35

1

14

Symbol Description: Valve type Replacement

possible

Description: Necessary conversions

2

1M1

1

12

Pilot actuated, spring return

2/2-way solenoid valve, with manual

override

X

Replacement possible, no conversion required?

2

1M1

31

12


3/2-way solenoid valve, normally closed,

with manual override

X

Replacement possible, conversion by closing

working port 2 using a blanking plug

2

1M1

31

10


3/2-way solenoid valve, normally open,

with manual override

X

Replacement possible, conversion by closing

working port 4 using a blanking plug

4

1M1

31

14

2

Pilot-actuated, spring return

4/2-way solenoid valve, with manual

override

X

Replacement possible, no conversion required


Solutions

Exercise 4: Realising the operation of a hinged lid Solutions


Exercise 4: Realising the operation of hinged lid

Name: Date:

Fundamentals: Selecting solenoid valves Sheet 2 of 3

The choice of a valve is made according to the following criteria:

• Problem definition,

• Required behaviour in the event of a power failure,

• Lowest possible overall costs

The following choice of valves is available for the actuation of a single-acting

cylinder:

• A pilot actuated, spring return 3/2-way solenoid valve with manual override

• A pilot actuated, spring return 5/2-way solenoid valve with manual override

– Make your choice and explain your reasons for this.

Note

Apart from the costs of the actual valve, the above mentioned overall costs of a

valve also include the costs for installation, maintenance and storage of

replacement parts.

Valve type Reason

Pilot actuated, spring

return 5/2-way

solenoid valve with

manual override

As can be seen from question 1, the 5/2-way solenoid valve has a broad

spectrum of possible applications. In practice this means that only one valve

type is required for different requirements or applications. This in turn

means a considerable cost reduction thanks to more alternatives when it

comes to the procurement of the valve and storage of replacement parts.

The maintenance of different valves entails considerable higher expenditure

compared to maintaining a single valve type. A 3/2-way valve can only

actuate single-acting cylinders whereas a 5/2-way valve can actuate single-

acting and double-acting cylinders. This is why the choice should be a 5/2-

way solenoid valve. The fact that the costs of a 3/2-way solenoid valve are

usually 5 % below that of a 5/2-way double solenoid valve is immaterial in

view of the above mentioned advantages.




Name: Date:

Fundamentals Sheet 3 of 3

Triggering the advance of the cylinder piston rod is to be possible using two

pushbuttons S1 and S2. If at least one of the two pushbuttons is actuated, the valve

coil 1M1 is energised, the solenoid valve 1V1 switches into the actuated position

and the piston rod advances. If both pushbuttons are released, the valve switches

into the initial position and the piston rod retracts.

– Create the appropriate function table and the logic symbol.

Note

0 means: Pushbutton not actuated, i.e. piston rod does not advance


S1 S2 1M1 1V1

0 (not actuated) 0 (not actuated) 0 (not actuated) 0 (not actuated)

0 (not actuated) 1 (actuated) 1 (actuated) 1 (actuated)

1 (actuated) 0 (not actuated) 1 (actuated) 1 (actuated)

1 (actuated) 1 (actuated) 1 (actuated) 1 (actuated)

Function table

S1

S2

1M1<=1

Logic symbol




Name: Date:


– Design the pneumatic and electrical circuit diagrams for the hinged lid.

1M1

1V1 24

35

1

1V2

1A1

2

1





Name: Date:

Complete the pneumatic and electrical circuit diagrams Sheet 2 of 2

K1

1412

11

1

S1 S2

K1 1M1

+24 V 32

0 V

A1

A2

K1

13 13

14 14

12

22

32

42

.314

24

34

44

11

21

31

41





Name: Date:


Initial position

In the initial position cylinder 1A1 is in the forward end position and the rear cylinder

chamber is filled with compressed air.

Steps 1-2

Actuation of pushbutton S1 or pushbutton S2 (both in the form of normally open

contacts), causes the relay K1 to be energised, the changeover contact K1

(connected in the form of a normally open contact) closes and the solenoid coil 1M1

of the 5/2-way valve 1V1 is energised. The valve 1V1 reverses and the rear chamber

of cylinder 1A1 is exhausted; the spring presses the cylinder into the retracted end

position.

Steps 2-3

As soon as the pushbutton S1 or S2 (both in the form of normally open contacts), are

no longer pressed, the relay K1 is de-energised, the changeover switch K1

(connected in the form of a normally open contact) opens. This causes the coil 1M1

to be de-energised and the valve 1V1 to be returned into the initial position via the

return spring. The rear chamber of cylinder 1A1 is filled with compressed air and the

cylinder returns into the forward end position.




Name: Date:

Compiling the equipment Sheet 1 of 1


an equipment list.

– Create the equipment list by entering the required equipment in the table below.






1 Relay

1 Manifold




Equipment list




Exercise 5: Realising the operation of a diverting device

Name: Date:

Fundamentals: Use of solenoid valves Sheet 1 of 4

Two factors are to be taken into consideration with regard to the question as to

which valve type is to be used for a particular application:

• Duration, i.e. time frame,

• Quantity or frequency

of required switching operations.

In order to utilise a directional control valve as efficiently as possible, you will need

to decide in each case whether

• a double-solenoid valve or

• a spring-return directional control valve

is more cost effective for the required application.

– Decide whether a double soleoid or a spring-return valve seems more cost

effective for the applications listed and explain the reasons for your choice.

Application 1

The clamping cylinder of a milling device is to firmly hold in position a workpiece for

the duration of a milling operation (duration of approx. 10 min, 60 clamping

operations per day).

Valve type Reason

Double solenoid

valve

An applied signal needs to be stored for lengthy switching operations. In the

case of double solenoid valve this occurs via static friction and with spring

return directional control valves via continuously energising the solenoid

coil. Clamped workpieces must not be released in the event of EMERGENCY-

STOP, hence the use of spring-return solenoid valves is not permissible in

this case.

Application 2

The ejecting cylinder of a sorting device is to push defective workpieces from a

conveyor (duration of approx. 1s, 600 ejecting operations per day).

Valve type Reason

Spring-returned

solenoid valve

For short switching operations an applied signal does not need to be stored.

Spring-return solenoid valves have the advantage: Only one valve coil needs

to be actuated, i.e. energised to switch the valve.


Solutions

Exercise 5: Realising the operation of a diverting device Solutions



Name: Date:



1M1 1M2

24

35

1

Description: Mode of operation of a directional control valve

Pilot actuated 5/2-way double solenoid valve, with manual override

Mode of operation:

If the piston is at the lefthand stop, ports 1 (compressed air supply) and 2 (working port), as well as

port 4 (working port) and port 5 (exhaust port)are connected. If the lefthand solenoid coil is energised,

the piston moves to the righthand stop and ports 1 and 4 as well as port 2 and port 3 (exhaust port)

are connected (power line, 14 and 12, function during actuation: Connection of compressed air supply

1 and working port 4, i.e. 2). If the valve is to return into the initial position, it is not sufficient to

interrupt the current to the lefthand solenoid coil since the righthand solenoid coil also needs to be

energised. If neither of the two solenoids is actuated the piston, owing to friction, remains in its last

assumed position (signal control in the power section). This also applies if both solenoids are

simultaneously energised since they then act against one another with identical force.

The valve can be switched via a manual override in the de-energised state .




Name: Date:


A spring-return solenoid valve is to be switched via pushbutton S1.

– Calculate the current consumption of the valve coil 1M1 at a voltage supply of

24 V DC and a coil resistance of 48 Ω (Ohm).

1M1

1

S1

13

14

+24 V

0 V

Current consumption in 1M1 Capacity of 1M1

According to Ohm’s law

R = U • I

A current consumption of 0.5 A (ampere) is calculated via

A5.048

V24

R

UI =

Ω==

According to

P = U • I = 24 V • 0.5 A = 12 W

a power consumption of 12 W (Watt) is calculated




Name: Date:


– Would the current consumption in S1 be the same, higher or lower if the above

valve coil is connected to a 24V AC voltage? Explain the reasons for your answer.

Identical Higher Lower Reason

X

The magnetic fields of the AC voltage create an induction

voltage in the coil windings which acts against the

voltage applied and which increases the coil resistance.

This resistance of the AC coil (impedance) is made up of

the ohmic resistance and the so-called inductive

reactance, thereby reducing the effective current.




Name: Date:


– Design the pneumatic and electrical circuit diagrams for the diverting device.

1M1 1M2

1A1

1V1 24

35

1

1V2 1V31 1

2 2





Name: Date:


K1

14 1412 12

11 11

1M1 1M2

1 2

S1 S2

+24 V

0 V

K1 K2

3 4

A1 A1

A2 A2

K2

13 13

14 14

1212

2222

3232

4242

.4.31414

2424

3434

4444

1111

2121

3131

4141





Name: Date:


Initial position

In the initial position, cylinder 1A1 is in the retracted end position.

