Pneumatic circuit design

7/27/2019 Pneumatic circuit design

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PROJECT EXERCISES

Exercise 1

Direct control of Double Acting Cylinder

Task: The piston of a double acting cylinder should advance on actuation of a push button

valve. After releasing the push button the cylinder retract back to its initial position

automatically

Condition: It is required that force should be exerted both during forward and return motion

Suggestion for the positioning of equipment on the working plate

Table: List of Equipment

04 Double-acting Cylinder (Z1)

08 5/2 Way Directional Control Valve (Single Pivoted)

02 Distributor manifold ( 6 fold)

01 Air Service unit (Filter Regulator assembly)


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Pneumatic circuit diagram

Selection: A Double acting cylinder has to be selected to meet the condition. A single piloted

valve can satisfy the task.

Task

The piston rod of a double-working cylinder (Z1) should extend after actuating a button.

After releasing the button (S1), the piston of the cylinder should retract automatically to its

back position.

Additions to the circuit diagram. All connections should be marked with the connection

symbols according to ISO 5599 or RP 68 P.Pneumatic circuit diagram

The cylinder is retracted in neutral position. The double-acting cylinder is directly controlled

by a manually operated 5/2 directional control valve (pos. 8). The spring cushioning mounted

in the cylinder can be adjusted.

Fig. 01: Pneumatic Circuit diagram: Direct control of double acting cylinder


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Exercise 2

Indirect control of Double Acting Cylinder

Task: On actuation of a manual push button a Double acting cylinder with large volume hasto advance. After releasing the push button the cylinder should automatically return to home

position


Condition: It is required that force should be exerted only in during the forward motion


04 Double-acting Cylinder (Z1)

10 5/2 Way Directional Control Valve (Single Piloted)

06 3/2 way Push button valve (NC)




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Selection: A Double acting cylinder has to be selected to meet the condition. A single piloted

valve can satisfy the task.

Aim

This exercise demonstrates the indirect control of a double-acting cylinder with a

pneumatically operated 5/2 directional control valve.

Task

The piston rod of a double-acting cylinder (drive element Z1), retracted in neutral position,

should extend after actuating a button (controlling element S1). Control of the cylinder (Z1)

should occur indirectly. After releasing the push-button (S1), the piston of the cylinder shouldretract automatically to its back position. Additions to the circuit plan. All connections should

be marked with the connection symbols according to ISO 5599 or RP 68 P.


A pneumatically operated 5/2 directional control valve (actuator) is controlled with a

manually operated 3/2 directional control valve (signaling element S1). The piston rod of the

double-acting cylinder (actuating drive Z1) extends.

Fig. 01: PneumaticCircuit diagram: Indirect control of double acting cylinder


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Exercise 2

Indirect control of Single Acting Cylinder



03 Single -acting Cylinder (Z1)

09 3/2 Way Directional Control Valve (Single Piloted)

[Use 5/2 way Single piloted valve and block port B]




Aim

This exercises conveys know-how on the indirect control of cylinders, using a single-acting

cylinder and a pneumatically operated 3/2 directional control valve as an example


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Task

The piston rod of a single-acting cylinder (Z1), retracted in neutral position, should advance

after pushing an easily pressed button (S1). Note: for the control of a large volume cylinder

(with a large piston diameter) an accordingly dimensioned directional control valve is

necessary. The cylinder is mounted a slight distance from the button (S1). After releasing the

manual pushbutton, the piston of the cylinder should retract automatically into its back

position. Additions to the circuit diagram. All connections should be marked with the portsymbols according to ISO 5599 or RP 68 P.


A manually operated 3/2 directional control valve in closed neutral position (start button S1)

applies pressure to a pneumatically operated 3/2 directional control valve. A large volume

single-acting cylinder is controlled via a pneumatically operated 3/2 directional control valve

(pos. 9), the piston rod extends.

Fig. 01: PneumaticCircuit diagram: Indirect control of single acting cylinder


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Exercise 3Speed Control of Single Acting CylinderSlow Speed Extension and

Rapid Retraction

Task: On actuation of a manual push button a Single acting cylinder should advance and

return to initial position after releasing the push button. The forward speed of the cylinder

should be slow and controllable. The return speed should be faster than the nominal speed.



