Festo Electro Pneumatic TextBook Advance Level PDF

Learning System for Automation and Technology
Electropneumatics
Workbook Advanced level
094467
Authorised applications and liability

The Learning System for Automation and Technology has been developed and prepared exclusively for training in the field of automation and
technology. The training organization and / or trainee shall ensure that
the safety precautions described in the accompanying Technical documentation are fully observed.
Festo Didactic hereby excludes any liability for injury to trainees, to the
training organization and / or to third parties occurring as a result of the
use or application of the station outside of a pure training situation,
unless caused by premeditation or gross negligence on the part of Festo
Didactic.
Order no.:
Description:
Designation:
Edition:
Layout:
Graphics:
Authors:
094467
TEACHW.E-PNEUM.
D.S202-C-SIBU-GB
05/2002
06.05.2002, OCKER Ingenieurbro
OCKER Ingenieurbro
D. Waller, H. Werner, Th. Ocker
Copyright by Festo Didactic GmbH & Co., D-73770 Denkendorf 2002

The copying, distribution and utilization of this document as well as the
communication of its contents to others without expressed authorization
is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved, in particular the right to carry out patent, utility model
or ornamental design registrations.
Parts of this training documentation may be duplicated, solely for training
purposes, by persons authorised in this sense.
Preface
The Festo Didactic Learning System for Automation and Technology has
been formulated according to various prerequisites and vocational
requirements. It has been divided into the following categories of training
packages:
Basic packages which convey basic knowledge spanning a wide

range of technologies
Technology packages which deal with important subjects of open and

closed-loop control technology
Function packages to explain the basic functions of automated systems
Application packages to facilitate practice-orientated vocational and

further training
The technology packages deal with the technologies of pneumatics,

electropneumatics, programmable logic controllers, hydraulics, electrohydraulics, proportional hydraulics and handling technology.
Mounting frame
Profile plate
U = 230V~
Storage tray
TP202 Festo Didactic
The modular design of the Learning System permits applications beyond

the scope of the individual packages. It is, for instance, possible to
design PLC controlled systems with pneumatic, hydraulic and electrical
actuators.
All training packages are based on an identical structure:
Hardware
Teachware
Software
Seminars
The hardware consists of industrial components and systems which

have been adapted for didactic purposes.
The courseware has been designed in line with didactic methods and
coordinated for use with the training hardware. The courseware comprises:
Textbooks (with exercises and examples)
Workbooks (with practical exercises, explanatory notes, solutions and

data sheets)
Transparencies and videos (to create a lively training environment)
The training and learning media is available in several languages, which

has been designed for use in the classroom as well as for self-tuition.
The software sector serves as a basis for providing computer training
program, simulation program and programming software for programmable logic controllers.
A comprehensive range of seminars on the subject of the various technology packages completes our program of vocational and further training.
Latest information about the technology package pneumaticTP 202

New in Pneumatic 2000:
Industrial components on the profile plate.
Fostering of key qualifications:

Technical competence, personal competence and social competence
form professional competence.
Training of team skills, willingness to co-operate, willingness to learn,

independence and organisational skills.
Aim Professional competence

Content
Part A
Course
Exercises
Part B
Fundamentals
Reference to the text book
Part C
Solutions
Function diagrams, circuits, descriptions of

solutions and quipment lists
Part D
Appendix
Storage tray, mounting technology

and datasheets
Table of contents
Introduction
Notes on safety and operation
11
Training contents of basic level and advanced level
13
Equipment set for the basic level (TP201)
15
Equipment set for the advanced level (TP202)
18
Component and exercise allocation (table)
20
Methodical structure of the exercises
21
Designation of components
22
Part A Course
Basic exercises
Exercise 1:
Bench drill
A-3
Exercise 2:
Feed unit for sheet metal strip
A-5
Exercise 3:
Filling device
A-7
Exercise 4:
Stamping device
A-9
Exercise 5:
Drilling jig
A-11
Exercise 6:
Clamping unit for grinding
A-15
Exercise 7:
Forming press
A-19
Consolidating exercises
Exercise 8:
Embossing device
A-21
Exercise 9:
Handling device
A-23
Exercise 10:
Drilling and reaming machine
A-25
Exercise 11:
Loading station
A-29
Exercise 12:
Internal grinding machine
A-33
Exercise 13:
Assembly unit
A-37
Exercise 14:
Moulding press
A-41
Exercise 15:
Pick-and-place unit
A-45
Exercise 16:
Galvanising process
A-49
Exercise 17:
Loading station
A-53
Exercise 18:
Rotary indexing station
A-57
Exercise 19:
Checking station
A-63
Exercise 20:
Handling device
A-67
Part B Fundamentals
Part C Solutions
Solution 1:
Bench drill
C-3
Solution 2:
C-9
Solution 3:
Filling device
C-17
Solution 4:
Stamping device
C-21
Solution 5:
Drilling jig
C-27
Solution 6:
C-35
Solution 7:
Forming press
C-41
Solution 8:
Embossing device
C-45
Solution 9:
Handling device
C-49
Solution 10:
C-55
Solution 11:
Loading station
C-59
Solution 12:
C-63
Solution 13:
Assembly unit
C-69
Solution 14:
Moulding press
C-75
Solution 15:
Pick-and-place unit
C-81
Solution 16:
Galvanising process
C-87
Solution 17:
Loading station
C-95
Solution 18:
C-103
Solution 19:
Checking station
C-111
Solution 20:
Handling device
C-117
Part D Appendix
Storage tray
D-2
Mounting technology
D-3
Plastic tubing
D-5
Data sheets
...
Introduction
This workbook forms part of Festo Didactics Learning System for Automation and Technology. The system provides a solid basis for practiceorientated vocational and further training. Technology package TP200 is
concerned exclusively with electro-pneumatic control systems.
The basic level TP201 is suitable for basic training in electro-pneumatic
control technology. It conveys knowledge concerning the physical fundamentals of electropneumatics as well as the function and use of
electro-pneumatic components. The equipment set permits the construction of simple electro-pneumatic control systems.
The advanced level TP202 is intended for further training in electropneumatic control technology. The equipment set permits the construction of a wide range of combinatorial circuits with logic operations of the
input and output signals as well as program controls.
Prerequisites for assembling control circuits are a fixed workstation and
a Festo Didactic profile plate. The profile plate has 14 parallel T-grooves
arranged at intervals of 50 mm. A short-circuit proof power supply unit
provides a constant power supply (Input: 230 V, 50 Hz, Output: 24 V,
max. 5 A). A mobile, silenced compressor may be used for compressed
air supply (230 V, maximum 8 bar = 800 kPa).
Working pressure should be a maximum of p = 6 bar (= 600 kPa)
Optimum operational safety is achieved by operating the control system
with unlubricated air at a pressure of p = 5 bar = 500 kPa.
The training hardware of both equipment sets (TP201 and TP202) will
be required for the practical assembly of the controls documented here.
The theoretical fundamentals required to understand this book of exercises can be found in the following textbook:
Learning System for Control Technology
Introduction to Electropneumatics
Also available are data sheets on the various components (cylinders,

valves, measuring devices, etc.).
10
11
Notes on safety and operation

In the interests of your own safety, the following advice should be observed:
Pressurised air lines that become detached can cause accidents.

Switch off supply immediately.
Lines must be connected up and secured before the compressed air

is switched on.
Warning!
Cylinders may advance or retract as soon as the compressed air is
switched on.
Do not operate the electrical limit switches manually during fault

finding (use a suitable tool).
Observe general safety regulations (DIN 58126 and VDE 100).
Distinction is to be made between the two different designs of the

electrical limit switches
Actuation from the left
Actuation from the right
Limit switches should be placed so that they contact only the side of
the trip cam and never the front at high piston speeds.
In the pneumatic circuits cylinders are shown without magnetic pistons, since these are only required when magnetic end-position
switches are used. Festo Didactic training sets only contain cylinders
with magnetic pistons.
Do not exceed permissible operating pressure (observe data sheets).
Only use extra-low voltage 24 V.
All components are provided with 4 mm safety sockets respectively

safety plugs. For electical connections use only electrical cable with
safety plugs.
Pneumatic circuit design:

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

The tubing can be released by simply pressing the clamping collet
(blue ring). (Cannot be disconnected under pressure!)
Switch off the pressure and power supply prior to disconnecting the
circuit.
12
The profile plate for the assembly of components is equipped for

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

the individual components.
13
Training contents of basic level and advanced level

Basic level (TP201)
Physical fundamentals of electricity and pneumatics
Function and application of electropneumatic components
Designation and drawing of electropneumatic symbols
Representation of motion sequences and switching statuses
Drawing pneumatic and electrical circuit diagrams
Assembly of control systems with relays
Direct and indirect manual control systems
Direct and indirect stroke-dependent control systems
Logical AND/OR functions of the input signals
Electrical latching circuits
Using a magnetic proximity switch
Using a pressure switch
Fault finding in simple electropneumatic control systems
Advanced level (TP202)

Function and use of electro-pneumatic components
Stroke-dependent control systems with sensors
Stroke-dependent control systems with preselect counter
Control systems with marginal conditions

(e.g. Single/continuous cycle, EMERGENCY-STOP)
Position-scheduled control/process orientated sequence controls
Timing controls/time orientated sequence controls
Program control systems with latching and resetting sequence
Fault finding in extensive electro-pneumatic control systems
14
List of training aims
Exercise
Training aim
To teach the student the principle of the latching sequence.
To teach the student the principle of the resetting sequence

(with reliable switching reversal).
To familiarise the student with the procedure for skipping program steps
and with the use of a timer.
To teach the student how to realise a stroke-dependent sequence

control with resetting sequence.
To teach the student how to realise multiple movements of a cylinder

and monitor service life using a preselect counter.
To familiarise the student with the use of a pneumatic/electric converter

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

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

step mode into a sequence.
To teach the student how to incorporate EMERGENCY-STOP and

marginal conditions in a latching sequence.
10
To teach the student how to realise a control system with an alternative

program by means of program switching.
11
To teach the student to program repetition using an additional movement.
12
To familiarise the student with step repetition using the preselect counter.
13
To teach the student how to set up manual activation of the cylinder with
protection against collision.
To familiarise the student with automatic setting conditions.
14
To teach the student how to construct a two-handed safety start-up with

relay. To familiarise the student with restart before the end of the cycle.
15
To teach the student how to develop a latching sequence with marginal

conditions.
16
To teach the student how to realise program branchings.