Steps 1-2


energised, the changeover contact K1 (connected in the form of a normally open

contact) to close and the solenoid coil 1M1 of the 5/2-way double solenoid valve

1V1 to be energised. The valve 1V1 reverses and the rear chamber of cylinder 1A1 is

filled with compressed air whilst the front chamber is exhausted. Cylinder 1A1

advances.

As soon as pushbutton S1 (normally open contact) is no longer actuated, the relay

K1 is de-energised and the changeover contact K1 (connected in the form of a

normally open contact) opens, thereby causing the coil 1M1 to be de-energised.

Steps 2-3


energised and the changeover contact K2 (connected in the form of a normally open

contact) to be closed. This causes the coil 1M2 to be energised and the valve 1V1 to

return into the initial position. The front chamber of the cylinder 1A1 is filled with

compressed air whilst the rear chamber is exhausted. The cylinder 1A1 returns into

the retracted end position.

As soon as pushbutton S2 (normally open contact) is no longer actuated, relay K2 is

de-energised and changeover contact K2 (connected in the form of a normally open

contact) opens. This causes the coil 1M2 to be de-energised.




Name: Date:



an equipment list.


below.




1 5/2-way double solenoid valve


2 Relay

1 Manifold




Equipment list



Name: Date:


The components of an electropneumatic system are represented in a pneumatic

circuit diagram and/or in an electrical circuit diagram.

– Determine where the components below are to be represented.

Component Pneumatic circuit

diagram

Electrical circuit

diagram

Manually operated pushbutton X

Cylinder X

Valves X

Valve coils X X

Relay X

Electromechanical limit switch X X

Electronic proximity sensor X X

Indicating devices X


Solutions

Exercise 6: Actuation of a stacking magazine Solutions



Name: Date:


The function of sensors in electropneumatic control systems is to acquire

information and transmit this for signal processing.

– What function(s) can an electromechanical limit switch fulfill in an

electropneumatic control system?

Description: Function (s) of electromechanical limit switches

To detect the forward and retracted end positions of the piston rod of drive cylinders

To establish the availability and position of a workpiece




Name: Date:

Fundamentals: Representation of limit switches Sheet 3 of 6

Limit switches can be actuated in different ways, via the function of a normally

closed or normally open contact or changeover switch and, in the normal position of

the system, can be either actuated or unactuated.

– Describe the appropriate design or function of the symbols shown.

Description: Design/ function Symbol

Roller actuated limit switch with normally closed function,

unactuated

2

1

Roller actuated limit switch with normally open function, unactuated 4

1




Name: Date:


One possibility of recording the allocated contacts of a relay is by means of listing

these in a logic element table.

– Create the logic element table for the relays K6 and K9.

K1

1412

11

K5

1412

11

K6 K7 K8 K9

10

A1 A1 A1 A1

A2 A2 A2 A2

K6 K7 K8 K9 K6 K7

14 14 14 14 34 3414 14 14

24 24 34 3424

12 12 12 12 32 3212 12 12

22 22 32 3222

11 11 11 11 31 3111 11 11

21 21 31 3121

1M1 2M1

12 14 16 18 1913 15 1711

K2 K4 K3

K6 K7 K9 K8K9

+24 V

...

...

0 V

2422

21

K8


Logic element-

table

Description: Logic element table

K6

11

12

18

1 Normally open contact in current path 11



K9

10

18

17


1 Normally closed contact in current path 10

1 Normally closed contact in current path 18




Name: Date:


Another method of recording the allocated contact sets of a relay can be seen in the

electrical circuit diagram below.

NA

EMERGENCY

STOP

K1

1412

11

K5

K11 K11 K11

14

14 24 34

12

12 22 32

11

11 21 31

K6 K7 K8 K9

11 25 27

A1 A1 A1 A1

A2 A2 A2 A2

12 12 12 12

22 22 22 22

32 32 32 32

42 42 42 42

.13 .15 .17 .19

.20

.26

.24

.14 .16 .18

.24

.23

.22 .23

.22

14 14 14 14

24 24 24 24

34 34 34 34

44 44 44 44

11 11 11 11

21 21 21 21

31 31 31 31

41 41 41 41

K6 K7 K8 K9

14 14 14 1414 14 14

2424 24 24

12 12 12 1212 12 12

2222 22 22

11 11 11 1111 11 11

2121 21 21

16 1817 191312

K4 K3

K6K10 K7 K8

S1

Start

K1 K2 K3 K4 K5K11

+24 V 2 4 6 8 101 3 5 7 9

0 V

1B1 1B2 2B1 2B2

A1 A1 A1 A1 A1A1

A2 A2 A2 A2 A2A2

13

21

14

22

12 12 12 1212 12

22 22 22 2222 22

32 32 32 3232 32

42 42 42 4242 42

.12

.20

.14 .18

.27

.12.11

.25

.27

.1614 14 14 1414 14

24 24 24 2424 24

34 34 34 3434 34

44 44 44 4444 44

11 11 11 1111 11

21 21 21 2121 21

31 31 31 3131 31

41 41 41 4141 41

2M1

1A1+ 2A1-2A1+ 1A1-

K6 K8K7 K9 K3

34 3434 34 2432 3232 32 22

31 3131 31 21

22 2423 26

44 4444 3442 4242 32

41 4141 31

K7 K9K8 K10

K10

A1

A2

12

22

32

42

.21

.12

.26

14

24

34

44

11

21

31

41

K10

1424

24

1222

22

1121

21

20 21

K1

K9

1M1 1M22M2





Name: Date:


– Complete the information regarding the relays shown by:

Indicating the current path in which the respective contact is used.

Specifying the function fulfilled by the contact set (normally open or normally

closed contact).

Relay Current path Function:

Normally

open contact

Function:

Normally

closed

contact

Current path 19 X

Current path 20 X

Current path 24 X

Relay K9

Current path 26 X

Current path 12 X

Current path 21 X

Current path 26 X

Relay K10




Name: Date:


– Design the pneumatic and electrical circuit diagrams.

1M1 1M2

1A1

1V1 24

35

1

1V2 1V3

1B2

1 1

2 2





Name: Date:


42

1

K1 K2

14 1412 12

11 11

1M1 1M2

1 2

S1 1B2

+24 V

0 V

K1 K2

3 4

A1 A1

A2 A2

13

14

1212

2222

3232

4242

.4.31414

2424

3434

4444

1111

2121

3131

4141




Exercise 6: Ansteuerung eines Schachtmagazins

Name: Date:


Initial position

Cylinder 1A1 is in the retracted and position in the initial position.

Steps 1-2


energised; the changeover contact K1 (connected in the form of a normally open

contact) closes and the solenoid coil 1M1 of the 5/2-way double solenoid valve 1V1

is energised. The valve 1V1 reverses. The rear chamber of the cylinder 1A1 is filled

with compressed air whilst the front chamber is exhausted. The cylinder 1A1

advances.

If pushbutton S1 (normally open contact) is no longer actuated, the relay K1 is de-

energised and the changeover switch K1 (connected in the form of a normally open

contact) opens. This also causes the coil 1M1 to be de-energised.

Steps 2-3

Once the cylinder has reached its forward end position, the piston rod actuates the

electrical limit switch 1B2. The changeover switch 1B2 (connected in the form of a

normally open contact) closes and the relay K2 is energised. The changeover contact

K2 (connected in the form of a normally open contact) closes and the solenoid coil

1M2 is energised. The valve 1V1 reverses into the initial position again.

The front chamber of the cylinder 1A1 is filled with compressed air whilst the rear

chamber is exhausted. The cylinder returns into the retracted end position again.

As soon as the electrical limits switch 1B2 is no longer actuated (changeover

contact, connected in the form of a normally open contact), the relay K2 is de-

energises and the changeover contact K2 (connected in the form of a normally open

contact) opens. This also causes the coil 1M2 to be de-energised.




Name: Date:



an equipment list.


below.






1 Limit switch (normally open contact)

2 Relay

1 Manifold




Equipment list



Name: Date:

Fundamentals: Calculation of piston force Sheet 1 of 3

The piston of a double-acting cylinder is of a diameter of 20 mm and the piston rod

of a diameter of 8 mm. The frictional losses within the cylinder are 10 %.

– Calculate the effective piston force in the advance and return stroke at an

operating pressure of 6 bar (600 kPa).

To be calculated Solution

Advance stroke F = 188 N

Return stroke F = 158 N


Solutions

Exercise 7: Sorting of packages Solutions



Name: Date:

Fundamentals: Calculation of electrical characteristic values Sheet 2 of 3

A relay of an electropneumatic circuit is designated as follows: 580 Ω, 1 W

– Calculate the permissible operating voltage which ensures that no overload

occurs on the relay.