03 Single acting Cylinder (Z1)

16 Quick Exhaust Valve

15 One way flow control valve




Aim

In addition to throttling the cylinder speed, this exercise shows how to achieve the highest

possible speed when retracting the piston rod by using a quick-exhaust valve.


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Task

The piston rod of a large volume, single-acting cylinder (Z1) is to extend with restricted,

adjustable speed. The retraction of the piston rod should occur at the highest possible speed,

also when the directional control valve (S1) is mounted a distance away from the cylinder.

The cylinder is controlled by a manually operated button (S1). After releasing the button, the

piston rod should retract automatically into its back position. Additions to the circuit diagram.All connections should be marked with the connection symbols according to ISO 5599 or RP

68 P.


Via the flow control valve with no return mounted in the working line the speed of the piston

rod when extending can be infinitely restricted. Through the quick-exhaust valve, also

mounted in the working line (as near to the cylinder port as possible), the cylinder piston

retracts with the maximum possible speed.

Fig. 01: PneumaticCircuit diagram: Speed Control of Single Acting CylinderSlow Speed Extension and Rapid

Retraction


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Exercise 4

Position Dependent Control of a Double Acting Cylinder with Mechanical

Limit Switches

Task: A Double acting cylinder is required to perform continuous reciprocating motions on

actuation of a detent manual push button. The piston should extend and retract over the

complete stroke length as interrogated by mechanical limit switches. The speed of travel of

the piston should be adjustable both during the forward and return motions



04 01 Double acting Cylinder (Z1)

11 01 Double Piloted 5/2 way Valve

15 02 One way flow control valves

06 01 3/2 way Push button valve (NC) with detent

13 02 3/2 way roller lever N.C. valve [Limit switches]

02 01 Distributor manifold ( 6 fold)

01 01 Air Service unit (Filter Regulator assembly)

Aim

The displacement-dependent control of a double-acting cylinder by using limit switches is

demonstrated in this exercise


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If the start button (S0) is actuated and the feeler roll (S1) mounted in the back end position of

the cylinder (Z1) is also actuated, then the signal reaches port 14 of the impulse valve and

switches it over, extending the piston rod. If limit switch S2 is contacted by the piston rod

plunger, the signal arrives at port 12 of the impulse valve, the impulse valve switches back to

the right switch position, the piston retracts. The limit switch S1 is actuated in the back end

position of the piston; now the control is ready for a new start. The speed of both cylinder

movements is infinitely adjusted with the flow control valves with non-return.

Fig. 01: PneumaticCircuit diagram: Position Dependent Control of a Double Acting Cylinder

with Mechanical Limit Switches


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Exercise 5

Logical Control with Shuttle and Twin-Pressure Valves

Task: The Piston of double acting cylinder of a supply station supplies work pieces under the

following logical conditions: The start button (S0) or an auxiliary button (S1) is actuated and

parts are available in the work piece magazine (B2) An optical display shows whether there

are still enough parts available in the magazine. The cylinder should only retract into its back

end position if it has actuation reached the front end position and an acknowledgement button

(S4) is actuated. A 5/2 impulse valve is used as an actuator. Additionally: for scanning work

pieces in the magazine (B2) it is not possible to use a mechanically operated signaler. The

scanning should therefore occur in a non-contact manner through a reflex sensor. The

working speed of the cylinder should be infinitely adjustable in both.

Aim

This exercise uses a logical control to demonstrate the use of the logic basic functions OR

(shuttle valve) or AND (two-pressure valve) in pneumatics. In this exercise, a proximity

switching signaling element (reflex nozzle) is also used.


Signal pressure then reaches the control line 14 of the actuating drive (piston extends) ifthe

following conditions prove true: the button S0 OR the button S1 is actuated, AND the reflexnozzle B2 (amplifier pos. 26) has switched. Signal pressure then reaches the control line 12

(piston retracts) of the actuating drive ifthe limit switch S3 AND the button S4 are actuated.

The reflex nozzle is supplied with low pressure of 0.4 bar via the pressure regulating valve

with filter pos. 24. The pneumatic pressure display indicates whether the reflex nozzle or the

amplifier is supplying a signal.