To teach the student how to make multiple use of time relays.
To familiarise the student with program section repetitions using the
preselect counter.
17
Consolidating the students knowledge. Program section repetition.
18
To familiarise the student with parallel program division.
19
To familiarise the student with the use of a timer with delayed switch-on
as a delayed starting element.
20
Familiarisation with an alternative solution to electropneumatics.
15
Equipment set for the basic level (TP201)

This equipment set is designed for basic training in electro-pneumatic
control technology. It contains all the components required to achieve
the specified training aims and may be extended as required with the
addition of other equipment sets. To construct fully operational controls,
it is also necessary to have a profile plate, a power supply unit and a
compressed air supply.
Designation
Order No.
Quantity
Relay, 3-off*
162241
Signal input plate, electrical *
162242
Indicator/distributor plate, electrical *
162244
Plastic tubing, 10 m, silver metallic
151496
Single-acting cylinder
152887
Double-acting cylinder
152888
On/off valve with filter regulator
152894
Manifold
152896
Proximity sensor, with cylinder mounting
167060
Limit switch, electrical, actuation from the left
183322
Limit switch, electrical, actuation from the right
183345
Pneumatic-electric converter
177459
3/2-way solenoid valve, normally closed
167073
5/2-way solenoid valve
167074
5//2-way double solnoid valve
167076
* These components can be attached to the profile plate by means of 4 adapters (Order
No. 323571).
Equipment set for the

basic level (TP201)
(Order No.: 080243)
16
Symbols of the
equipment set
Signal input plate, electrical
Indicator/distributor, electrical
Relay, 3-off
Manifold
17
Proximity sensor with cylinder mounting
Limit switch, electrical,

Actuation from left or right*
3/2-way solenoid valve,

normally closed
5/2-way double solenoid valve
Symbols of the
equipment set
18
Equipment set for the advanced level (TP202)

This equipment set for the advanced level is designed for further training
in electro-pneumatic control technology. The two equipment sets (TP201
and TP202) contain all the components required to achieve the specified
training aims and may be extended as required with the addition of other
equipment sets from the Learning System for Automation and Technology.
Equipment set for
the advanced level
(TP202)
(Order No: 184461)
Designation
Order No.
Quantity
Relay, 3-off*
162241
Signal input plate, electrical*
162242
Time relay, 2-off*
162243
Preselect counter, electrical, incrementing*
162355
167076
Proximity sensor, inductive
178574
Proximity sensor, capacitive
178575
Proximity sensor, optical
178577
EMERGENCY-STOP button
183347
* These components can be attached to the profile plate by means of 4 adapters (Order
No. 323571).
19
Relay, 3-off
Time relay, 2-off

with switch-on delay
with switch-off delay
Preselect counter, electrical, incrementing
Symbols of the
equipment set
advanced level
20
Component and exercise allocation (table)

Exercise
Designation
10 11 12 13 14 15 16 17 18 19 20
Relay, 3-off*
6* 6* 6* 6* 6* 6*
Signal input module,

electrical *
Time relay, 2-off
Preselet counter, electrical,

incrementing
Distributor plate, electrical
1
1
3* 3* 3* 3*
On-off valve with

filter regulator
Manifold


Actuation from the left

Actuation from the right
2* 2* 2*
1
2
2
3/2-way solenoid valve,

normally closed
Proximity sensor with

cylinder mounting
5/2-way double solenoid

valve
1
1
* Components which are not available in full quantity in equipment sets 201 and 202.
21
Methodical structure of the exercises

All 20 exercises in part A are of the same methodical design.
The two exercise sheets are divided into:
-
Subject
Title
Training aim
Exercise
sowie
-
Problem description
Positional sketch
Displacement-step diagram
The proposed solutions in part C cover a minimum of four pages and are
divided into:
-
Circuit diagram, pneumatic
Circuit diagram, electrical
Solution description
Component list
22
Designation of components
The components in the circuit diagrams are designated in accordance
with ISO 1219-2. All components within a circuit have the same main
code. Letters are assigned dependent on the component. If there are
several components within a circuit, these are numbered consecutively.
Pressure lines are identified with the designation P and are numbered
separately.
Actuators:
1A, 2A1, 2A2, ...
Valves:
1V1, 1V2, 1V3, 2V1, 2V2, 3V, ...
Signal detecter:
1S1, 1S2, ...
Accessories:
0Z1, 0Z2, 1Z, ...
Electrical sensors:
1B1, 1B2, ...
Pressure lines:
P1, P2, ...
A-1
Part A Course
Basic exercises
Exercise 1:
Bench drill
A-3
Exercise 2:
A-5
Exercise 3:
Filling device
A-7
Exercise 4:
Stamping device
A-9
Exercise 5:
Drilling jig
A-11
Exercise 6:
A-15
Exercise 7:
Forming press
A-19
Consolidating exercises
Exercise 8:
Embossing device
A-21
Exercise 9:
Handling device
A-23
Exercise 10:
A-25
Exercise 11:
Loading station
A-29
Exercise 12:
A-33
Exercise 13:
Assembly unit
A-37
Exercise 14:
Moulding press
A-41
Exercise 15:
Pick-and-place unit
A-45
Exercise 16:
Galvanising process
A-49
Exercise 17:
Loading station
A-53
Exercise 18:
A-57
Exercise 19:
Checking station
A-63
Exercise 20:
Handling device
A-67
A-2
A-3
Aufgabe 1
Electropneumatics
Subject
Bench drill
Title
To teach the student the principle of a latching sequence.
Training aim
Drawing the pneumatic and electrical circuit diagrams.
Exercise
Construction of the pneumatic and electrical circuits.
Checking the circuit sequence.
A-4
Aufgabe 1
Problem description
Workpieces are inserted into the clamping device by hand. Clamping

cylinder 1A is to extend when the start button is pressed. When the
workpiece is clamped, it is to be drilled via feed unit 2A and the drill
retracted once again. At the same time, the swarf is to be blown away by
an air jet 3Z. Then, the clamping cylinder 1A is to release the workpiece.
Fig. 1/1:
Positional sketch
2A
3Z
1A
Fig. 1/2:
5=1
1S2
1S1
2B2
2B1
1A
2A
A-5
Aufgabe 2
Electropneumatics
Subject
Title
To teach the student the principle of a resetting sequence

(with reliable switching reversal).
Training aim
Exercise
A-6
Aufgabe 2
Problem description
A sheet metal strip is to be fed from a drum towards the cutting tool. The
feed unit may only start when the punch-tool is in the upper position (this
signal must be simulated by a push button S3). Cylinder 1A holds the
sheet metal strip and cylinder 2A retracts. Cylinder 1A releases the strip
and cylinder 2A returns to the forward end position.
Operating condition
The sheet metal strip feed unit must be provided with a main switch S1.
When cylinder 2A has retracted and cylinder 1A has released the strip, a
signal (optical indicator) is to be passed on to the press for the next part
to be punched out.
Fig. 2/1:
Positional sketch
1A
2A
Fig. 2/2:
6=1
1B2
1B1
2S2
2S1
1A
2A
A-7
Exercise 3
Electropneumatics
Subject
Filling device
Title
To familiarise the student with the procedure for skipping program

steps.
Training aim
To familiarise the student with the use of a timer with switch-on delay.
Exercise
A-8
Exercise 3
Problem description
Bottles are transported along a conveyor belt to a rotary table. Cylinder