Max. Operating

voltage

A maximum operating voltage of 24 volts is calculated on the basis of the

formula

R

VRIIVP

2

2=⋅=⋅=




Name: Date:


Triggering of the advancing movement of a cylinder piston rod is to be achieved by

means of two pushbuttons S1 and S2. The valve coil 1M1 is energised if both

pushbuttons are actuated simultaneously and the solenoid valve 1V1 switches into

the actuated position causing the piston rod to advance. If at least one of the

pushbuttons is released, the valve switches into the initial position and the piston

rod retracts.

– Create an appropriate function table and the logic symbol.

Note

0 means: Pushbutton not actuated, i.e. piston rod not advancing


S1 S2 1M1 1V1

0 (not actuated) 0 (not actuated) 0 (not actuated) 0 (not actuated)

0 (not actuated) 1 (actuated) 0 (not actuated) 0 (not actuated)

1 (actuated) 0 (not actuated) 0 (not actuated) 0 (not actuated)

1 (actuated) 1 (actuated) 1 (actuated) 1 (actuated)

Function table

S1

S2

1M1&

Logic symbol




Name: Date:



1M1 1M2

1A1

1V1 24

35

1

1V2 1V3

1B1 1B2

1 1

2 2





Name: Date:


42

1

42

1

1 B2

K3 1M2

1 2

1B1

+24 V

0 V

K1

1412

11

K2

1412

11

K1 K2

3 4

A1 A1

A2 A2

12

22

32

42

.414

24

34

44

11

21

31

41

12

22

32

42

.414

24

34

44

11

21

31

41

12

22

32

42

.514

24

34

44

11

21

31

41

K3

1412

11

5

1M1

S1

13

14





Name: Date:


Initial position

The cylinder 1A1 is in the retracted end position in the initial position.

If the cylinder is in the retracted end position, then the electrical limit switch 1B1 is

actuated (changeover contact, connected in the form of a normally open contact)

and the changeover switch 1B1 closed and the relay K2 energised.

Steps 1-2


energise. The changeover contact K1 (in the form of a normally open contact) closes

and the solenoid coil 1M1 of the 5/2-way double solenoid valve 1V1 is energised.

The double solenoid valve 1V1 reverses. The piston end of cylinder 1A1 is filled with

compressed air whilst the piston rod end is exhausted and cylinder 1A1 advances.

As soon as the cylinder 1A1 moves out of the retracted end position, limit switch 1B1

is no longer actuated and the changeover switch 1B1 opens. This causes the

normally open contact K2 to open and the solenoid coil 1M1 to be no longer

energised. However the double solenoid valve still remains in the righthand

switching position.

Steps 2-3

Once the cylinder reaches its forward end position, the piston rod actuates the

electrical limit switch 1B2 (changeover contact, connected in the form of a normally

open contact). The changeover switch 1B2 closes and the relay K3 is energised. The

closing of the changeover contact K3 (connected in the form of a normally open

contact), also causes the solenoid coil 1M2 to be energised. The

valve 1V1 reverses.

The piston rod chamber of cylinder 1A1 is filled with compressed air whilst the

piston end is exhausted. The cylinder moves into the retracted end position again.

As soon as the electrical limit switch 1B2 is no longer actuated (changeover contact,

connected in the form of a normally open contact), the relay K3 is de-energised and

the changeover contact K3 (connected in the form of a normally open contact)

opens. This also causes the coil 1M2 to be de-energised. The cylinder remains in the





Name: Date:



an equipment list.


below.






2 Limit switch (normally open contact)

3 Relay

1 Manifold




Equipment list





Name: Date:

Fundamentals: Signal storage Sheet 1 of 3

The actuation of the pushbutton must be stored if the piston rod of a double-acting

cylinder is to advance even if the pushbutton is only briefly actuated. This signal

storage can be effected either in the power section or in the signal control section of

a circuit.

– Describe how signal storage is devised in the power section or signal control

section respectively.

Place of signal storage Description: Signal storage


power section

A double solenoid valve is to be used for signal storage.

Owing to the static friction of the valve piston, the double solenoid valve

maintains its switching position even when the corresponding solenoid

coil is no longer energised.


signal control section

By means of a spring-return solenoid valve with self-latching loop .

The relay coil is energised and a contact closes. Once the ON pushbutton

is released, current continues to flow through the coil via the closed

contact. The relay remains in the actuated position and therefore also the

spring-returned solenoid valve. Actuation of an OFF pushbutton causes the

current to be interrupted. Depending on the configuration of the two

pushbuttons, differentiation is made between dominant setting or

dominant resetting self-latching loops.


Solutions

Exercise 8: Actuation of a sliding platform Solutions



Name: Date:

Fundamentals: Analysing circuits Sheet 2 of 3

– Describe the behaviour of the circuit specified (pilot actuated, spring-return 5/2-

way solenoid valve with manual override, double-acting cylinder) in the event of

– Power failure

– Pressure failure

– Pressure and power failure.

Power failure Pressure failure

The spring-return solenoid valve switches into

the normal position, the double-acting cylinder

moves into the retracted end position. The

solenoid valve and consequently the cylinder

can be switched manually using the manual

override.

The solenoid valve switches into the normal

position due to the reduced operating

pressure, the double-acting cylinder is without

pressure and assumes an undefined position.




Name: Date:

Fundamentals: Logic functions Sheet 3 of 3

The lamp P1 is to be illuminated whenever pushbutton S1 is not actuated.

– Draw up the appropriate function table and the logic symbol.

Note

0 means: Pushbutton S1 not actuated, i.e. lamp P1 off

1 means: Pushbutton S1 actuated, i.e. lamp P1 illuminated

S1 P1

0 (not actuated) 1 (actuated)

1 (actuated) 0 (not actuated)

Function table

S2 P1

1

Logic symbol




Name: Date:



1M1

1A1

1V1 24

35

1

1V2 1V31 1

2 2





Name: Date:


12

22

32

42

.2

.3

14

24

34

44

11

21

31

41

K1

14 2412 22

11 21

1

S1

K1 1M1

+24 V 32

0 V

A1

A2

K1

S2

31

13

32

14





Name: Date:


Initial position

Cylinder 1A1 is in the retracted end position in the initial position.

Steps 1-2



contact) in current path 2 closes and activates the self-latching loop of relay K1. In

addition, the changeover contact K1 in current path 3 closes and the solenoid coil

1M1 of the 5/2-way solenoid valve 1V1 is energised. The valve 1V1 reverses. The

piston end of cylinder 1A1 is then filled with compressed air whilst the piston rod

side is exhausted. Cylinder 1A1 advances.

Steps 2-3

Actuation of pushbutton S2 (normally closed contact) cancels the self-latching loop

of relay K1. The changeover contact K1 (connected in the form of a normally open

contact) in current path 3 opens and the relay K1 is de-energised. The valve 1V1

reverses via the return spring.

The piston rod end of cylinder is filled with compressed air whilst the piston end is

exhausted. the cylinder returns into the retracted end position.




Name: Date:



an equipment list.


below.






1 Pushbutton (normally closed contact)

1 Relay

1 Manifold




Equipment list





Name: Date:


A latching relay circuit is required in order to store a signal in the signal control

section.

– The relay coil is to be energised by pressing pushbutton S1. Complete the

electrical circuit diagram below so that the relay latches after the pushbutton S1

is released.

12

22

32

42

.214

24

34

44

11

21

31

41

K1

1412

11

1

S1

K1

+24 V 2

0 V

A1

A2

13

14



Solutions

Exercise 9: Expanding a diverting device Solutions



Name: Date:


An additional normally closed contact is required in order to cancel a set latching

circuit.

Differentiation is made between two groups depending on the configuration of this

normally closed contact:

• Dominant setting self-latching loop

• Dominant resetting self-latching loop

– Complete the electrical circuit diagram so that the self-latching loop is reliably

cancelled via the actuation of a pushbutton S2.

12

22

32

42

.214

24

34

44

11

21

31

41

K1

1412

11

1

S1

K1

+24 V 2

0 V

A1

A2

S2

31

13

32

14

12

22

32

42

.214

24

34

44

11

21

31

41

K1

1412

11

1

S1

K1

+24 V 2

0 V

A1

A2

13

S2

31

3214

Electrical circuit diagram; left: Dominant resetting self-latching loop; right: Dominant setting self-latching loop



Exercise 9: Expansion of a diverting device

Name: Date:


The various circuits for signal storage exhibit different behaviour:

• with simultaneously applicable set and reset conditions

• in the event of power failure or cable fracture

– Complete the table and enter the behaviour of the respective valve.

