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Electropneumatics

Advanced Level

Workbook TP 202

CD-ROM included

Festo Didactic
541091 en
Intended use

The Festo Didactic Learning system has been developed and produced solely for
vocational and further training in the field of automation and technology. The
training company and/or instructor need to ensure that trainees observe the safety
precautions specified in this workbook.
Festo Didactic hereby disclaims any legal liability for damages or injury to trainees,
the training company and/or other parties, which may occur during the
use/application of this equipment set other than in a training situation and unless
such damages are caused with intention or through gross negligence on the part of
Festo Didactic.

Order No.: 541091


Status: 04/2005
Authors: M. Pany, S. Scharf
Editor: Frank Ebel
Graphics: Doris Schwarzenberger
Layout: 10/2005

© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2005
Internet: www.festo-didactic.com
e-mail: did@festo.com

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.

2 © Festo Didactic GmbH & Co. KG • 541091


Contents

Preface ______________________________________________________________ 5
Introduction__________________________________________________________ 7
Notes on safety and operation ___________________________________________ 9
Technology packages for electropneumatics (TP200) _______________________ 11
Training aims of Advanced Level (TP202) _________________________________ 13
Allocation of training aims and exercises _________________________________ 15
Equipment set – Advanced Level (TP202) _________________________________ 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 – Basic Level (TP201) _____________________________________ 29
Training aims – Basic Level (TP201)______________________________________ 30

Part A – Exercises

Exercise 1: Realising a diverting device ___________________________________A-3


Exercise 2: Insertion of drinks bottles ___________________________________A-15
Exercise 3: Realising a selection station _________________________________A-23
Exercise 4: Machining of key blanks ____________________________________A-39
Exercise 5: Bending of mounting brackets _______________________________A-49
Exercise 6: Realising a filling system ____________________________________A-57
Exercise 7: Bonding of components _____________________________________A-67
Exercise 8: Selecting modes of operation ________________________________A-75
Exercise 9: Machining of key blanks and
the use of an EMERGENCY-STOP function ______________________A-85
Exercise 10: Bending of mounting brackets and
the use of an EMERGENCY-STOP function______________________A-95
Exercise 11: Conveying bars of chocolate and
the use of an EMERGENCY-STOP function____________________ A-103
Exercise 12: Eliminating a fault on a machining station ___________________ A-113

© Festo Didactic GmbH & Co. KG • 541091 3


Contents

Part B – Fundamentals

Part C – Solutions

Exercise 1: Realising a diverting device ___________________________________C-3


Exercise 2: Insertion of drinks bottles ___________________________________C-13
Exercise 3: Realising a selection station _________________________________C-21
Exercise 4: Machining of key blanks ____________________________________C-37
Exercise 5: Bending of mounting brackets________________________________C-47
Exercise 6: Realising a filling system ____________________________________C-57
Exercise 7: Bonding of components _____________________________________C-67
Exercise 8: Selecting modes of operation ________________________________C-75
Exercise 9: Machining of key blanks and
the use of an EMERGENCY-STOP function ______________________C-85
Exercise 10: Bending of mounting brackets and
the use of an EMERGENCY-STOP function______________________C-95
Exercise 11: Conveying bars of chocolate and
the use of an EMERGENCY-STOP function_____________________C-107
Exercise 12: Eliminating a fault on a machining station ____________________C-117

Part D – Appendix

Organiser _________________________________________________________ D-2


Assembly technology ________________________________________________ D-3
Plastic tubing_______________________________________________________ D-4
Data sheets
Circuit diagrams

4 © Festo Didactic GmbH & Co. KG • 541091


Preface

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


towards different training and vocational requirements and is therefore structured
into the following training packages:
• Basic packages to provide technology-spanning basic knowledge
• Technology packages to address the major subjects of open and closed-loop
technology
• Function packages to explain the basic functions of automated systems
• Application packages to facilitate vocational and further training based on actual
industrial applications

The technology packages deal with the following technologies: Pneumatics,


electropneumatics, programmable logic controllers, automation using a personal
computer, hydraulics, electrohydraulics, proportional hydraulics and handling
technology.