1A is to retract only when a bottle has arrived on the conveyor belt
(position 1) and the START signal (continuous/single cycle) has been
given. The table is then to continue indexing (2A+), when the signal
bottle on indexing table (position 2) has been sent. When a bottle has
reached the filling station (position 3), cylinder 3A is to open the filling
valve, remain it open for approx. 2 seconds and then reclose it.
Operating condition
If no bottle is reported as present at the filling station (position 3), the

installation must be indexed manually until a bottle is present for filling.
Sensing of the bottles is to be simulated by push button.
Fig. 3/1:
Positional sketch
1A
3A
2A
A-9
Aufgabe 4
Electropneumatics
Subject
Stamping device
Title
To teach the student how to realise a stroke-dependent sequence

control with a resetting sequence.
Training aim
Drawing the displacement-step diagram and the pneumatic and

electrical circuit diagram.
Exercise
A-10
Aufgabe 4
Problem description
Cylinder 1A is to push parts out of the gravity feed magazine and clamp
them. Only then can cylinder 2A stamp the part and retract once again.
Next, clamping cylinder 1A is to unclamp. The part is to be ejected by
cylinder 3A, which then returns to the retracted end position.
Fig. 4/1:
Positional sketch
Fig. 4/2:
7=1
1S2
1S1
2B2
2B1
3B2
3B1
1A
2A
3A
A-11
Exercise 5
Electropneumatics
Subject
Drilling jig
Title
To teach the student how to realise multiple movements of a cylinder.
Training aim
To familiarise the student with the use of an incrementing preselect

counter.
Drawing the pneumatic and electrical circuits.
Exercise
A-12
Exercise 5
Problem description
Rectangular castings are to be drilled in 4 positions. Castings are inserted by hand and clamped by an eccentric cam.
Feed unit 3A with hydraulic cushioning cylinder is aligned vertically (Zaxis). Positioning cylinders 1A and 2A move the table in X- and Ydirection so that drilling positions (1), (2), (3) and (4) can be approached
consecutively.
The first hole is drilled by means of feed unit 3A after the START button
has been pressed. Next, double-acting cylinder 1A retracts and the
second drilling process takes place. After double-acting cylinder 2A has
retracted, feed unit 3A carries out the third double stroke. When cylinder
1A has once again reached its forward end position, the fourth hole is
drilled. In the 12th step, cylinder 2A extends once again and the initial
position is obtained.
Operating condition
To ensure that the service life of the drill is not exceeded, it is to be

monitored via a counter. This is to emit a signal and interrupt the cycle
once a predetermined number of drilling operations has taken place.
Once the drill has been replaced and the counter has been reset by
hand, the cycle is to continue again.
A-13
Exercise 5
Fig. 5/1:
Positional sketch
1
4
2
3
Fig. 5/2:
1
10
11
12
13=1
1B2
1B1
2B2
2B1
3S2
3S1
1A
2A
3A
A-14
Exercise 5
A-15
Exercise 6
Electropneumatics
Subject
Title
To familiarise the student with the use of a pneumatic/electric converter.
Training aim
To teach the student how to construct a control system using single

and double solenoid valves (Resetting sequence with extension).
Exercise
A-16
Exercise 6
Problem description
Semi-finished flanges of workpieces are to be placed manually in a

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

Feed cylinders 2A and cross feed cylinder 3A are both double-acting
and each controlled via a double solenoid valve.
Monitoring of clamping pressure.
A-17
Exercise 6
Fig. 6/1:
Positional sketch
1A
2A
3A
9=1
1S2
1S1
2B2
2B1
3B2
3B1
1A
2A
3A
Fig. 6/2:
A-18
Exercise 6
A-19
Aufgabe 7
Electropneumatics
Subject
Forming press
Title
To teach the student how to realise a control system with specified

EMERGENCY-STOP conditions.
Training aim
To teach the student how to realise a two-hand safety control via a

timer with switch-on delay.
Exercise
A-20
Aufgabe 7
Problem description
A metal plate is inserted by hand into the forming press. A profile is to be

stamped into the metal plate by means of a two-handed operation.
When the operation is complete, the formed metal part is to be ejected
by means of ejecting cylinder 2A.
Operating condition
The START signal is obtained through a two-hand safety control with

delayed switch-on timer. When the EMERGENCY-STOP button is
pressed, the two cylinders must return immediately to their initial positions.
Fig. 7/1:
Positional sketch
1A
Fig. 7/2:
5=1
1S2
1S1
2B2
2B1
1A
2A
A-21
Exercise 8
Electropneumatics
Subject
Embossing device
Title
To teach the student how to incorporate step repetitions and manual

step mode into a sequence.
Training aim
Drawing the pneumatic and electrical circuits.
Exercise
A-22
Exercise 8
Problem description
Workpieces to be embossed are inserted manually into a retainer and

pushed under the embossing stamp by cylinder 1A. Cylinder 2A extends
and embosses the workpiece. Then, cylinder 2A retracts again followed
by cylinder 1A.
Operating condition
It must be possible to carry out the individual movements step by step

via a push button (manual step mode). In addition, steps 2A+/2A- must
be repeatable to enable adjustment of the embossing cylinder. Cylinder
2A+ is to be moved in manual step mode, meaning that the 2A- movement must be effected via an additional push button. Step repetition and
manual step mode should only be possible when no START signal is
present.
Fig. 8/1:
Positional sketch
Fig. 8/2:
5=1
1B2
1B1
2S2
2S1
1A
2A
A-23
Exercise 9
Electropneumatics
Subject
Handling device
Title
To teach the student how to incorporate EMERGENCY-STOP and

marginal conditions in a latching sequence.
Training aim
Exercise
Checking the circuits sequence.
A-24
Exercise 9
Problem description
Round parts are to be fed by a handling device from the outlet channel
of processing station I to the inlet channel of processing station II. As an
additional start condition, the outlet channel is to be interrogated for
round parts.
Operating condition
Separate push buttons for SINGLE/CONTINUOUS CYCLE. EMERGENCY-STOP: Linear drive 2A must be unpressurised. Gripper 1A must
remain closed or open according to status. When EMERGENCY-STOP
is no longer being actuated, pressing a push button is to bring the linear
drive back into the initial position. A second push button is then to release the gripper (if this was closed in the EMERGENCY-STOP status).
This push button must also simultaneously latch the start button (after
the EMERGENCY-STOP), so that it is only possible to restart via the
START button after this button has been pressed.
Fig. 9/1:
Positional sketch
Fig. 9/2:
5=1
1S2 open
1A
Gripper
0
1S1 closed
2B2
2A
Linear drive
0
2B1
A-25
Exercise 10
Electropneumatics
Subject
Title
To teach the student how to realise a control system with an alternative program by means of program switching step jump.
Training aim
Exercise
A-26
Exercise 10
Problem description
Program 1: - Drilling
Parts, which only need to be drilled, are clamped by hand. The part is
drilled when the START button is actuated. (Cylinder 1A).
Program 2: - Drilling and reaming
Parts, which also need to be reamed, are also clamped by hand. Then,
upon actuation of a PROGRAM SELECTOR button and the START
button, cylinder 1A starts the drilling process. When the drilling process
is completed, positioning cylinder 2A extends and transfers the drilled
part to the reaming station (cylinder 3A). When reaming of the part has
taken place, positioning cylinder 2A retracts and the part can be removed. The PROGRAM SELECTOR button must be actuated before the
START button in order to start up program 2. If these buttons remain
unactuated, then program 1 is to automatically run.
A-27
Exercise 10
Fig. 10/1:
Positional sketch
Fig. 10/2:
Program 1
1
Program 2
3=1
1S2
1S1
2B2
1A
7=1
1S2
1S1
2B2
1A
2A
2A
0
2B1
2B1
3B2
3B2
3B1
3A
3A
0
3B1
A-28
Exercise 10
A-29
Exercise 11
Electropneumatics
Subject
Loading station
Title
To teach the student to program repetition using an additional movement.
Training aim
To familiarise the student with the use of an incrementing preselect

counter.
Exercise
A-30
Exercise 11
Problem description
A plate on a conveyor belt is fitted with two steel parts.

The parts advanced via a rail are centred by a spigot and held by an
electromagnet whilst being transferred.
The motion sequence towards position 1 is to be executed via cylinders
1A and 2A.
Position 2 is to be reached by means of the same sequence as that
employed for position 1, with the addition of cylinder 3A (see displacement-step diagram).
Operating condition
Sensing of steel parts is to be realised via a push button S2.

When the conveyor belt has passed on the next plate for loading and
transmitted a signal to the loading unit (simulated by push button S1),
the machine is to proceed automatically.
The functioning of the electromagnet is to be simulated by means of a
lamp H1.
A-31
Exercise 11
Fig. 11/1:
Positional sketch
Conveyor belt
Plate
Position 2
Position 1
Fig. 11/2:
1
10
11
12
13=1
1S2
1S1
2B2
2B1
3B2
3B1
1A
2A
3A
Position 1
Position 2
A-32
Exercise 11
A-33
Exercise 12
Electropneumatics
Subject
Title
To familiarise the student with step repetition using the preselect

counter.
Training aim
Exercise
Construction of the pneumatic and electrical circuit diagrams.
A-34
Exercise 12
Problem description
Workpieces are fed along a conveyor belt. The forwardmost workpiece

is pushed against the stop by the following one. When a workpiece is
present, it is signalled by a sensor (switch) and the clamping stop is
raised (cylinder 1A).
Next, cylinder 2A is to clamp the part and signal when the clamping
pressure has been reached so that the grinding process can commence.
Cylinder 3A is to advance and the grinding wheel switched on simultaneously (simulation by means of visual indicator). Then cylinder 3A is to
travel up and down ten times (half strokes) and then return to the initial
start position. Next, cylinders 1A and 2A are are to retract simultaneously.
Cylinder 2A now is to extend once again and push the part onto the
conveyor belt which is to carry it away (only a minimal section of the
stroke was required for the clamping operation). When cylinder 2A has
returned once again and another workpiece has reached the stop, the
cycle is to be repeated.
Operating condition
START and STOP at the end of each cycle are each controlled by one
push button.
A-35
Exercise 12
Fig. 12/1:
Positional sketch
3A
2A
1A
Fig. 12/2:
1
22
23
24
25
26=1
1B2
1B1
2S2
2S1
3B3
1A
2A
3A
3B2
0
3B1
A-36
Exercise 12
A-37
Exercise 13
Electropneumatics
Subject
Assembly unit
Title
To teach the student how to set up manual activation of a cylinder

including precautions with protection against collision.
Training aim
To familiarise the student with automatic setting conditions.
Exercise
A-38
Exercise 13
Problem description
Bushes which are placed ready for assembly in a gravity feed magazine
are pressed into metal blocks which are also introduced in a similar
manner.
Cylinder 1A pushes a metal block from the magazine to a stop and
clamps it. Then, cylinder 2A extends and presses the first bush into
place. Next, cylinder 3A is activated, pressing the second bush into
place. Then cylinders 1A and 3A retract simultaneously, followed by
cylinder 2A retracting. The assembled metal block drops onto a conveyor belt.
Operating condition
The installation is to operate in a continuous cycle.