Valve position unchanged/valve is actuated/valve switches to normal position

Signal storage via electrical latching circuit

combined with spring-return valve

Signal storage via

double solenoid

valve Dominant setting Dominant resetting

Set and reset signal shared Valve position

unchanged

Valve is actuated Valve switches to

normal position

Power failure Valve position

unchanged

Valve switches to

normal position

Valve switches to

normal position




Name: Date:

Fundamentals: Limit switches and proximity sensors Sheet 4 of 4

The function of limit switches and proximity sensors is to acquire information and to

transmit this for signal processing.

These include:

Mechanical position switches (limit switches), magnetic proximity sensors (reed

switches), optical proximity sensors, capacitive proximity sensors, inductive

proximity sensors

– Allocate the designations to the corresponding symbols in the table.

Designation Symbol

Magnetic proximity sensor (reed switch) BN

BU

BK

Optical proximity sensor BN

BU

BK

Inductive proximity sensor BN

BU

BK

Mechanical position switch (limit switch) 42

1

Capacitive proximity sensor BN

BU

BK




Name: Date:



1M1 1M2

1V1 24

351

1V2 1V3

1A1

1B1 1B2

1 1

2 2





Name: Date:


12 12 12

22 22 22

32 32 32

42 42 42

.2 .7 .8

.7

14 14 14

24 24 24

34 34 34

44 44 44

11 11 11

21 21 21

31 31 31

41 41 41

K3

1412

11

K1

24

21

K2

1412

11

K1

1412

11

1

S1

K3K2K1 1M1 1M2

+24 V 3 5 7 82 4 6

0 V

1B1 1B2

A1A1A1

A2A2 A2

S2

22

31

13

32

14

BN

BU

BK

BN

BU

BK




Exercise 9: Exansion of a diverting device

Name: Date:


Initial position


If cylinder 1A1 is in the retracted end position, then the proximity sensor 1B1 is

actuated, and the relay K2 is energised; the changeover contact K2 (connected in the

form of a normally open contact) in current path 7 closes.

Steps 1-2



contact) in current path 2 closes and activates the self-latching loop of relay K1. In

addition the changeover contact K1 (connected in the form of a normally open

contact in current path 7 closes and the solenoid coil 1M1 of the 5/2-way double

solenoid valve 1V1 is energised. The double solenoid valve 1V1 reverses. The rear

chamber of the cylinder 1A1 is now filled with compressed air whilst the front

chamber is exhausted. Cylinder 1A1 advances. As soon as the cylinder 1A1 moves

out of the retracted end position, proximity sensor 1B1 is no longer actuated. This

also causes the changeover contact K2 (connected in the form of a normally open

contact) in current path 7 to open and current no longer flows through the solenoid

coil 1M1. The double solenoid valve nevertheless remains in the righthand switching

position.

Steps 2-n

The proximity sensor 1B2 is actuated when the cylinder reaches the forward end

position and the relay K3 is energised. The changeover contact K3 (connected in the

form of a normally open contact) in current path 8 closes and the solenoid coil 1M2

is energised. This causes the valve 1V1 to return into the initial position and the

cylinder 1A1 to return into the retracted end position. The relay K3 is de-energised

as soon as proximity sensor 1B2 is no longer actuated; the changeover contact K3

(connected in the form of a normally open contact) in current path 8 opens, causing

the coil 1M2 to be de-energised.

Since the electrical latching circuit of relay K1 is still active, the solenoid coil 1M1

receives another switching pulse as soon as the retracted end position is reached so

that the cylinder 1A1 immediately advances again.




Name: Date:


Step n-(n+1)

The oscillating movement of cylinders 1A1 can be interrupted by means of pressing

pushbutton S2 (normally closed contact), thereby cancelling the self-latching loop of

relay K1. The cylinder moves into the retracted end position and remains there.




Name: Date:



an equipment list.


below.




2 Proximity sensor, electronic



1 Pushbutton (normally closed contact)

3 Relay

1 Manifold




Equipment list





Name: Date:


In contrast with limit switches proximity sensors are switched contactlessly and

without an external mechanical actuating force.

– Describe the design and function of a magnetic proximity sensor (reed switch).

Description: Design and function Symbol Schematic representation

Reed switches are magnetically actuated

proximity sensors, which consist of two contact

blades located inside an inert gas filled glass

tube. The effect of a magnet causes the two

blade contacts to be closed thereby enabling an

electrical current to flow. In the case of reed

switches in the form of normally closed contacts,

the contact blades are pretensioned by means of

small magnets. This pretension is overcome by a

much stronger switching magnet. Reed switches

have a long service live and minimal switching

time (approx. 0.2 ms).

They are maintenance-free, but must not be used

in areas subject to strong magnetic fields, (e.g. in

the proximity of resistance welders).


Solutions

Exercise 10: Designing a stamping device Solutions



Name: Date:


As regards polarity there are two different designs of electronic proximity sensors,

i.e. PNP or NPN

– Describe the differences between these two types.

PNP NPN

In the case of negative switching sensors a

supply voltage is applied at the output in the

absence of a part within the response range of

the sensor. The approaching of a workpiece or

machine part causes the output to switch to 0V

voltage.

In the case of positive switching sensors, zero

voltage is applied at the output in the absence of a

part within the response range of the sensor. The

approaching of a workpiece or machine part causes

the output to switch so that supply voltage is

applied.




Name: Date:

Fundamentals: Pressure switches Sheet 3 of 5

Pressure sensitive sensors, so-called PE converters, are used to monitor pressure in

a system.

– Describe the mode of operation of a PE converter.

Description of mode of operation

With a PE converter, a pneumatic pressure signal switches an electrical signal generator (generally in

the form of a changeover switch); consequently a pneumatic input signal is output as an electrical

signal.

If the switching pressure is adjustable, this is known as a pressure sensor.




Name: Date:

Fundamentals: Pressure sensor Sheet 4 of 5

Pressure sensors can be divided into two groups whereby differentiation is made

between:

• Pressure sensors with mechanical contact (mechanical principle of action)

• Pressure sensors with electronic switching

(electronic principle of action)

– Describe the purpose and function of the pressure sensor shown below.

Description: Purpose and function Symbol Schematic representation

Pressure sensors are used in order to generate

an electrical output signal at a defined

pressure.

With this mechanically operating pressure

sensor, the pressure acts on a piston surface.

The piston moves, if the force resulting from

the pressure exceeds the spring force, and

actuates the changeover contact. The

switching pressure can be set by pretensioning

the spring, hence this pressure sensor is

knows as a pressure switch.




Name: Date:

Fundamentals: Choice of proximity sensors Sheet 5 of 5

The end positions of a drive cylinder are to be sensed by means of proximity

sensors.

The following requirements apply regarding the proximity sensors:

• The end positions of the piston rod are to be sensed contactlessly

• The proximity sensors are to be insensitive to dust

• The piston rod and trip cam of the cylinder are made of metal

– Choose which proximity sensors meet the specified requirements and explain

your reasons for this.

Proximity sensor Reason

Inductive proximity sensor

or

magnetic proximity sensor

Both proximity sensors operate contactlessly and without

mechanical actuation. Both proximity sensors are insensitive

to dirt. Since the trip cam is made of metal, both inductive as

well as magnetic proximity sensors are feasible.




Name: Date:



1M1 1M2

1V1 24

351

1V2

1B3

1V3

1A1

1B1 1B2

p

1 1

2 2





Name: Date:


K1

1412

11

K3

1412

11

K2

1412

11

7

S1

K2 K3K1 1M1 1M2

+24 V 1 3 5 82 4 6

0 V

1B1 1B2 1B3

A1 A1A1

A2 A2 A2

p

13

14

12 1212

22 2222

32 3232

42 4242

.8 .8.714 1414

24 2424

34 3434

44 4444

11 1111

21 2121

31 3131

41 4141

BN

BU

BK

BN

BU

BK

BN

BU

BK





Name: Date:


Initial position


The proximity sensor 1B1 is actuated if the cylinder 1A1 is in the retracted end

position. This causes the relay K1 to be energised and the changeover contact K1

(connected in the form of a normally open contact) in current path 7 to be closed.

Steps 1-2

Actuation of pushbutton S1 (normally open contact) causes the solenoid coil 1M1 of

the 5/2-way double solenoid valve 1V1 to be energised. The double solenoid valve

1V1 reverses and cylinder 1A1 advances. As soon as the cylinder 1A1 moves out of

the retracted end position, the proximity sensor 1B1 is no longer actuated. This

causes the changeover contact K1 (connected in the form of a normally open

contact) in current path 7 to open and the solenoid coil 1M1 is no longer current-

carrying. The double solenoid coil nevertheless remains in the righthand switching

position.