© Festo Didactic GmbH & Co. KG • 541091 5


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.

6 © Festo Didactic GmbH & Co. KG • 541091


Introduction

This workbook is a component part of the Learning System for Automation and
Technology of Festo Didactic GmbH & Co. KG. This system provides a solid basis for
practice-oriented vocational and further training. Technology package 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 complete control
systems for all 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.).

© Festo Didactic GmbH & Co. KG • 541091 7


Introduction

8 © Festo Didactic GmbH & Co. KG • 541091


Notes on safety and operation

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

• Pressurised air lines that become detached can cause accidents. Switch off
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. (DIN 58126 and VDE 100).
• 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 ≤ 24V.
• 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 4 mm outer diameter,
the tubing is plugged 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.

© Festo Didactic GmbH & Co. KG • 541091 9


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. On/off
valves with filter regulating valve). These components 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.

10 © Festo Didactic GmbH & Co. KG • 541091


Technology package for electropneumatics (TP200)

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.

Important elements of • Fixed workstation with Festo Didactic profile plate


TP200 • 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 Level 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

© Festo Didactic GmbH & Co. KG • 541091 11


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 circuits

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.

12 © Festo Didactic GmbH & Co. KG • 541091


Training aims of Advanced Level (TP202)

• To familiarise yourself with the design and function of valve terminals.


• To be able to use valve terminals in accordance with requirements.
• To be able to design a displacement-step diagram for a sequence control.
• To be able to transcribe a function chart to GRAFCET .
• To be able to solve the problem of signal overlaps in a sequence control
according to the group method.
• To be able to detect signal overlaps in a sequence control.
• To be able to design a sequence chain using spring-return valves.
• To be able to design a sequence chain using double solenoid valves.
• To familiarise yourself with the mode of operation of different proximity sensors.
• To be able to select proximity sensors in line with parameters.
• To familiarise yourself with logic operations and to be able to realise these.
• To familiarise yourself with the design and function of a pneumatic-electrical
converter.
• To familiarise yourself with the options for sensing pressure and time in electro-
pneumatic control systems.
• To familiarise yourself with the function and possible applications of a time relay
with switch-on delay.
• To familiarise yourself with modes of circuit operation and to be able to design
circuits with which single cycle and continuous cycle modes can be realised.
• To familiarise yourself with the function of an electrical preselect counter and to
be able to use this in circuits.
• To be able to develop and design the EMERGENCY-STOP function for a control
system with spring-return valves.
• To be able to develop and design the EMERGENCY-STOP function for a control
system with double solenoid valves.
• To be able to design a specified motion sequence with EMERGENCY-STOP.
• To be able to design the EMERGENCY-STOP condition „Cylinder remains in its
current position during EMERGENCY-STOP“.
• To familiarise yourself with the design and mode of operation of a 5/3-way valve.
• To be able to replace a 5/3-way solenoid valve with 3/2-way solenoid valves.
• To be able to integrate the mode of operation „resetset“.
• To be able to identify and eliminate faults in complex electropneumatic control
systems.

© Festo Didactic GmbH & Co. KG • 541091 13


Training aims of Advanced Level (TP202)

14 © Festo Didactic GmbH & Co. KG • 541091


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 the design • •


and function of valve terminals.
To be able to use valve terminals in • •
accordance with requirements.
To be able to solve the problem of •
signal overlap in a sequence control
according to the group method.

To be able to design a displacement- • • •


step diagram for a sequence control.

To be able to transcribe a function •


chart to GRAFCET.

To be able to design a sequence chain •


with spring-return valves.

To be able to detect signal overlaps in •


a sequence control.

To be able to design a sequence chain •


using double solenoid valves.

To familiarise yourself with the mode •


of operation of different proximity
sensors.

To be able to select proximity sensors •


in line with parameters.

To familiarise yourself with logic •


operations and to be able to realise
these.