It must be possible to select between manual and automatic operating
mode.
Manual operation is to be indicated by a lamp H1.
Separate push buttons are to actuate each of the cylinders. This installation may only be run in manual mode; only one cylinder is to extend at a
time.
A-39
Exercise 13
Fig. 13/1
Positional sketch
6=1
1S2
1S1
2B2
2B1
3B2
3B1
1A
2A
3A
Fig. 13/2:
A-40
Exercise 13
A-41
Exercise 14
Electropneumatics
Subject
Moulding press
Title
To teach the student how to construct a two-handed safetystart-up

control with relay.
Training aim
To familiarise the student with restart before the end of the cycle.
Exercise
A-42
Exercise 14
Problem description
Plastic plates are to be formed from duroplastic pellets. The pellets are
inserted manually into the lower part of the mould.
When the START button is pressed (two-handed safety control), the
upper part of the mould is guided into the lower part of the mould.
When the forward end position is reached, pressure must be sustained
for approximately ten seconds to guarantee hardening of the formed
part. Then, the plates are removed from the mould tool by the extractor
unit and stacked next to the press.
Operating condition
The START signal must continue until cylinder 1A has assumed its
forward end position.
The press cylinder may extend immediately the extractor unit has been
removed from the working area (half return stroke of cylinder 2A).
The two-handed safety control using a relay.
The function of the vacuum generator 4Z is to be represented by a lamp.
A-43
Exercise 14
Fig. 14/1:
Positional sketch
7=1
1B2
1B1
2B3
1A
2A
2B2
0
2B1
3S2
3S1
3A
Fig. 14/2:
A-44
Exercise 14
A-45
Exercise 15
Electropneumatics
Subject
Pick-and-place unit
Title
To teach the student how to develop a latching sequence with marginal conditions.
Training aim
Drawing the pneumatic and electrical circuit diagrams..
Exercise
A-46
Exercise 15
Problem description
A triple-axis unit is used for insertion of parts from position 2 into positions 3 and 4 of a gear housing. The vacuum gripper 4Z is to be simulated by a lamp (gripper suction = lamp on, no gripper suction = lamp
off). The start position is to be position 1, where the gripper is raised
(Z-axis) and there is no suction. When the START button is pressed,
position 2 is to be approached and a part picked up from the feed hopper and then deposited in position 3. Another part is then picked up from
position 2 and deposited in position 4. The gripper then returns to initial
position 1.
Operating condition
Sensing of the magazine (simulated by a switch and indicated via a

lamp):
When the magazine is empty, the control system is to remain in position
1 or position 2 and must only proceed or restart when the magazine has
been filled and the start button pressed.
Sensing of the gear housing:
This is to guarantee that a gear housing which is inserted into a device
is removed after processing (switch and lamp off). The initial start positions of the double-acting cylinders are: 1A+, 2A+, 3A-.
A-47
Exercise 15
Fig. 15/1:
Positional sketch
2A
1A
3A
Fig. 15/2:
down
up
Vaccuum
generator on
Vaccuum
generator off
Vaccuum
generator on
Vaccuum
generator off
A-48
Exercise 15
A-49
Exercise 16
Electropneumatics
Subject
Galvanising process
Title
To teach the student how to realise program branchings.
Training aim
To teach the student how to make multiple use of time relays.
To familiarise the student with program section repetitions using the

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

system.
Exercise
A-50
Exercise 16
Problem description
An overhead trolley beam transports the parts to be galvanised from a

work surface across the three baths and back again. A doubleacting
cylinder positions the basket on the work surface or else lowers it into
the baths. It remains in the forward end position (bath 2) or swings the
basket up and down in the bath (baths 1 and 3). Partial strokes are
sensed by three limit switches.
If the trolley has approached a horizontal position, a control lamp is
illuminated (bath 1 lamp H1, bath 2 lamp H2, bath 3 lamp H3 and work
surface lamp H4).
In the initial position, the basket hangs above the work surface. When
the up/down switch S2 is actuated, the cylinder extends and the basket
is deposited on the work surface for loading. When the initial start position has once more been reached, the cylinder can be actuated via start
button S. The movements of the trolley (from work surface to bath 1,
from bath 1 to bath 2, from bath 2 to bath 3 and from bath 3 back to the
work surface) are simulated by four identical time periods t1 = 2 seconds.
Once the basket has been dipped into bath 1 (and bath 3), the piston
extends four half strokes in the forward stroke area. The basket remains
in bath 2 in the forward stroke area t2 = 3 seconds.
Operating condition
When the main power supply has been switched on, the control is to be
activated via the SET button S1 and the time interval t1 started simultaneously.
During this time period, the cylinder is to be brought into the initial position (as it would have moved into the forward end position by leakage
losses when the installation was stopped).
When the time t1 has expired, the positioning lamp H4 is illuminated.
The installation can only be started once a pneumatic-electrical converter has signalled the supply of compressed air.
A-51
Exercise 16
Fig. 16/1:
Positional sketch
Bath 1
Bath 2
Bath 3
Fig. 16/2:
START
Bath 1
2
Bath 2
7
10
Bath 3
11
t2
12
13
14
15
16
17=1
1B3
1A
1B2
1B1
S1
t1
t1
t1
t1
A-52
Exercise 16
A-53
Exercise 17
Electropneumatics
Subject
Loading station
Title
Consolidating the students knowledge.
Training aim
Program section repetition.
Exercise
A-54
Exercise 17
Problem description
A loading station is used for loading boxes. Empty boxes which are
supplied via a conveyor belt must be placed onto the transfer unit by
hand. Transfer unit 1A moves underneath the swivel device 4M, which
then fills the box with containers row by row. The motion sequence can
be seen in displacement-step diagram 1. Indicate on the diagram the
step which has been reached by the installation shown in the positional
sketch.
Operating condition
The functioning of the suction cups is to be simulated by lamp. The

motion sequences which recur (see displacement-step diagram 1, steps
3....21), should be brought together in a subroutine which is to be repeated itself a number of times (see displacement-step diagram 2).
Fig. 17/1:
Positional sketch
4M
3A
1A
2A
The loading station shown here is not in the initial position.
A-55
1B2
1B1
2B2
2B1
3S2
3S1
4B
4S
Fig. 17/2:
Displacement-step
diagram 1
4M
3A
2A
1A
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25=1
1
Exercise 17
1A+ 3A+ 4M+ 4M- 3A- 2A+ 3A+ 4M+ 4M- 2A- 3A- 2A+
3A+ 4M+ 4M- 2A- 3A- 2A+ 3A+ 4M+ 4M- 3A- 1A-
Abbreviated notation
A-56
1B1
2B2
2B1
3S2
3S1
4B
4S
1B2
Abbreviated notation
4M
3A
2A
1A
21
21
22
23
24
25=1
Fig. 17/3:
Displacement-step
diagram 2
Exercise 17
1A+ 3A+
4M+ 4M- 2A- 3A- 2A+ 3A+
4M+ 4M- 3A- 1A-
Main program
3 x Subroutine
Main program
A-57
Exercise 18
Electropneumatics
Subject
Title
To familiarise the student with parallel program division.
Training aim
Drawing the pneumatic and electrical circuit diagram.
Exercise
A-58
Exercise 18
Problem description
Workpieces are drilled vertically and horizontally on an eight-station

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

Separate push buttons for START and STOP (continuous cycle).
The start signal must be maintained until the machine has been supplied
with lubricant via a centralised lubrication system (the pump motor is to
be simulated by a lamp). Then, the start signal is to be stored and indicated by a lamp.
Workpiece sensing on conveyor belt 1 is simulated by a switch.
The air blast for swarf removal is to be simulated using a solenoid valve.
A-59
Exercise 18
EMERGENCY-STOP
The electrical power to the control must be switched off.
The feed units are to retract.
The transfer units and the cylinder of the indexing table are to complete
their movements.
When the vacuum generators are active, they must continue to remain
active until, after the RESET and a renewed START, the controller gives
the command to deposit.
RESET
If, after indexing on, processing can no longer take place because the
EMERGENCY-STOP has been actuated, processing must be carried
out in RESET mode via a time control.
All cylinders must be brought into their initial position. In the case of the
transport units, cylinders 1A and 3A must retract before cylinder 2A and
4A.
Note regarding solution
For the purpose of simulation, this exercise can be solved using four
cylinders:
The transer units are to be represented by double-acting cylinders.
Cylinders 1A and 2A are sufficient for this as the movements of the two
units are synchronised.
Cylinder 5A for indexing of the table is also represented by a doubleacting cylinder.
All feed units are to be represented by a single-acting cylinder.
Only the limit switches of the four cylinders are to be drawn in the electrical circuit diagram.
A-60
Exercise 18
Fig. 18/1:
Positional sketch
Discharge
Conveyor 2
9A
Counter 2
8A
1A
Counter 1
Rotary indexing table
Conveyor 1
7A
Drilling 1
A-61
Exercise 18
Transfer 1
7=1
1S2 (1B2)
1S1 (1B1)
2S2 (2B2)
2S1 (2B1)
1A
2A
Transfer 2
7=1
3S2
3S1
4S2
4S1
3A
4A
7=1
1
Rotary indexing
table
5A
5S2
5S1
1
Drilling 1
7=1
6S2 (6B)
6S1 (6S)
7S2
7S1
8S2
8S1
9S2
9S1
10S2
10S1
11S2
11S1
6A
Drilling 2
Counterboring 1
Counterboring 2
Deburring 1
Deburring 2
7A
8A
9A
10A
11A
Fig. 18/2:
A-62
Exercise 18
A-63
Exercise 19
Electropneumatics
Subject
Checking station
Title
To familiarise the student with the use of a timer with delayed switchon as a delayed starting element.
Training aim
Exercise
A-64
Exercise 19
Problem description
Transfer cylinder 1A is to push a container onto the scales. Then, cylinder 2A is to release the scales and cylinder 1A is to return to its initial
position.
After a waiting time of approx. 3 seconds, cylinder 2A is to block the
scales again. If the container is within the weight tolerance (switch S4 is
activated), cylinder 3A is to push it onto the conveyor belt to move it on
and then to retract once again. However, if the tolerance limit is not
maintained (switch S4 not activated), cylinder 4A is to transfer the container to the outlet chute and then to retract again. Then, the container is
to be transferred on by the conveyor belt (simulated by a lamp H1).
Operating conditions
The installation is to operate in continuous mode and started by a push