Steps 2-3

When the cylinder reaches the forward end position, the proximity sensor 1B2 is

actuated and the relay K2 energised. The changeover contact K2 (connected in the

form of a normally open contact) in current path 8 closes. In the meantime, the

pressure sensor 1B3 measures the pressure applied at cylinder 1A1. The pressure

sensor (programmed as a normally open contact) switches if the pressure is

identical or greater than the set required value and the relay K3 is energised; the

changeover contact K3 (connected in the form of a normally open contact) in current

path 8 closes and the solenoid coil 1M2 is now energised. This causes the valve 1V1

to reverse and the cylinder 1A1 to move into the retracted end position.

As soon as the proximity sensor 1B2 is no longer actuated, the relay K2 is de-

energised and the changeover contact K2 (connected in the form of a normally open

contact) opens.

The pressure sensor (programmed as normally open contact) switches off if the set

required value is not met and the relay K3 is de-energised; the changeover contact

K3 (connected in the form of a normally open contact) in current path 8 opens

thereby also causing the coil 1M2 to be de-energised.




Name: Date:



an equipment list.


below.






1 Pressure sensor


3 Relay

1 Manifold




Equipment list





Name: Date:

Fundamentals: Designing the displacement-step diagram Sheet 1 of 3

– Design the displacement-step diagram for the problem definition described.

1A1

0

1

2A1

0

1

1 2 3 4=1

1B2

S1

2B2



Solutions

Exercise 11: Realising a pallet loading station Solutions



Name: Date:


– Design the pneumatic and electrical circuit diagrams for the pallet loading

station.

1M1 1M2

1V1 24

35

1

1V2 1V3

1A1

1B2 2B2

2V2

2

2M1

31

2A1

2V1

1 1

2 2

2

1





Name: Date:


K3

1412

11

K2

1412

11

K1

1412

11

K2K1 K3 1M1 1M2 2M1

+24 V 1 3 5 6 7 82 4

0 V

1B2 2B2

A1A1 A1

A2 A2 A2

S1

13

14

12 12 12

22 22 22

32 32 32

42 42 42

.8 .7 .614 14 14

24 24 24

34 34 34

44 44 44

11 11 11

21 21 21

31 31 31

41 41 41

BN

BU

BK

BN

BU

BK





Name: Date:


Initial position

Cylinders 1A1 and 2A1 are in the retracted end position in the initial position.

Steps 1-2

Actuation of pushbutton S1(normally open contact) causes the relay K3 to be

energised. The changeover contact K3 (connected in the form of a normally open

contact) closes and the solenoid coil 1M1 of the 5/2-way double solenoid coil 1V1 is

energised. The double solenoid valve 1V1 reverses and the cylinder 1A1 advances.

As soon as pushbutton S1 (normally open contact) is no longer actuated, the relay

K3 is de-energised and the changeover contact K3 (connected in the form of a

normally open contact) opens.

Consequently, the coil 1M1 is also de-energised.

Steps 2-3

As soon as the cylinder 1A1 reaches the forward end position, the proximity sensor

1B2 switches and the relay K1 is energised. The changeover contact K1 (connected

in the form of a normally open contact) in current path 8 closes and the solenoid coil

2M1 of the 3/2-way solenoid valve 2V1 is energised. The valve 2V1 reverses and the

cylinder 2A1 advances.

Steps 3-4

The proximity sensor 2B2 is actuated when the cylinder 2A1 reaches the forward end

position and the relay K2 is energised. The changeover contact K2 (connected in the

form of a normally open contact) in current path 7 closes. The solenoid coil 1M2 is

now energised, thereby causing the valve 1V1 to reverse and the cylinder 1A1 to

move into the retracted end position.

Relay K1 is de-energised as soon as the cylinder 1A1 moves out of the forward end

position. The normally open contact K1 in current path 8 opens and the solenoid coil

2M1 is de-energised. The return spring switches the valve 2V1 into the initial

position again and the cylinder 2A1 moves into the retracted end position.




Name: Date:



an equipment list.


below.









3 Relay

1 Manifold




Equipment list





Name: Date:

Fault finding in simple electropneuamtic circuits Sheet 1 of 4

The following fault occurs in the circuit shown below:

The piston rod of cylinder 1A1 and the piston rod of cylinder 2A1 advance and


– Describe what the potential cause of the fault could be.

1M1 1M2

1V1 24

35

1

1V2 1V3

1A1

1B2 2B2

2V2

2

2M1

31

2A1

2V1

1 1

2 2

2

1



Solutions

Exercise 12: Eliminating a fault on the pallet loading station Solutions



Name: Date:


K3

1412

11

K2

1412

11

K1

1412

11

K2K1 K3 1M1 1M2 2M1

+24 V 1 3 5 6 7 82 4

0 V

1B2 2B2

A1A1 A1

A2 A2 A2

S1

13

14

12 12 12

22 22 22

32 32 32

42 42 42

.8 .7 .614 14 14

24 24 24

34 34 34

44 44 44

11 11 11

21 21 21

31 31 31

41 41 41

BN

BU

BK

BN

BU

BK

List of potential causes of faults

Sensor 2B2 at cylinder 2A1 maldjusted, sensor faulty

Line interruption in current path 3 (e.g. cable break or loose connection)

Line interruption in signal line of sensor 2B2, current path 4(e.g. cable break or loose connection)

Line interruption in earthing wire of 1M2, current path 7 (e.g. cable break or loose connection), valve

coil 1M2 faulty

Line interruption in earthing wire of relay K2, current path 4 (e.g. cable break or loose contact), relay

K2 faulty

Line interruption in current path 7, supply line of relay contact 14 (relay K2) or supply line of relay

contact 11 (relay K2) after valve coil 1M2 (e.g. cable break or loose contact)




Name: Date:


A cable break occurs at the points marked in the circuit shown below.

– Describe what the effects of a cable break at these respective points are on the

functioning of the circuit.

K3

1412

11

K2

1412

11

K1

1412

11

K2K1 K3 1M1 1M2 2M1

+24 V 1 3 5 6 7 82 4

0 V

1B2 2B2

A1A1 A1

A2 A2 A2

S1

13

14

12 12 12

22 22 22

32 32 32

42 42 42

.8 .7 .614 14 14

24 24 24

34 34 34

44 44 44

11 11 11

21 21 21

31 31 31

41 41 41

BN

BU

BK

BN

BU

BK





Name: Date:


Fault Effect of fault

Break in earthing wire of

relay K1, current path 2

Piston rod of cylinder 1A1 advances, sensor 1B2 is actuated => Relay K1 is not energised => Relay contact in

current path 8 (changeover contact, connected in the form of normally open contact) does not switch =>

Piston rod of cylinder 2A1 does not move into the forward end position (remains retracted), sensor 2B2 is

not actuated => Piston rod of cylinder 1A1 remains advanced since 1M2 is not actuated.

Break in signal wire of

sensor 2B2,

current path 4

Piston rod of cylinder 1A1 advances, sensor 1B2 is actuated => Piston rod of cylinder2A1 moves into the

forward end position, sensor 2B2 is actuated => Relay K2 is not energised => Relay contact in current path 7

(changeover contact, connected in the form of a normally open contact) does not switch => Piston rod of 1A1

and piston rod of cylinder 2A1 remain advanced.


K3, current path 5

Current path 5 is not closed, relay K3 is not energised, no reaction in response to start signal => Piston rod

of cylinder 1A1 and piston rod of cylinder 2A1 remain retracted.


contact 14

(relay K2), current path 7

Piston rod of cylinder 1A1 advances, sensor 1B2 is actuated => Piston rod of cylinder 2A1 moves into the

forward end position, sensor 2B2 is actuated => Relay K2 is energised, relay contact in current path 7

(changeover contact, connected in the form of a normally open contact) switches, but valve coil 1M2 is not

energised due to cable break => Piston rod of cylinder 1A1 and piston rod of cylinder 2A1 remain advanced.

Break in earthing wire 2M1,

current path 8

Piston rod of cylinder 1A1 advances => Sensor 1B2 is actuated => Relay K1is energised, relay contact in

current path 8 (changeover contact, connected in the form of a normally open contact) switches, but valve

coil 2M1 is not energised due to cable break => Piston rod of cylinder 2A1 remains retracted, piston rod of

1A1 remains advanced.




Name: Date:

List of faults Sheet 1 of 1

Simulation of faults Cause of fault Effect of fault

Displace sensor 1B2 on cylinder

1A1 in the retracted end position

direction

Sensor 1B2 at cylinder

1A1 maladjusted

Piston rod of cylinder 1A1 advances, sensor 1B2 is briefly actuated =>

Piston rod of cylinder 2A1 does not move up to the forward end position,

sensor 2B2 is not actuated => Piston rod of cylinder 1A1 remains

advanced since 1M2 is not actuated.