To familiarise yourself with the •


options for sensing pressure and time
in electro-pneumatic control systems.

To familiarise yourself with the design •


and function of a pneumatic-electrical
converter.

To familiarise yourself with the •


function and possible applications of a
time relay with switch-on delay.

© Festo Didactic GmbH & Co. KG • 541091 15


Allocation of training aims and exercises

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

Training aim

To familiarise yourself with modes of • •


circuit operation and to be able to
design circuits with which single cycle
and continuous cycle modes can be
realised.

To familiarise yourself with the •


function of an electrical preselect
counter and to be able to use this in
circuits.

To be able to develop and design the •


EMERGENCY-STOP function for a
control system with spring-return
valves.

To be able to develop the •


EMERGENCY-STOP function for a
control system using double solenoid
valves.

To be able to develop and design a •


specified motion sequence with
EMERGENCY-STOP.

To be able to design the EMERGENCY- •


STOP condition „Cylinder remains in
its current position“ during
EMERGENCY-STOP.

To familiarise yourself with the design •


and mode of operation of a 5/3-way
solenoid valve.

To be able to replace a 5/3-way •


solenoid valve with 3/2 way solenoid
valves.

To be able to integrate the mode of •


operation „reset“.

To be able to identify and eliminate •


faults in complex electropneumatic
control systems.

16 © Festo Didactic GmbH & Co. KG • 541091


Equipment set – Advanced Level (TP202)

The equipment set for the advanced level has been compiled for further training in
electro-pneumatic control technology. The two equipment sets (TP201 and TP202)
contain all the components required to meet the specified training aims and can be
expanded as desired with other equipment sets of the Learning System for
Automation and Technology.

Equipment set – Advanced Description Order No. Quantity


Level (TP202
EMERGENCY-STOP button 183347 1
Order No.: 540713)
Non-return valve, piloted 540715 2

Preselect counter, electrical 162355 1

Proximity sensor, capacitive 178575 1

Proximity sensor, inductive 178574 1

Relays, 3-off 162241 2

Signal input plate, electrical 162242 1

Time relay, 2-off 162243 1

Valve terminal with 4 valve slices (MMJJ) 540696 1

© Festo Didactic GmbH & Co. KG • 541091 17


Equipment set – Advanced Level (TP202)

Equipment set symbols Description Symbol

Relay, 3-off
12 14 22 24 32 34 42 44
A1

A2 11 21 31 41

12 14 22 24 32 34 42 44
A1

A2 11 21 31 41

12 14 22 24 32 34 42 44
A1

A2 11 21 31 41

Signal input plate, electrical


13 23 31 41

14 24 32 42

13 23 31 41

14 24 32 42

13 23 31 41

14 24 32 42

18 © Festo Didactic GmbH & Co. KG • 541091


Equipment set – Advanced Level (TP202)

Description Symbol

Time relay, 2-off

17 27 35 45
A1

with switch-on delay

A2
18 28 36 46

17 27 35 45
A1

with switch-off delay

A2
18 28 36 46

Preselect counter, electrical


A1 1 R1

A2 R2
4 2

Proximity sensor, inductive

Proximity sensor, capacitive

EMERGENCY-STOP button 13 21

14 22

Non-return valve, piloted


2

1 21

© Festo Didactic GmbH & Co. KG • 541091 19


Equipment set – Advanced Level (TP202)

20 © Festo Didactic GmbH & Co. KG • 541091


Allocation of equipment and exercises

Equipment set TP202

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

Equipment

Proximity sensor, inductive 1

Proximity sensor, capacitive 1

EMERGENCY-STOP button 1 1 1

Relay 2 6 6 6 6 6 4 5 6 6 6 6

Pushbutton, electrical, normally open 2 1 1 1 1 1 1 2 1 3 1

Pushbutton, electrical, normally 1


closed

Non-return valve, piloted 2

Valve terminal with 4 valve slices 1 1 1 1 1 1 1 1 1 1 1 1


(MMJJ)