button S1 and stopped at the end of the cycle by a second push button
S6.
The good parts are to be counted.
As the sensor for the containers is not attached directly to transfer
cylinder 1A, for technical reasons, the run-time of the conveyor belt must
be controlled as follows:
The conveyor belt continues running until a sensor (push button S4)
outside the transfer area, signals the presence of a container and uses
this to control a timer. When the time has expired, the conveyor belt can
stop and cylinder 1A then commences the cycle once again.
A-65
Exercise 19
Fig. 19/1:
Positional sketch
1A
3A
4A
6=1
1B2
1B1
2B2
2B1
3B1
3S1
4S2
4S1
1A
2A
3A
4A
Fig. 19/2:
A-66
Exercise 19
A-67
Exercise 20
Electropneumatics
Subject
Handling device
Title
Familiarisation with an alternative solution to Electropneumatics.
Training aim
Exercise
A-68
Exercise 20
Problem description
Cylindrical parts are to be distributed evenly from outlet channel 1 onto

the two inlet channels 2 and 3 (see displacement-step diagram)
Operating condition
The unit is to be operated in continuous cycle only. START and STOP

AT END OF CYCLE are each to be effected by one push button.
Sensing of parts at channel 1 is to be simulated by a switch. If this
switch is not activated, the unit is to stop at the end of the cycle.
After the swivel movement to inlet channels 2 and 3 has been carried
out, the gripper is not to open until a short delay time has expired.
After actuation of the EMERGENCY-STOP switch, cylinders 1A, 2A and
3A are to retract and cylinder 4M switched to an unpressurised condition.
When the EMERGENCY-STOP has been unlatched, the reset button is
to return cylinder 4M to the initial position.
It must be possible to limit the number of cycles using a preselect
counter.
A-69
Exercise 20
Fig. 20/1:
Positional sketch
Fig. 20/2:
1
10
11
12
13=1
1S2
1S1
2B2
2B1
3B2
3B1
4B
4S
1A
2A
3A
4A
A-70
Exercise 20
B-1
Part B - Fundamentals
The theoretical fundamentals for the training package Electropneumatics
are summarised in the textbook
Learning System for Automation and Technology
Introduction to
Electropneumatics.
Basic Level TP201
B-2
C-1
Part C Solutions
Solution 1:
Bench drill
C-3
Solution 2:
C-9
Solution 3:
Filling device
C-17
Solution 4:
Stamping device
C-21
Solution 5:
Drilling jig
C-27
Solution 6:
C-35
Solution 7:
Forming press
C-41
Solution 8:
Embossing device
C-45
Solution 9:
Handling device
C-49
Solution 10:
C-55
Solution 11:
Loading station
C-59
Solution 12:
C-63
Solution 13:
Assembly unit
C-69
Solution 14:
Moulding press
C-75
Solution 15:
Pick-and-place unit
C-81
Solution 16:
Galvanising process
C-87
Solution 17:
Loading station
C-95
Solution 18:
C-103
Solution 19:
Checking station
C-111
Solution 20:
Handling device
C-117
C-2
C-3
Solution 1
Bench drill
Fig. 1/3:
**
* For the purposes of this exercise, feed unit 2A is replaced by a

double-acting cylinder.
** Detailed representation of the on/off valve with filter regulator.
K1
K4
1S1
24
A1
23
4
5
11
K2
K1
1S2
2
3
10
14
A2
K1
13
A2
42
A1
41
14
1
13
24 V- 1
K2
14
13
2B2
BU
BN
K3
A2
24
A1
23
11 7
9
K2
BK
6
K3
14
13
2B1
BU
BN
K4
K3
BK
A2
24
A1
23
1Y
34
1A+
K1
33
10
2Y
42
41
34
2A+
K3
K2
33
11
3Y
K3
3Z
34
33
12
C-4
Solution 1
Fig. 1/4
Ausblasen
C-5
Solution 1
Since in this case the memory function is via a relay, single solenoid
valves are generally activated using a latching sequence. It should be
remembered that the coil circuit should be interrupted by a second
contact for the return motion, for example, in order to achieve spring
return of the valve to the initial position. (The final step represents an
exception to this since it is possible to dispense with a normally closed
contact as all valves are returned to their initial positions through interruption of all the circuits). This is why a latching sequence is used since
in the case of power failure all cylinders will return to an accurately
defined initial position. This is important for accident prevention, although it is important to watch out for overlapping of movements which
may occur on reaching the initial position.
24 V- 1
13
13
K1
14
1
10
33
K1
14
34
1S1
4
41
K4
42
A1
K1
1Y
A2
1A+
When START button S is actuated and normally open contact 1S1 is

activated via cylinder 1A, the circuit to relay K1 is closed via the normally
closed contact of K4, which then goes into self-holding (latching) via the
parallel contact of K1.
A further normally open contact of K1 switches the circuit to solenoid coil
1Y. This in turn switches the solenoid valve and cylinder 1A travels into
the forward end position.
Fig. 1/5:
Step 1, Cylinder 1A+
C-6
Solution 1
Fig. 1/6:
Step 2, Cylinder 2A+
24 V- 1
13
13
1S2
K1
14
1
14
13
K2
4
10
11
33
K1
14
33
K2
34
34
1S1
4
41
23
41
K1
K4
42
A1
K1
K3
24
A1
K2
A2
42
1Y
2Y
A2
1A+
2A+
When cylinder 1A has reached its forward end position, it actuates limit
switch 1S2. Then, the circuit for relay K2 is closed via S2 and the setting
condition K1, this then goes into self-latching via a parallel normally
open contact.
A second normally open contact of K2 switches the current to solenoid
coil 2Y via normally closed contact K3; this switches the valve and
cylinder 2A extends.
The principle of the latching sequence is to interrogate the preceding
step and its acknowledgement (limit switch) and then to set a new memory for the next step. Finally, the complete sequence (the self-latching
circuits) is reset by the last step (or cycle) no self-latching is required
for the last step.
C-7
Solution 1
Quantity
Designation
Relay, 3-off
Indicator/distributor plate, electrical
Manifold
Cable set with safety plug
Electrical power supply unit, 24 V
Components list
C-8
Solution 1
C-9
Solution 2
1B1
1B2
2S1
1A
Fig. 2/3:
2S2
2A
1Y1
1Y2
5
2Y1
2Y2
5
0Z2
0Z1
Simplified representation of on/off valve with filter regulator
K1
K4
K8
2S2
S2
S1
A1
22
23
12 5
17
K2
K1
2
3
14
13
A2
K1
A2
42
A1
41
14
4
11
14
1
14
13
13
BU
1B1 BN
K3
K6
K2
BK
6
7
A2
42
A1
41
14
13
5
K3
14
13
K4
K3
8
18
A2
A1
24
23
K5
K8
K4
2S1
9
10
A2
22
A1
21
14
4
13
8
K5
14
13
K6
A2
A1
24
23
5 12
16
19
K5
10
Fig. 2/4:
(1)
24 V- 1
C-10
Solution 2
1B2