Remove sensor 1B2 signal line or

displace sensor at forward end

position

Cable break in signal line

of sensor 1B2, or sensor

maladjusted

Piston rod of cylinder 1A1 advances => No sensor signal, i.e. sensor 1B2

is not actuated => Piston rod of cylinder 2A1 remains retracted, piston

rod of cylinder 1A1 remains advanced.

Remove sensor 2B2 signal line or

displace sensor at forward end

position

Cable break in signal line

of sensor 2B2, or sensor

maladjusted

Piston rod of cylinder 1A1 advances, sensor 1B2 is actuated => Piston

rod of cylinder 2A1 advances into the forward end position, no sensor

signal, i.e. sensor 2B2 is not actuated => Piston rod of cylinder 1A1 and

piston rod of cylinder 2A1 remain advanced.

Interrupt current path 2 (e.g.

earthing wire of relay K1, signal

line or current path 8, e.g. supply

lines of relay contact 14 or relay

contact 11 (relay K1), remove

earthing wire of 2M1

Cable break in earthing

wire of 2M1, K1 or supply

lines of relay contact

14/11 (relay K1)

Piston rod of cylinder 1A1 advances => Piston rod of cylinder 2A1

remains retracted since current path 2 or current path 8 is interrupted.

Interrupt earthing wire of relay K2,

current path 4 or current path 7,

or remove relay K2 or supply lines

of relay contact 14 or relay contact

11 (relays K2), earthing wire of

1M2


wire of 1M2, K2 or supply

lines of relay contact

14/11 (relay K2)

Piston rod of cylinder 1A1 and piston rod of cylinder 2A1 advance and


Interrupt earthing wire of relay K3,

current path 5 or current path 6

Remove 1M1 or K3 or supply line

of relay contact 14 at K3


wire 1M1, K3 or supply

line of relay contact 14 at

K3

No reaction to start signal => Piston rod of cylinder 1A1 and piston rod of

cylinder 2A1 remain retracted.




Name: Date:

Notes for the trainer Sheet 1 of 1

Notes for the trainer

It is advisable to deal with this exercise after solving exercise 11 of TP 201, since the

correct configuration of circuit will then be available and in tested form.

The fault can be directly built into the circuit by the trainer (see list of simulation of

faults).

It is important to make sure that trainees proceed systematically during fault finding.

Alternative

If the circuit of exercise 11 is not available fully assembled, it is also possible to

carry out the fault finding theoretically:

• The trainer explains the fault („cylinder 1A1 advances, the circuit then comes to a

stop.“)

• Trainees then localise the fault with the help of the function chart.

• Trainees draw up a list of potential causes of faults and describe how they

proceed during the fault finding (where do you need to measure, what needs to

be checked).

© Festo Didactic GmbH & Co. KG • 541090 D-1

Organiser __________________________________________________________ D-2

Assembly technology ________________________________________________ D-3

Plastic tubing_______________________________________________________ D-4

Single-acting cylinder _____________________________________________ 152887

Double-acting cylinder ____________________________________________ 152888

Manifold________________________________________________________ 152896

Relay, 3 off______________________________________________________ 162241

Signal input plate, electrical________________________________________ 162242

Proximity sensor, optical __________________________________________ 178577

Limit switch, electrical, actuated from the left__________________________ 183322

Limit switch, electrical, actuated from the right ________________________ 183345

Pressure sensor with display _______________________________________ 539757

One-way flow control valve_________________________________________ 539773

2 x 3/2-way solenoid valve with LED, normally closed ___________________ 539776

5/2-way solenoid valve with LED ____________________________________ 539777

5/2-way double solenoid valve with LED______________________________ 539778

Start-up valve with filter control valve ________________________________ 540691

Proximity sensor, electronic, with cylinder mounting ____________________ 540695

Part D – Appendix

Data sheets

D-2 © Festo Didactic GmbH & Co. KG • 541090

Equipment set in the organiser

All components of the equipment set for the technology package TP201 are stored in

an organiser within a Systainer. The organiser also serves as a drawer insert for use

in conjunction with our range of laboratory furniture.

Organiser

© Festo Didactic GmbH & Co. KG • 541090 D-3

The components of the equipment set are intended for assembly on the Festo

Didactic profile plate, which consists of 14parallel T-slots, 50 mm apart.

Three variants are available for the assembly of equipment on the profile plate:

Variant A

A latching system, without auxiliary means, clamping mechanism using a lever and

spring, adjustable in the direction of the slot, for lightweight non-loadable

components.

Variant B

A rotary system, without auxiliary means, knurled nut with locking disc and T-head

bolts, vertical or horizontal alignment, for medium weight loadable components .

Variant C

A screw system, with auxiliary means, socket head screw with T-head bolt, vertical

and horizontal alignment, for heavy loadable components and equipment which is

rarely released from the profile plate.

The proven ER units on plug-in board can be attached to the profile plate with

adapters.

In the case of variant A, a slide is engaged in the T-slot of the profile plate. The slide

is pre-tensioned by means of a spring and, by pressing the blue lever, is pulled back

whereby the component can be removed from or attached to the profile plate.

Components are aligned along the slot and can be moved in the direction of the slot.

With variant B, components are attached to the profile plate by means of a T-head

bolt and blue knurled nut. A locking disc serves to fix the device in position, which

can be secured in any 90° direction. Devices can thus be mounted on the profile

plate either lengthwise or diagonally to the slot.

Once the desired locking disc position is set, the device is mounted on the profile

plate. By turning the knurled nut in a clockwise direction, the T-head bolt is turned in

the slot by 90° owing to thread friction. The component is pressed against the profile

plate by further turning the knurled nut.

Assembly technology

D-4 © Festo Didactic GmbH & Co. KG • 541090

Variant C is used for heavy or similar devices, screwed on to the profile plate only

once or very seldom. Components are attached by means of socket head screws

with internal hex and T-head bolts.

The time-tested ER units on a plug-in board with locating pins in a 50 mm grid can be

mounted on the profile plate using adapters. A black plastic adapter is required for

each locating pin. The adapters are plugged into the T-slot, positioned at intervals of

50 mm and secured by means of a 90° turn. The locating pins of the ER unit are

plugged into the adapter holes.

The polyurethane tubing is particularly flexible and kink resistant.

Technical data

Pneumatics

Colour Silver metallic

Outer diameterr 4 mm

Inner diameter 2.6 mm

Minimum bending radius within

temperature range of -35 to +60°C

17 mm

Maximum operating pressure

within temperature range of -35 to +30°C

within temperature range of +30 to +40°C

within temperature range of +40 to +60°C

10 bar (1000 kPa)

9 bar (900 kPa)

7 bar (700 kPa)

Subject to change

Plastic tubing

152887

Single-acting cylinder

© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/1

The single-acting cylinder with trip cam and push-in fitting is mounted on a plastic

retainer. The unit is mounted on the profile plate via quick release detent system

with two blue trip grip nuts (mounting alternative "B").

The piston rod of the single-acting cylinder moves into the forward end position

through the supply of compressed air. When the compressed air is switched off, the

piston is returned to the retracted end position via a return spring.

The magnetic field of a permanent magnet, which is attached to the cylinder piston,

actuates the proximity switches.

Pneumatic

Medium Compressed air, filtered (lubricated or unlubricated)

Design Piston cylinder

Operating pressure max. 1000 kPa (10 bar)

Piston diameter 20 mm

Max. stroke length 50 mm

Thrust at 600 kPa (6 bar) 139 N

Spring return force min. 13.6 N

Connection QS-G1/8-4 fittings for plastic tubing PUN 4 x 0.75

Design

Function

Technical data

© Festo Didactic GmbH & Co. KG, 07/2005

152888

Double-acting cylinder


The double-acting cylinder with trip cam and push-in fittings is mounted on a plastic

retainer. The unit is mounted on the profile plate via a quick release detent system

with two triple grip nuts (mounting alternative "B").

The piston rod of the double-acting cylinder is reversed by means of alternating

supply of compressed air. End position cushioning at both ends prevents a sudden

impact of the piston on the cylinder housing. The end position cushioning can be

adjusted by means of two regulating screws.

The magnetic field of a permanent magnet attached to the cylinder piston actuates

the proximity switches.

Pneumatic


Design Piston cylinder

Operating pressure max. 1000 kPa (10 bar)

Piston diameter 20 mm

Max. stroke length 100 mm

Thrust at 600 kPa (6 bar) 189 N

Return force at 600 kPa (6 bar) 158 N

Connection QS-G1/8-4 fittings for plastic tubing PUN 4 x 0.75

Design

Function

Technical data


152896

Manifold


The manifold with eight self-sealing push-in fittings is screwed on to a universal

plate. The unit is mounted on the profile plate via a quick release detent system with

blue lever (mounting alternative "A").