Preselect counter, electrical 1

Time relay, 2-off 1

Equipment set TP201

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

Equipment

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

One-way flow control valve 2 4 4 4 4 4 2 2 4 4 2 4

Pressure sensor 1 1

Limit switch, electrical 2 2 2 2 2 2 2 2

Proximity sensor, electronic 2 2 2 2 2 2 2 2 2 2 2

Proximity sensor, optical 1 1

Pushbutton, electrical, normally 2 3


closed contact

Relay 3 4 2 4 5 3 3

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

On/off valve with filter regulating 1 1 1 1 1 1 1 1 1 1 1 1


valve

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

© Festo Didactic GmbH & Co. KG • 541091 21


Allocation of equipment and exercises

22 © Festo Didactic GmbH & Co. KG • 541091


Methodological help for the trainer

• 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. You will require the
components of the equipment set for Basic Level TP 201 and Advanced Level
TP202. Each of the Advanced Level exercises can be assembled on a profile plate.
For exercise 11 you will require an additional electrical input or will need to
assemble the circuit in a different form.
• Representation
Abbreviated notation and motion diagrams are used for the represention of
motion sequences and switching statuses.

© Festo Didactic GmbH & Co. KG • 541091 23


Methodological help for the trainer

24 © Festo Didactic GmbH & Co. KG • 541091


Methodological structure of the exercises

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 design
• Equipment list

© Festo Didactic GmbH & Co. KG • 541091 25


Designation of equipment

The designation of components in a circuit 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 multiple pressure
ports is P and these are consecutively numbered separately.

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


Valves: 1V1, 1V2, 1V3, 2V1, 2V2, 3V1, ...
Sensors: 1B1, 1B2, ...
Signal input: 1S1, 1S2, ...
Accessories: 0Z1, 0Z2, 1Z1, ...
Pressure ports: P1, P2, ...

26 © Festo Didactic GmbH & Co. KG • 541091


Contents of the CD-ROM

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 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.

Data sheets The data sheets for the equipment of the technology package are available in the
form of pdf files.

Demo 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 system developed.

Festo catalogue 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 FluidSIM® circuit diagrams are stored in this directory for all 12 exercises in the
technology package.

For the introduction to logic programming, all FluidSIM® circuit diagrams are also
stored in a variant with logic control in addition to the circuit diagrams with relay
control.

© Festo Didactic GmbH & Co. KG • 541091 27


Contents of the CD-ROM

Industrial applications 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.

Presentations Brief presentations are stored in this directory regarding the equipment for this
technology package. These presentations can for instance be used to create project
presentations.

Product information 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.

Videos A number of videos of industrial applications complete the media for the training
package. Short sequences are shown of practice-related applications.

28 © Festo Didactic GmbH & Co. KG • 541091


Equipment set – Basic Level (TP201)

This equipment set has been compiled for basic training in electropneumatic control
technology. It comprises all the components required for the training aims specified
and can be expanded in any way with other equipment sets. In addition you will also
need a profile plate, electrical power supply unit and compressed air supply to
assemble a fully functional control system.

Equipment set – Basic: Description Order No. Quantity


Level (TP201
2 x 3/2-way way solenoid valve, normally open 539776 1
Order No.: 540712)
5/2-way double solenoid valve 539778 2

5/2-way solenoid valve 539777 1

Blanking plug 153267 10

One-way flow control valve 539773 4

Pressure sensor 539757 1

On/off valve with filter regulating valve 540691 1

Limit switch, electrical, actuation from the left 183322 1

Limit switch, electrical, actuation from the right 183322 1

Plastic tubing 4 x 0.75, 10 m 151496 2

Proximity sensor, electronic 540695 2

Proximity sensor, optical 178577 1

Relay, 3-off 162241 2

Signal input plate, electrical 162242 1

Push-in sleeve 153251 10

Push-in T-connector 153128 20

Manifold 152896 1

Cylinder, double-acting 152888 2

Cylinder, single-acting 152887 1

© Festo Didactic GmbH & Co. KG • 541091 29


Training aims of Basic Level (TP201)

• 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 electropneuamtic control
systems.