K7
K8
K7
A1
24
21
1
20
14
SET 13
15
13
15
14
11
14
A2
K7
13
A2
42
A1
41
14
13
12
K2
K6
BK
BU
BN
24 V- 11
H1
K6
24
23
16
1Y1
24
23
1A-
K2
17
2Y1
24
23
2A-
K4
18
1Y2
34
33
1A+
K6
19
2Y2
34
31
2A+
K8
20
C-11
Solution 2
Fig. 2/5:
(2)
C-12
Solution 2
When the SET button is pressed, relay K7 goes into self-latching and
switches relay K8, which represents the start condition.
If appropriate, the SET button should be latched in such a way that it can
only be active at the time when the main current supply is applied, in
order to safeguard the circuit sequence.
Once the feed has been initiated with S1 and S2, K1 goes into selflatching and K2 switches, self-latching at K7 is cancelled via a normally
closed contact of K2.
A further possibility is to replace the SET key by a relay (see exercise 13).
Fig. 2/6:
Step 1, Cylinder 1A-
24 V- 1
13
S1
13
K1
14
13
17
23
K1
14
23
K2
22
24
S2
14
1
2S2
4
11
K8
14
41
K4
42
A1
A1
K2
K1
A2
1Y1
A2
1A-
When START button S1 is actuated, the circuit for relay K1 is closed via
the signal from pressing S2, the limit switch S22, the setting signal for
relay K8 and the normally closed contact K4. The relay goes into selflatching via the parallel normally open K1. At the same time, a further
normally open contact of K1 switches the circuit for the relay K2.
A normally open contact of K2 switches the circuit in the power section
to solenoid coil 1Y1. The valve switches and cylinder 1A travels into the
retracted end position and there actuates limit switch 1B1.
C-13
Solution 2
Fig. 2/7:
Step 2, Cylinder 2A24 V- 1
13
S1
13
K1
14
13
23
13
K1
14
K3
22
S2
17
K3
18
23
23
14
1B1 BN
BK
BU
14
1
7
K2
23
K4
24
24
24
13
K2
2S2
4
11
14
K8
14
41
41
K4
K6
42
A1
K2
K1
A2
42
A1
A1
K3
A2
A1
K4
A2
1Y1
2Y1
A2
1A-
Now sensor 1B1 emits a signal which closes the circuit for relay K3 via
the normally open contact K2 and the normally closed contact K6. This
goes into self-latching via the parallel normally open contact K3. At the
same time, relay K4 is switched via a further normally open contact K3.
Only now, when self-latching of K3 has been established, is the setting
condition K1 or K2 reset by normally closed contact K4 and in the power
section, the normally open contact K4 switches the circuit to solenoid
coil 2Y1, which in turn switches the valve, cylinder 2A retracts and
activates 2S1 in the end position.
Owing to its additional switching time, relay K4 serves as a delay between the build-up of self-latching of K3 and the reset of setting condition K2. This guarantees that K3 is in self-latching before the setting
signal is set.
Then, the next step is activated (K5, K6) by 2S1 via K4. The principle of
the latching sequence is based on the interrogation of the preceding
step and its acknowledgement (limit switch). The next step is activated
on the basis of these conditions; when this happens, the preceding step
is reset.
The reset sequence is particularly suitable for the control of double
solenoid valves, since here the memory behaviour is assumed by the bistable solenoid valve.
2A-
C-14
Solution 2
This can be very important in the case of power failure, in respect of

accident prevention.
To be able to start up again after power failure or switch off the main
power supply (circuit dead), relays K7 and K8 must be switched. This
happens here via the SET key. The principle of reversal of the latched
sequence which is shown here is completely reliable owing to the use of
an additional relay per step and can be used for every type of relay.
Where there is a late opening or early closing relay, it may be possible to
get by without an additional one. (Normally, only contactors have this
type of switching behaviour). In such a case, the circuit up to step 2
would look as follows. Compare this simplified circuit diagram with the
electrical circuit diagram.
Fig. 2/8
Circuit diagram, simplified
24 V13
S1
13
13
K1
14
13
K2
14
1B1 BN
S2
14
1
23
K1
14
23
K2
24
24
BK
BU
23
K1
2S2
4
11
24
K8
14
41
K2
41
K4
42
A1
K1
42
A1
K3
A2
1Y1
2Y1
A2
1A-
2A-
C-15
Solution 2
Quantity
Designation
Relay, 3-off
Manifold
Components list
C-16
Solution 2
C-17
Solution 3
Filling device
Fig. 3/2:
1S1
2B1
1S2
1A
2B2
3A
2A
1Y
2Y
1
3Y
1
0Z2
0Z1
1
3
3B1
3B2
3B1
S1 = Single cycle
S2 = Continuous cycle
K1
K7
K1
K2
14
13
K3
K2
1S2
24
A1
23
8
10
19
24
A1
23
14
13
18 6
7
K2
S4
1S1
4
5
18
14
13
A2
K1
A2
14
13
A2
42
A1
36
41
35
14
S3 13
14
BK
S1 13 S2
K6
BU
BN
1
K3
14
13
8
2B2
BU
BN
K4
A2
24
A1
23
19 11
13
17
K3
BK
10
K4
14
13
11
Fig. 3/3:
(1)
24 V-
C-18
Solution 3
st
S3 = 1 interrogation
S4 = 2nd interrogation
2B1
24 V-
BU
BN
12
rd
S5 = 3 interrogation
S6 = Idle cycle without filling

K5
K4
S5
BK
14
16
20
A2
24
A1
23
14
13
13
K5
14
13
14
2B2
A2
24
A1
A2
34
A1
33
14
13
17
K4
K7
S6
23
16
K5
BK
K6
BU
BN
15
1Y
42
41
34
33
1A-
K2
K1
18
2Y
42
41
34
33
2A+
K4
K3
19
3Y
34
33
3A+
K5
20
C-19
Solution 3
Fig. 3/4:
(2)
C-20
Solution 3
Components list
When S1 or S2 and S3 are activated, the control system is started up.

Cylinder 1A retracts and the bottles move along. If S4 is actuated, the
cylinder extends again. Then, the indexing table (cylinder 2A) inches
round one position. Once a bottle has reached the filling station, it is
filled until the time delay closes the container (cylinder 3A), and the
control system is brought back into the initial start position. If no bottle is
reported as being present at the filling station, the control can be returned to the initial start position via S6. Then the indexing table can be
supplied with bottles until a signal is received from S7.
Quantity
Designation
Relay, 3-off
Time relay, 2-off
Manifold
C-21
Solution 4
Stamping device
2B1
Fig. 4/3:
2B2
2A
1A
1S1
1S2
3A
2Y1
4
1Y1
3Y1
0Z2
0Z1
1
3
3B2
2Y2
1Y2
1
3B1
3Y2
1
3B1
K4
K1
K12
A1
24
23
K6
1S2
K2
41
14
13
K3
14
13
K4
K3
A1
24
23
7
2B2
BU
BN
A2
20 5
23
A2
3
4
42
A1
K3
6
7
A2
42
A1
9
24
A2
K5
K8
K4
BK
13
10
11
A2
12
A1
11
K2
K1
41
14
13
14
K1
14
14
13
11
K5
14
13
10
Fig. 4/4:
(1)
24 V- 1
C-22
Solution 4
K6
21
6
7
14
15
12
A1
K9
9
24
A2
24
A1
21
K12
K8
1S1
11
A1
24
21
24
K8
K7
16
14
13
14
11
15
5 13
25
K7
K10
K6
BK
K7
14
A2
BU
2B1 BN
13
A2
A1
24
23
12
A2
K5
24 V- 11
K9
14
11
17
K10
K9
9
24
A2
A1
24
21
18
C-23
Solution 4
Fig. 4/5:
(2)
3B2
K11
K2
K10
K11
16 2
20
A1
24
21
20
22
K12
K11
22
A2
14
SET 13
21
A2
42
A1
41
22
21
14
11
20
1Y1
24
23
1A+
K2
23
2Y1
24
23
2A+
K4
24
2Y2
24
23
2A-
K6
25
1Y2
34
31
1A-
K8
26
3Y1
34
31
3A+
K10
27
3Y2
34
31
3A-
K12
28
Fig. 4/6:
(3)
24 V- 19
C-24
Solution 4
C-25
Solution 4
This solution corresponds to a reset sequence of 6 steps with single

cycle operation. Only when the last step has been set via the SET
button, can another single cycle be started. The signal generators are
directly switched to limit the number of relays.
Quantity
Designation
Relay, 3-off
Manifold
Components list
C-26
Solution 4
C-27
Solution 5
Drilling jig
Fig. 5/3:
1B2
1B1
2B1
1A
2B2
3S1
3A
3S2
2A
1Y
2Y
1
3Y
1
0Z2
0Z1
* For the purposes of this exercise, feed unit 3A is replaced by a single-acting cylinder.
A 3/2-way solenoid valve may also be used as a final control element.
3A
3Y
3S1
3S2
Fig. 5/4:
Part of circuit diagram,
pneumatic
K1
K14
A1
K1
K2
23
14
11
K3
14
13
K4
3S1
A1
A2
5
13
20
27
A2
3
5
35
12
A1
A2
35 6
8
K3
24
A1
8
15
22
29
A2
K5
K3
K16
K4
11
14
11
9
11
33
A2
24
A1
23
K2
3S2
11
14
13
12
K1
14
13
K5
14
13
Fig. 5/5:
(1)
2B2
24 V- 1
C-28
Solution 5
1B1
24 V- 10

K6
K5
24
A1
23
24
21
36 14
15
K7
K6
K2
12
13
36
14
13
13
A2
K6
12
A2
24
A1
23
11
K7
14
13
14
K8
K7
K16
K4
16
18
34
A2
24
A1
23
22
21
24
21
15
K8
14
13
16
BU
2B1 BN
17
K9
K8
BK
19
20
37
A2
24
A1
23
18
K9
14
11
19
C-29
Solution 5
Fig. 5/6:
(2)
K10
K11
K10
K16
K4
24
A1
21
32
31
34
31
33 23
25
14
11
37 21
22
K10
A2
24
A1
21
34
31
22
A2
K9
K2
21
K11
14
11
23
1B2
BU
BN
24
K12
K11
BK
26
27
38
A2
24
A1
21
25
K12
14
11
26
K13
A2
24
A1
21
44
41
38 28
29
K12
K2
27
K13
14
11
28
K14
K13
K16
K4
A2
24
A1
21
42
41
44
41
29
K15
31
A2
A1
30
Fig. 5/7:
(3)
24 V- 20
C-30
Solution 5