The manifold with a common P-supply enables a control system to be supplied with

compressed air eight individual connections.

Pneumatic

Connection 1 QS-1/8-6 for plastic tubing PUN 6 x 1

8 QSK-1/8-4 for plastic tubing PUN 4 x 0.75

Design

Function

Technical data


162241

Relay, 3-off


This component consists of three relays with connections and two bus-bars for the

power supply. All electrical connections are in the form of 4 mm sockets. The unit

can be mounted in a mounting frame or on the profile plate using four plug-in

adapters.

1412 2422 3432

32

4442

11 21 31 41

A1

A2

1412 2422 34 4442

11 21 41

A1

A231

1412 2422 3432 4442

11 21 31 41

A1

A2

Design

162241

Relay, 3-off

2/4 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005

124A1 A2

2 3

1

5

67

4

The relay consists of a coil with a core (1) and winding (3) with connection lugs (7),

an armature (4), a return spring (2) and a contact assembly with four changeover

contacts (5) and connection lugs (6). When power is applied to the coil connections,

current flows through the winding, creating a magnetic field. The armature is pulled

onto the coil core and the contact assembly is actuated. Electrical circuits are

opened or closed via this assembly.

When the electrical current is removed, the magnetic field collapses and the

armature and contact assembly are returned to their original position by a return

spring.

The switching status of the relays is indicated by LEDs, which are protected against

incorrect polarity.

The four changeover contacts of the contact assembly can be used as normally-open

contacts (1), normally-closed contacts (2) or changeover contacts (3).

Function

Note

162241

Relay, 3-off


1M1

1

S1

13

14

+24 V

0 V

K1

2

A1

A2

K1

1412

11

12

22

32

42

.214

24

34

44

11

21

31

41

Example of application: Circuit diagram, electrical

1+24 V 2

1412

11

K1

A1

A2

Changeover switch connected asnormally-open contact

1+24 V 2

1412

11

K1

A1

A2

Changeover switch connected asnormally-closed contact

Normally-open contacts, normally-closed contacts: Allocation of contacts on relay plate

162241

Relay, 3-off


Electrical

Voltage 24 V DC

Contact assembly 4 changeover contacts

Contact rating Max. 5 A

Contact interrupt rating Max. 90 W

Pichup time 10 ms

Drop-off time 8 ms

Connections For 4 mm safety connector plug

Electromagnetic compatibility

Emitted interference tested to EN 500 81-1

Noise immunity tested to EN 500 82-1

Technical data

162242

Signal input plate, electrical


This component consists of two illuminated pushbuttons in the form of momentary-

contact switches and one illuminated pushbutton in the form of a detented switch.

All electrical connections are in the form of 4 mm safety connectors. The unit can be

mounted in a mounting frame or on the profile plate using four plug-in adapters.

The illuminated pushbutton in the form of a detented switch consists of a contact

assembly with two normally-open contacts and two normally-closed contacts,

together with a colourless transparent pushbutton cap with a miniature lamp. The

contact assembly is actuated by pressing this cap. Electrical circuits are opened or

closed via the contact assembly. When the cap is released, the switching status is

maintained. The contact assembly is returned to its initial position by pressing the

pushbutton a second time.

The illuminated pushbuttons in the form of momentary-contact switches consist of

a contact assembly with two normally-open contacts and two normally-closed

contacts, together with a colourless transparent pushbutton cap with a miniature

lamp. The contact assembly is actuated by pressing this cap. Electrical circuits are

opened or closed via the contact assembly. When the cap is released, the contact

assembly returns to its initial position.

13

13

13

23

23

23

14

14

14

24

24

24

31

31

31

41

41

41

32

32

32

42

42

42

Design

Function

162242

Signal input plate, electrical


When power is applied to the connections of the visual indicator, the switching

status is displayed by the built-in miniature lamp in the pushbuttons.

1M1

1

S1

13

14

+24 V

0 V

K1

2

A1

A2

K1

1412

11

12

22

32

42

.214

24

34

44

11

21

31

41

Example: Circuit diagram, electrical

Electrical

Voltage 24 V DC

Contact assembly 2 normally-open contacts, 2 normally-closed contacts


Power consumption (miniature lamp) 0.48 W

Connections For 4 mm safety connector plug




Note

Technical data

178577



The optical proximity sensor with LED and electrical connections is assembled on a

polymer assembly base. The electrical connection is effected by means of safety

connectors or via a 3-pin plug socket. The unit is mounted on the profile plate via a

quick release detent system with blue triple grip nut (mounting alternative “B”).

Optical proximity sensors consist of two main modules, the emitter and the receiver.

In the case of diffuse sensor, these are built into one housing. The emitter of the

diffuse sensor emits a pulsating, red light which is within the visible spectral range.

The object to be detected reflects part of the light emitted. This light is detected by a

semiconductor device in the receiver which is also built into the sensor housing and

causes a change in the switching status.

The object to be detected may be reflective, matt, transparent or opaque. All that is

needed is for a sufficiently high proportion of light to be reflected directly or

diffusely.

The operational switching distance may be varied by means of a potentiometer. The

proximity sensor has a PNP output, i.e. the signal line is switched to the positive

potential in the switched status. The switch is designed as a normally closed

contact. The connection of the load takes place between the signal output of the

proximity sensor and the load. The switching status is indicated by a yellow LED. The

sensor is protected against polarity reversal, overload and short circuit.

Design

Function

178577



+24V-

B

BN

BU

BK

+

S

The correct polarity of the applied voltage is necessary for proper functioning. The

connections for the operating voltage are colour coded as follows: red for positive,

blue for negative and black for the signal output. The load is connected to the

switching output and the negative terminal of the current supply.

Electrical

Switching voltage 10 – 30 V DC

Residual ripple maximum 10%

Nominal switching distance 0 to 100 mm (adjustable)

Switching frequency maximum 200 Hz

Output function Normally open contact, positive switching

Output current maximum 100 mA

Protection class IP65

Connections for 4 mm safety connector plug or 3-pin socket

Cable with 4 mm safety connector plug


Eitted interference tested to EN 500 81-1


Note

Technical Data

183322

Limit switch, electrical, actuated from the left


The two electrical limit switches, order no. 183322 for actuation from the left and

order no. 183345 for actuation from the right, have the same symbol in the circuit

diagram.

A microswitch with roller lever and electrical connections is installed in a plastic

housing. The electrical connection is effected by means of safety connectors or via a

3-pin plug socket. The component is mounted on the profile plate using the rotary

system by means of two blue grip nuts (mounting variant “B”).

This electrical limit switch consists of a mechanically-actuated microswitch. It is

actuated when the roller lever is pressed, for example by the trip cam of a cylinder.

The switch contacts are used to open or close a circuit. The microswitch returns to

its original position when the roller lever is released.

42

1

Design

Function

183322

Limit switch, electrical, actuated from the left


The microswitch can be connected up to act as a normally-open contact (1),

normally-closed contact (2) or changeover contact (3). In cases where piston speeds

are high, the limit switch should be actuated by the trip cam of a cylinder only in the

specified direction. The limit switch must not be actuated from the front.

Electrical

Design Mechanically-actuated electrical microswitch in limit-switch

housing

Voltage 24 V DC


Switching frequency Max. 200 Hz

Reproducible switching accuracy 0.2 mm

Switch travel 2.7 mm

Actuation force 5 N

Connection For 4 mm safety connector plug or 3-pin plug socket




Note

Technical data

183345

Limit switch, electrical, actuated from the right


The two electrical limit switches, order no. 183322 for actuation from the left and

order no. 183345 for actuation from the right, have the same symbol in the circuit

diagram.

A microswitch with roller lever and electrical connections is installed in a plastic

housing. The electrical connection is effected by means of safety connectors or via a

3-pin plug socket. The component is mounted on the profile plate using the rotary

system by means of two blue grip nuts (mounting variant “B”).

This electrical limit switch consists of a mechanically-actuated microswitch. It is

actuated when the roller lever is pressed, for example by the trip cam of a cylinder.

The switch contacts are used to open or close a circuit. The microswitch returns to

its original position when the roller lever is released.

42

1

Design

Function

183345

Limit switch, electrical, actuated from the right


The microswitch can be connected up to act as a normally-open contact (1),

normally-closed contact (2) or changeover contact (3). In cases where piston speeds

are high, the limit switch should be actuated by the trip cam of a cylinder only in the

specified direction. The limit switch must not be actuated from the front.