30 © Festo Didactic GmbH & Co. KG • 541091


Contents

Part A – Exercises

Exercise 1: Realising a diverting device ___________________________________A-3


Exercise 2: Insertion of drinks bottles ___________________________________A-15
Exercise 3: Realising a selection station _________________________________A-23
Exercise 4: Machining of key blanks ____________________________________A-39
Exercise 5: Bending of mounting brackets _______________________________A-49
Exercise 6: Realising a filling system ____________________________________A-57
Exercise 7: Bonding of components _____________________________________A-67
Exercise 8: Selecting modes of operation ________________________________A-75
Exercise 9: Machining of key blanks and
the use of an EMERGENCY-STOP function ______________________A-85
Exercise 10: Bending of mounting brackets and
the use of an EMERGENCY-STOP FUNCTION ____________________A-95
Exercise 11: Conveying bars of chocolate and
the use of an EMERGENCY-STOP function____________________ A-103
Exercise 12: Eliminating a fault on a machining station ___________________ A-113

© Festo Didactic GmbH & Co. KG • 541091 A-1


Contents

A-2 © Festo Didactic GmbH & Co. KG • 541091


Exercise 1: Realising a diverting device

Training aims • To familiarise yourself with the design and function of valve terminals.
• To be able to use valve terminals in accordance with requirements.

Problem definition Drinks bottles are to be diverted from one conveyor to another using a diverting
device. By pressing a pushbutton the frame of the diverting device is to advance. A
bottle is transferred and conveyed in the opposite direction. By pressing another
pushbutton, the frame is to return into the initial position.

Parameters • A double-acting cylinder is to be used.


• Cylinder control is to be realised indirectly and via a pushbutton.
• In the event of a power failure the cylinder piston rod is to remain in the assumed
position.

Project task 1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
2. Draw the pneumatic and electrical circuit diagrams.
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.

© Festo Didactic GmbH & Co. KG • 541091 A-3


Exercise 1: Realising a diverting device

Positional sketch

Diverting device for drinks bottles

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


2. The 5/2-way double solenoid valve 1V1 is to switch by pressing pushbutton S1
and the cylinder to move into the forward end position.
3. The 5/2-way double solenoid valve is to reverse by pressing pushbutton S2 and
the cylinder to move into the retracted end position.

A-4 © Festo Didactic GmbH & Co. KG • 541091


Exercise 1: Realising a diverting device

Exercise 1: Realising a diverting device

Name: Date:

Fundamentals: Installation costs Sheet 1 of 5

The configuration, tubing and wiring of the components of an electropneumatic


control system should be selected such as to keep the sum total of equipment,
installation and maintenance costs as low as possible. The following choices are
available as regards wiring:

• Conventional wiring technology, e.g. terminal strips


• Advanced installation concepts, e.g. wiring using multi-pin connectors

The following choices are available in respect of configuration, i.e. number of drives
and tubing requirements:

• Individual mounting of solenoid operated directional control valves


• Block mounting (manifold or valve terminal)

© Festo Didactic GmbH & Co. KG • 541091 A-5


Exercise 1: Realising a diverting device

Exercise 1: Realising a diverting device

Name: Date:

Fundamentals: Installation costs Sheet 2 of 5

– Compare the above listed concepts using the example of this control system in
terms of reducing the tubing costs.

Note
Use the individual valves from TP201 or the MPA valve terminal from TP202 and the
respective technical descriptions.

Components Individual mounting Block mounting of Saving when using


of directional control directional control block mounting
valves valves

Tubing

Number of compressed
air distribution units

Amount of tubing for


supply to compressed air
distribution unit

Amount of tubing for


compressed air supply to
control chains

Amount of tubing
between directional
control valves and
cylinders

Silencers

Number of silencers for


control chains

A-6 © Festo Didactic GmbH & Co. KG • 541091


Exercise 1: Realising a diverting device

Exercise 1: Realising a diverting device

Name: Date:

Fundamentals: Installation costs Sheet 3 of 5

– Which concept enables you to achieve a reduction in tubing costs? Explain the
reason for your choice.