K16
8
15
22
29
K15
A2
A1
14
11
24 V- 31
32
1Y
32
31
34
33
1A-
K11
K5
33
2Y
34
33
2A-
K8
34
3Y
42
K7
42
41
41
33
34
K6
36
34
33
3A+
K3
K1
35
K10
K9
32
31
34
31
37
K13
K12
32
31
34
31
38
C-31
Solution 5
Fig. 5/8:
(4)
C-32
Solution 5
The preselect counter receives pulses from 3S2. When the preselect
figure or the end of the drill life has been reached, the sequencer is
stopped. It will not continue running until the drill has been changed
(counter reset).
Signal generators 3S1 and 3S2 must be switched indirectly to ensure
reliable sensing. Otherwise, self-latching would supply a continuous
signal (see example) when a latching sequence is being used.
Example
Fig. 5/9:
Kn+1 can be set without acknowledgement 3S1 being activated since

current can flow via the self-latching of K3 and Kn.
24 V3S1
K2
K3
K3
Kn+1
Kn
Kn+1
C-33
Solution 5
The signal generators indirectly switched (as in the solution to the exercise).
Fig. 5/10:
Alternative circuit (1)
24 VK1
3S1
K3
K2
K1
K1
Kn+1
Kn
K3
Kn+1
As the connection is interrupted here by K4 via K3, Kn+1 may only be

set if Kn and 3S1 are activated.
Fig. 5/11:
Alternative circuit (2)
24 V3S1
K3
3S2
K4
Kn+1
K4
K2
K3
K3
K4
Kn
Kn+1
C-34
Solution 5
Components list
Quantity
Designation
Relay, 3-off
Manifold
C-35
Solution 6
Fig. 6/3:
1A
1S1
1S2
2A
2B1
2B2
3A
3B1
3B2
1B
P1
4
2Y1
2Y2
1Y
3Y1
1
0Z2
0Z1
* For the purposes of this exercise, feed unit 2A is replaced by a double-acting cylinder.
3Y2
1
K1
K14
1S1
1B
BU
BN
24
1
23
K9
K7
K5
K2
K13
BK
K2
A1
42
41
14
13
4
5
P2
P1
1S2
K1
2
3
28
14
13
A2
K1
A2
12
A1
11
14
13
K3
K2
7
29
A2
A1
24
23
5
2B2
K4
K7
K3
BK
BU
BN
8
9
A2
12
A1
11
14
13
7
K4
14
13
K5
A2
A1
24
23
4 11
31
K4
BU
2B1 BN
10
K6
K9
K5
BK
12
13
A2
12
A1
11
14
13
11
K6
14
13
12
Fig. 6/4:
(1)
24 V- 1
C-36
Solution 6

K7
A1
24
21
12
A1
11 18
4 30
A2
K10
K13
K9
21
19
20
A2
12
A1
11
K9
K8
18
11
14
11
17
24
K8
16
24
21
16
17
K8
K11
K7
7 15
4 33
3B2
15
A2
A1
24
23
14
A2
K6
24 V- 13
K10
14
11
19
K11
A2
A1
24
21
15 21
32
K10
20
K12
A2
24
A1
21
24
21
27 22
23
K14
K11
21
K12
14
11
22
C-37
Solution 6
Fig. 6/5:
(2)
12
A1
11
24
21
1 26
21
K14
K15
K13
18 25
4 34
3B1
25
A2
A1
24
21
24
A2
K13
K12
24 V- 23
K14
34
31
26
K12
25
K15
A2
32
A1
31
24
23
27
1Y
34
33
1A+
K1
28
2Y1
24
23
2A+
K3
29
K9
34
31
30
2Y2
24
23
2A-
K5
31
K11
34
31
32
3Y1
34
31
3A+
K7
33
3Y2
44
41
3A-
K13
34
C-38
Solution 6
Fig. 6/6:
(3)
C-39
Solution 6
In this exercise, two problems can be solved with minimal modifications

to the reset sequence:
Memorising of the start signal (K1) for the movement 1A+,
Resetting of the final step (K14) via START button S.
The pressure switch does not switch over until the clamping pressure
has been reached; consequently the sequencer stops until the required
pressure has built up.
In this exercise, sensor 2B1 and 2B2 can be interrogated directly several
of times without faulty actuation of the control taking place (compare with
exercise 5).
Quantity
Designation
Relay, 3-off
Manifold
Components list
C-40
Solution 6
C-41
Solution 7
Forming press
1A
1S1
2B1
1S2
2B2
2A
1Y
2Y
5
0Z2
0Z1
1
3
Fig. 7/3:
K1
ES
36
A1
35
14
14
13
14
13
12
13
4 14
K2
K3
S2
S1
K4
K5
11
14
A2
K1
13
A2
A1
22
21
24 V- 1
K3
K2
A2
42
A1
41
24
23
= 0,5s
24
23
5
2B1
BU
BN
BK
K4
A2
A1
C-42
Solution 7
Fig. 7/4:
(1)

K6
K5
1S1
34
A1
31
11
13
15
24
21
10
3 9
14 10
K5
A2
42
A1
41
A2
K5
K7
1S2
24 V-
K6
14
11
11
2B2
BU
BN
12
K7
K6
BK
A2
24
A1
21
13
1Y
42
41
14
13
1A+
K5
K2
14
2Y
34
31
2A+
K6
15
C-43
Solution 7
Fig. 7/5:
(2)
C-44
Solution 7
If the EMERGENCY-STOP switch ES is not activated, current path (1) is

supplied with current. In order to switch relay K2, the two push buttons
S1 and S2 must be actuated simultaneously (START signal). If one of
the push buttons is pressed before the other, the time relay with switchon delay is energised which then switches after 0.5 secs. (For safety
reasons, the switch-on delay must not exceed 0.5 seconds). The result
of this is that the normally closed contact K3 in current path 3 opens
and, thus the connection to K2. If two buttons are actuated simultaneously so that the time relay does not switch through, relay K2 is switched
and cylinder 1A extends.
When the EMERGENCY-STOP switch is actuated, the current to path 1
is interrupted and the solenoid coils are no longer supplied with current.
The result of this is that the reset springs reverse the solenoid valves
and the cylinders return to the initial position.
Components list
Quantity
Designation
Relay, 3-off
Time relay, 2-off
Manifold
C-45
Solution 8
Embossing device
1A
1B1
1B2
2A
2S1
1Y
2Y
1
0Z2
0Z1
1
3
2S2
Fig. 8/3:
K1'
A1
18 13
16
14
11
4 2
6
10
K1
A2
A1
12
11
14
13
A2
K6
K1
S1
K2
K1
S2
7
11
14
17
A2
22
A1
21
14
13
1B1
K3
K7
K1
8
10
19
A2
22
A1
21
34
31
K2
14
11
7
K3
14
11
1B2
K4
K7
K3
K1
12
13
20
A2
12
A1
24
11
21
44
41
10
K2
24
21
11
K4
14
11
12
Fig. 8/4:
(1)
24 V- 1
C-46
Solution 8
S1 = START-button
S2 = Manual step mode

S3 = Step repetition
A2
24
A1
21
14
11
20 15
16
K5
K1
K1'
2S2
24 V- 13
K2
34
31
14
K5
14
11
15
K6
1
6
K5
K1'
2S1
A2
24
A1
21
24
21
16
K2
44
41
17
10
K1'
K7
S3
A2
32
A1
31
14
13
18
1Y
34
31
1A+
K3
19
2Y
32
31
34
31
2A+
K5
K4
20
C-47
Solution 8
Fig. 8/5:
(2)
C-48
Solution 8
By pressing the START button, the program is started in accordance

with the displacement-step diagram.
Manual step mode
By pressing push button S2, it is possible to carry out one movement per
actuation in accordance with the program or control sequence.
Step repetition
When, after pressing S2, cylinder 1A has advanced via K3 and cylinder
2A via K4, self-latching at K4 can be reset via K7 by means of push
button S3. As a result of this, K4 is de-energised and cylinder 2A retracts. Cylinder 2A is now able to advance again via S2.
Components list
Quantity
Designation
Relay, 3-off
Manifold
C-49
Solution 9
2B1
1S1
1S2
Fig. 9/3:
2B2
2A
1A
1Y
2Y1
1
2Y2
0Z2
0Z1
* For the purposes of this exercise, linear drive 2A is replaced by a double-acting

cylinder.
2A
2B1
2Y1
2Y2
1
Fig. 9/4:
Part of circuit diagram,
pneumatic
2B2
S1 = Single cycle
S2 = Continuous cycle
S3 = STOP
4
6
32
A1
31
24
21
14
13
2
5
K2
S3
K5
S2
A2
14
13
A2
12
A1
11
14
K1
2
K2
14
13
K3
K1
11
25
A2
A1
24
23
5
K2
24
23
A2
A1
22
21
19 8
26
K4
ES
K1
K9
K5
11
14
13
NA
K5
1S2
K4
1
3
18
A2
A1
14
11
1B
2B1
BU
BN
10
K6
K9
K3
BK
12
13
21
A2
24
A1
21
14
13
11
K6
14
11
12
Fig. 9/5:
(1)
S1
24 V-
C-50
Solution 9
1B = Sensing of parts
ES = EMERGENCY-STOP
S4 = RESET linear drive