Electrical

Design Mechanically-actuated electrical microswitch in limit-switch

housing

Voltage 24 V DC


Switching frequency Max. 200 Hz

Reproducible switching accuracy 0.2 mm

Switch travel 2.7 mm

Actuation force 5 N

Connection For 4 mm safety connector plug or 3-pin plug socket




Note

Technical data

539757

Pressure sensor with display


The pressure sensor with display is screwed onto the adapter plate plate. The unit is

attached via the grid system with the blue lever (assembly variant „A“).

The pressure sensor is a piezoresistive relative pressure transducer with integrated

amplifier and built-in temperature compensation. The pressure to be measured is

transferred onto a silicone coated piezoresistive element. The signal change

generated therein is output as a voltage or switching signal at the connector plug via

an intergrated amplifer.

p

Design

Function

539757

Pressure sensor with display


+24V-

BBN

BU

BKp

The polarity of the applied voltage is to be observed for the correct functioning of

the device. The connections for the operating voltage are to be identified by colour:

Red for positive and blue for negative. The signal output is black. The load is to be

connected to the switch output and to the negative pole of the power supply.

Electrics

Switching voltage 15 – 30V DC

Residual ripple Max. 10%

Operating pressure 0 to 10 bar (0 to 1000 kPa)

Analogue output 0 to 10 V

Output function Normally open contact, positive switching

Switching current Max. 150 mA


Connection Plug M8x1

Cable With 4 mm jack plug


Emitted interference Tested to EN 500 81-1

Noise immunity Tested to EN 500 82-1

Note

Technical data

539773

One-way flow control valve


The adjustable one-way flow control valve is screwed into the function plate,

incorporating a straight push-in fitting. The unit is slotted into the profile plate via a

quick release detent system with a blue lever (mounting alternative “A”).

The one-way flow control valve consists of a combination of a flow control valve and

a non-return valve.

The non-return valve blocks the flow of air in one direction, whereby the air flows via

the flow control valve. The throttle cross section is adjustable by means of a knurled

screw. The setting can be fixed by means of a knurled nut. Two arrows indicate the

direction of flow control on the housing. In the opposite direction, the air flow is

unrestricted via the non-return valve.

Pneumatic

Medium Compressed air, filtered, (lubricated or unlubricated)

Design One-way flow control valve

Pressure range 20 to 1000 kPa (0.2 to 10 bar)

Standard nominal flow rate in throttled direction: 0 – 110 l/min

free flow direction: 110 l/min (Throttle open)

65 l/min (Throttle closed)

Connection QSM-M5-4 for plastic tubing PUN 4 x 0.75

21

Design

Function

Technical Data


539776

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


This 3/2-way single solenoid valve with push-in fittings is attached to a function

plate which is equipped with a P port and silencer. The two electrical connections

are equipped with safety connectors. The unit is mounted on the profile plate using

a quick release detent system with a blue lever (mounting alternative "A").

The solenoid valve is reversed when voltage is applied to the solenoid coil (1 2)

and brought back into its initial position (1 0) by a return spring when the signal

is removed. The switching status is displayed via an LED in the terminal housing. The

valve is equipped with a manual override.

The solenoid coil is characterised by very low power consumption and low heat

generation. The electrical connection incorporates protection against incorrect

polarity for the LED and a protective circuit.

2

1M1

31

1M1

Design

Function

Note

539776

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


Pneumatic


Design Spool valve, pilot-actuated, with return spring

Pressure range 300 to 800 kPa (3 to 8 bar)

Switching time at 600 kPa (6 bar) On: 20 ms

Off: 33 ms

Standard nominal flow rate 1000 l/min

Connection QS 3 for plastic tubing PUN 4 x 0.75

Electrical

Voltage 24 V DC

Duty cycle 100 %


Connection M8x1 central plug, cable with socket and 4 mm safety plugs

Technical Data

539777

5/2-way single solenoid valve with LED


This 5/2-way single solenoid valve with push-in fittings is bolted onto a function

plate which is equipped with a P port and silencer. The two electrical connections


a snap-lock system with a blue lever (mounting variant "A").

The solenoid valve is reversed when voltage is applied to the solenoid coil (1 4)

and brought back into its initial position (1 2) by a return spring when the signal

is removed. The switching status is shown by an LED in the terminal housing. The

valve is equipped with a manual override.


generation. The electrical connection incorporates protection against incorrect

polarity for the LED and a protective circuit.

1M1

24

35 1

1M1

Design

Function

Note

539777

5/2-way single solenoid valve with LED


Pneumatic


Design Spool valve, pilot-actuated, with return spring


Switching time at 600 kPa (6 bar) On: 25 ms

OFF: 40 ms


Connection QS-1/8-4-I fittings for plastic tubing PUN 4 x 0.75

Electrical

Voltage 24 V DC

Duty cycle 100 %



Technical Data

539778

5/2-way double solenoid valve with LED


This 5/2-way double solenoid valve with push-in fitting is bolted onto a function

plate which is equipped with a P port and silencer. The four electrical connections


a snap-lock system with a blue lever (mounting variant "A").

The double solenoid valve is reversed when voltage is applied to a solenoid coil and

remains in this switching position after the signal is removed until an opposed signal

is applied. The presence of switching signals is shown by the LEDs in the terminal

housings. The valve is equipped with a manual override.


generation. The electrical connections incorporate protection against incorrect

polarity for the LEDs and protective circuits.

1M1 1M2

24

35 1

1M1 1M2

Design

Function

Note

539778

5/2-way double solenoid valve with LED


Pneumatic


Design Spool valve, pilot-actuated


Switching time at 600 kPa (6 bar) 15 ms


Connection 3 QS-1/8-4-I fittings for plastic tubing PUN 4 x 0.75

Electrical

Voltage 24 V DC

Duty cycle 100 %



Technical Data

540691



The filter regulator with pressure gauge, on/off valve, push-in fitting and quick

coupling plug is mounted on a swivelling retainer. The filter bowl is fitted with a

metal bowl guard. The unit is mounted on the profile plate by means of cheese head

screws and T-head nuts (mounting alternative “C”). Attached is a quick coupling

socket with threaded bush and connector nut for plastic tubing PUN 6 x 1.

The filter with water separator cleans the compressed air of dirt, pipe scale, rust and

condensate.

The pressure regulator adjusts the compressed air supplied to the set operating

pressure and compensates for pressure fluctuations. An arrow on the housing

indicates the direction of flow. The filter bowl is fitted with a filter drain screw. The

pressure gauge shows the preset pressure. The on/off valve exhausts the entire

control. The 3/2-way valve is actuated via the blue sliding sleeve.

2

31

2

31

Design

Function

540691



When constructing a circuit, please ensure that the filter regulator is installed in the

vertical position. The pressure regulator is fitted with an adjusting knob, which can

be turned to set the required pressure. By sliding the adjusting knob towards the

housing, the setting can be locked.

Pneumatic

Medium Compressed air

Design Sintered filter with water separator, diaphragm control valve

Assembly position Vertical ±5°

Standard nominal flow rate * 110 l/min

Upstream pressure 100 to 1000 kPa (1 to 10 bar)

Operating pressure 50 to 700 kPa (0.5 to 7 bar)

Connection Coupling plug for coupling socket G1/8 QS push-in fitting for

plastic tubing PUN 6 x 1

* Upstream pressure: 1000 kPa (10 bar), Operating pressure: 600 kPa (6 bar),

Differential pressure: 100 kPa (1 bar).

Note

Technical Data

540695

Proximity sensor, electronic, with cylinder mounting


The proximity sensor consists of the sensor, mounting kit and cable . The cable is

equipped with a socket and three jack plugs.

This proximity sensor emits an electrical signal when approaching a magnetic field

(e.g. permanent magnet on a cylinder piston). The electrical connections are

moulded into the cable. The switching status is indicated via an LED. The yellow LED

is illuminated when actuated.

+24V-

B

BN

BU

BK

+

The polarity of the applied voltage is to be observed for the correct functioning of

the device. The wires inside the socket cable must therefore be allocated by colour:

Red (BN) for positive, blue (BU) for negative and black (BK) for the signal output. In

this case, the load (relay) is connected to the sensor and to the negative pole. The

switch is protected against reverse polarity but not against short circuit.

Design

Function

Note

540695

Proximity sensor, electronic, with cylinder mounting


Electrics

Switching voltage 10 to 30 V DC

Switching current Max. 200 mA

Switching accuracy ±0.1 mm

Switching time On: 0.5 ms

Off: 0.5 ms

Connection M 8x1 plug socket for socket with cable

Cable With 4 mm jack plug


Emitted interference Tested to EN 500 81-1

Noise immunity Tested to EN 500 82-1

Technical data

Documents

Elektropneumatika Seminari