Note
Use the individual valves from TP201 or the MPA valve terminal from TP202 and the
respective technical descriptions.

Reason Individual mounting Block mounting of


of directional control directional control
valves valves

© Festo Didactic GmbH & Co. KG • 541091 A-7


Exercise 1: Realising a diverting device

Exercise 1: Realising a diverting device

Name: Date:

Fundamentals: Installation costs Sheet 4 of 5

– Compare the above listed concepts using the example of this control system with
regard to reducing wiring costs

Note
Use the individual valves of TP201 or the MPA valve terminal from TP202 and the
respective technical descriptions.

Wiring table

Components Cables Number of Number of


terminals/components terminals/components
Conventional wiring Multi-pin wiring concept
technology

Control cabinet 1 1

Terminal strip 1 in control cabinet Earthing cable

Supply voltage (24 V)

PLC outputs (actuation of solenoid


coils)

PLC inputs (evaluation of proximity


sensors)

Terminal strip 1 in control cabinet, overall

Cable from control cabinet to Cable between terminal strips 1 and


terminal box 2

Cable from terminal strip 2 Proximity sensors (3 wires per


(in terminal box) proximity sensor)

Solenoids
(2 wires per solenoid)

Terminal strip 2, overall

Cable to directional control valves Connection of solenoid coils


and sensors
Connection of sensors

A-8 © Festo Didactic GmbH & Co. KG • 541091


Exercise 1: Realising a diverting device

Exercise 1: Realising a diverting device

Name: Date:

Fundamentals: Reducing the wiring costs Sheet 5 of 5

– Which concept enables you to achieve a reduction in wiring costs? Explain the
reason for your choice.

Note
Use the individual valves from TP201 or the MPA valve terminal from TP202 and the
respective technical descriptions.

Reason Conventional wiring Multi-pin wiring


technology concept

© Festo Didactic GmbH & Co. KG • 541091 A-9


Exercise 1: Realising a diverting device

Exercise 1: Realising a diverting device

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 1 of 3

– Complete the pneumatic circuit diagram for the diverting device.

4 2

5 3
1

Pneumatic circuit diagram with individual valve

A-10 © Festo Didactic GmbH & Co. KG • 541091


Exercise 1: Realising a diverting device

Exercise 1: Realising a diverting device

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 2 of 3

– Complete the pneumatic circuit diagram for the diverting device.

0V1
-V- 4 2 -V- 4 2 1V1 4 2 -V- 4 2
S M M J J

14 14 14 12 14 12
-M1 -M1 1M1 1M2 -M1 -M2

3/5 3/5 3/5 3/5 3/5 3/5


82/84 82/84 82/84 82/84 82/84 82/84
12/14 12/14 12/14 12/14 12/14 12/14
1 1 1 1 1 1

Pneumatic circuit diagram with valve terminal (circuit diagram in DIN A3 format in Part D)

© Festo Didactic GmbH & Co. KG • 541091 A-11


Exercise 1: Realising a diverting device

Exercise 1: Realising a diverting device

Name: Date:

Completing the pneumatic and electrical circuit diagrams Sheet 3 of 3

– Complete the electrical circuit diagram for the diverting device.

+24 V 1 2 3 4

A1 A1

A2 A2

0V 12 12
11 14 11 14
22 22
21 24 21 24
32 32
31 34 31 34
42 42
41 44 41 44

Electrical circuit diagram

A-12 © Festo Didactic GmbH & Co. KG • 541091


Exercise 1: Realising a diverting device

Exercise 1: Realising a diverting device

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

© Festo Didactic GmbH & Co. KG • 541091 A-13


Exercise 1: Realising a diverting device

A-14 © Festo Didactic GmbH & Co. KG • 541091