Example of application


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Position Qty Description of component

04 01 Double acting Cylinder (Z1)

11 01 5/2 double Piloted Valve

13 02 3/2 way D.C. Valve (N.C.) Roller operated

18 01 Shuttle Valve, OR

19 02 Two Pressure Valves, AND

20 01 Pressure display,pneumatic,red,minimum pressure1.2bar

24 01 Pressure regulator with filter and regulator

25 01 Reflex Nozzle

26 01 Pneumatic Amplifier

15 02 One way flow control valves

07 01 3/2 way Push button valve (NC)




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Single and multiple OR or AND circuits with shuttle and twin pressure valve


Fig. 01: Pneumatic circuit diagram


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Exercise 6

Sequential Control of two double acting cylinders without overlapping

signals


Functional diagram

Aim

This exercise helps to understand sequential controls and provides practical knowledge of

setting up and commissioning a control system with two pneumatic drives. Practice in

developing sequential diagram and pneumatic circuit diagram is exercised.

Functional diagram


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Task: Transport of Work pieces

Statement of the Application

The Work pieces coming in on the right roller conveyor should be elevated and sent in a new

direction. After actuating the start button, the piston of cylinder raises the work pieces to the

height of the second roller conveyor with its elevating platform. Cylinder 1 remains in this

position until cylinder 2 has pushed the work pieces from the elevating platform onto upper

roller conveyor. When cylinder 2 has securely pushed all the work pieces onto the upperRoller conveyor, cylinder 1 moves down again only when cylinder has retracted into its lower

end position does cylinder 2 also retract. Additionally a new start is only possible when

cylinder is actually in its back end position.

The working speed of both cylinders should be infinitely adjustable in both Directions the

functional diagram is to be developed with actuator and drive element. Draw the circuit

diagram with port symbols according to ISO 5599.

Functional Diagram

The Status of the cylinder displacement and actuation of set and reset signals at the A doublepiloted directional control valve is shown in the Functional Diagram: Above In order to meet

all the requirements a Pneumatic control circuit can be developed as shown below.



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Position Qty. Description of components

04 02 Double-acting Cylinders (Z1 and Z2)

11 02 5/2 Way Directional Control Valves (Double piloted)

15 02 One way Flow control Valves (adjustable)

06 01 3/2 way Push button valve (NC)(S0)

13 04 3/2 way roller lever Limit switch (S1,S1,S3,S4)




Fig. 01: Pneumatic circuit diagram


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Task

"Transport of Workpiece"

The workpieces coming in on the right roller conveyor should be elevated and sent in a new

direction. After actuating the start button (S0) the piston of cylinder 1 (Z1) raises theworkpieces to the height of the second roller conveyor with its elevating platform. Cylinder 1

(Z1) remains in this position until cylinder 2 (Z2) has pushed the workpieces from the

elevating platform onto the upper roller conveyor. When cylinder 2 (Z2) has securely pushed

all the workpieces onto the upper roller conveyor, cylinder 1 (Z1) moves down again. Only

when cylinder 1 (Z1) has retracted into its lower end position does cylinder 2 (Z2) also

retract. Additionally: a new start is only possible when cylinder 2 (Z2) is actually in its back

end position.

The working speed of both cylinders should be infinitely adjustable in both directions. The

functional diagram is to be developed with actuator and drive element. Drawing up the circuitdiagram with symbols and port symbols according to ISO 5599 or RP 68 P.


Two double-acting cylinders, retracted in neutral position, are displacement-dependently

controlled by impulse valves. After actuating the start button S0, a control signal arrives at

port 14 of the impulse valve for cylinder Z1 via the actuated limit switch S3. The piston rod

of cylinder Z1 extends and in its front end position actuates the limit switch S2. The limit

switch S2 sends a signal to the control port 14 of the impulse valve for cylinder 2. The piston

rod of cylinder 2 extends into the front end position and actuates the limit switch S4. The

limit switch S4 delivers the control signal to port 12 from the impulse valve for cylinder Z1.The piston of cylinder Z1 retracts and in its back end position actuates limit switch S1. The

limit switch S1 delivers a signal to port 12 from the impulse valve for cylinder Z2, the piston

retracts to the back end position. The system control is in its initial position.

Documents

Pneumatic circuit design