BU
BN
K8
K7
BK
24
A1
21
17
18
23
2B2
16
30 14
15
29
14
11
15
A2
K7
14
A2
K7
24
A1
21
13
K6
1S1
24 V-
K8
12
11
17
K9
K8
K5
A2
24
A1
21
34
31
18
A2
32
A1
31
22
29 20
30
K10
S4
K4
21
19
K10
14
11
20
K11
K13
K12
K6
22
28
A2
14
A1
12
13
11
32
31
21
K11
14
11
22
C-51
Solution 9
Fig. 9/6:
(2)
K12
A1
24
21
23
K13
K3
21 24
24
A2
24
A1
K12
23
25
A2
K13
42
23
41
34
21
24
K4
24
23
26
S5
32
31
27
1Y
24
1A+
K11
21
28
2Y1
22
34
21
31
2A+
K10
K7
29
2Y2
32
42
31
41
3A-
K10
K7
30
Fig. 9/7:
(3)
K5
K8
31
24 V- 23
C-52
Solution 9
S5 = RESET gripper
C-53
Solution 9
Line 1 is supplied with current via relay K4 (provided the EMERGENCYSTOP button has not been pressed). The cycle is started via S1 or S2. A
latching sequence is then constructed for this motion sequence through
current paths 9 to 18.
When the EMERGENCY-STOP switch (ES) has been actuated, the
gripper is to remain in its current position, whether open or closed. The
signal close gripper is acquired via relay K6. This signal must be stored
after actuation of EMERGENCY-STOP to keep the gripper in a closed
position (see current paths 21 and 22). However, this memory must be
erased if, at the time of the EMERGENCY-STOP actuation, the control
had opened the gripper. In this case, the open signal K8 MUST BE
STORED (SEE CURRENT PATHS 23 AND 24). Relay K13 is required
to ensure that the reset button for gripper S5 is only active when the
EMERGENCY-STOP key has already been switched off and the controller has been stopped. This is only released when no start signal or
EMERGENCY-STOP signal is present and push button S5 has been
actuated.
Coil Y2 is actuated by signal K7 and the linear drive proceeds. Selflatching of relay K10 is required to switch the linear drive to unpressurised on actuation of the EMERGENCY-STOP and to memorise this
status. This is then reset by RESET button S4 and the unit is returned
once again to the initial start position.
A new start signal is not memorised until the gripper has actuated limit
switch 1S2 (K5).
The cycle only starts if parts are present in the outlet channel (sensor 1B) and the initial position of the linear drive (sensor 2B1) is being
signalled.
Owing to multiple sensing, limit switch 1S2 must be switched indirectly
via relay K5.
C-54
Solution 9
Components list
Quantity
Designation
Relay, 3-off
Manifold
C-55
Solution 10
Fig. 10/3:
1A
1S1
2B1
1S2
2B2
3A
3B1
2A
1Y
2Y
5
3Y
5
0Z2
0Z1
* In order to assemble this control system on the profile plate, feed unit 1A is replaced
by a double-acting cylinder and feed unit 3A by a single-acting cylinder.
3B2
K1
K8
K2
2
5
8
A2
12
A1
11
42
14
41
13
K1
14
13
BU
2B1 BN
K4
K2
K3
BK
5
7
19
A2
A1
12
11
14
14
13
13
K8
K1
K2
22
24
21
23
14
13
K3
1S1
4
9
A2
A1
K4
A2
24
A1
23
4 8
19 9
K2
1S2
K4
K1
24
34
21
33
K5
K4
K3
10
12
20
A2
34
A1
31
24
23
9
K5
14
11
10
Fig. 10/4:
(1)
24 V- 1
C-56
Solution 10
S = START-button
PS = PROGRAM SELECTION button
2B2
BU
BN
24 V- 11
K6
K5
BK
K7
K6
24
A1
21
21 16
18
3B2
15
13
15
21
14
11
14
A2
K6
13
A2
24
A1
21
12
K7
14
11
16
3B1
17
K8
1
5
K7
A2
24
A1
21
18
1Y
42
41
34
33
1A+
K4
K2
19
2Y
34
31
2A+
K5
20
3Y
32
31
34
31
3A+
K7
K6
21
C-57
Solution 10
Fig. 10/5:
(2)
C-58
Solution 10
Relay K1 is switched via the PROGRAM SELECTOR BUTTON PS. This

is only possible prior to actuation of the START button.
If program 2 (drilling and reaming) is selected, the latched sequence
runs through as usual. However, if program 1 (drilling) is required, it is
simply necessary to press the start button. If 1S2 and contact K2 switch
the relay K4, the sequencer is reset by K4 and cylinder 1A retracts.
Components list
Quantity
Designation
Relay, 3-off
Manifold
C-59
Solution 11
Loading station
Fig. 11/3:
1A
1S1
1S2
2A
2B1
3B1
2B2
3B2
3A
1Y
2Y
5 1 3
5 1
3Y
5 1 3
0Z2
0Z1
* For the purposes of this exercise, cylinder 1A is replaced by a single-acting cylinder.
K1
K10
2
4
15
A2
A1
42
41
K1
14
11
2B1
S2
K2
A2
A1
42
41
24
1
14
21
11
5
6
21
22
K7
K1
K9
4
K2
14
11
K3
A2
A1
24
21
12
11
15 7
22 8
K2
K4
1S2
6
K3
14
11
K4
A2
A1
24
21
12
11
6 9
12
24
K3
K5
1S1
8
K4
24
21
K4'
25
A2
A1
10
2B2
11
K5
A2
34
A1
31
24
21
8 12
13
23
K4
K5
12
K6
A2
34
A1
31
12
11
21 13
22 14
K5
K6
13
Fig. 11/4:
(1)
S1
24 V-
C-60
Solution 11
S1 = START button
S2 = Sensing of steel parts
A2
25
A2
A1
K8
A1
31
32
K3
34
24
21
K1
31
15
K1
R2
R1
14
13
16
3B1
BU
BN
17
BK
K9
Electromagnet
K7
K6
14
A2
A1
18
3B2
BK
K10
BU
BN
19
1 16
A2
A1
20
32
31
34
42
41
1A+
K6
42
41
44
41
22
K5
K2
1Y
Electromagnet
H1
K6
K2
31
21
K5
44
41
23
44
2A+
2Y
K4
41
24
3Y
14
11
14
3A+
K4'
K8
11
25
C-61
Solution 11
Fig. 11/5:
(2)
C-62
Solution 11
The cycles of the control are counted to enable cylinder 3A to extend.

Where there is a preselected figure 2, cylinder 3A is extended together
with cylinder 2A on the second cycle of the control system in order to
bring the part past position 2.
If cylinder 3A has extended, start condition K1 is reset via 3B2 (K10) and
the counter is reset to zero.
Components list
Quantity
Designation
Relay, 3-off
Manifold
C-63
Solution 12
Fig. 12/3:
3A
1A
1B1
2A
1B2
2S1
2S2
3B1
3B3
2B
P1
2Y
1Y
1
3Y
5
0Z2
0Z1
* For the purposes of this exercise, cylinder 1A is replaced by a single-acting cylinder

and feed unit 3A by a double-acting cylinder. The inductive proximity sensor 3B2 is
switched to mid-position by the trip cam.
3B2
K1
S3
S1
S2
A1
4
29
K2
2S1
2
4
14
13
A2
K1
A2
32
A1
31
14
13
K3
K14
K2
K1
5
7
32
A2
14
A1
11
14
1
24
13
23
4
K3
14
13
5
1B2
K4
K3
8
10
33
A2
24
A1
23
7
K4
p
14 p1
2
13
8
2B
BU
BN
K5
K4
BK
11
14
22
35
A2
A1
24
23
10
K5'
K5
37
A2
A1
14
13
11
3B3
BU
BN
12
K6
BK
20 14
16
A2
A1
13
Fig. 12/4:
(1)
24 V- 1
C-64
Solution 12
S1 = START-button
S2 = Part of the stop
S3 = STOP-button
C-65
Solution 12
Fig. 12/5:
(2)
1B1
K13
K12
K2
17
30
31
35
A2
24
A1
21
24
23
29
K13
24
21
30
K14
2S2
A2
A1
31
1Y
32
31
34
33
1A+
K12
K3
32
2Y
42
41
34
33
2A+
K12
K4
33
K13
42
41
34
3Y
42
41
32
31
44
41
3A+
K11
K7
K5
35
K10
34
31
36
H1
K12'
K5'
12
11
14
11
37
Fig. 12/6:
(3)
24 V- 28
C-66
Solution 12
Grinding wheel
C-67
Solution 12
When the installation is started up and the initial position of cylinder 2A

(2S1) and a workpiece (S2) are signalled, cylinder 1A extends. Then
cylinder 2A extends and clamps the part. When the clamping pressure
has been reached, cylinder 3A is extended via K5. Sensor B5 is activated in the forward end position. This in turn activates relay K6. Then
feed cylinder 3A retracts again. In addition, K6 passes on a counting
pulse to the preselect counter.
Sensor 3B2 is activated when the cylinder has retracted by a half. This
then reverses the valve via further contacts (K6, K7, K9) and cylinder 3A
extends again. This sequence is carried out until the preselected figure
has been reached. If 3B2 is activated on the return stroke, the valve may
not switch since counter contact K9 interrupts the circuit. The sequence
is switched on via a second counter contact.
Quantity
Designation
Relay, 3-off
Manifold
Components list
C-68
Solution 12
C-69
Solution 13
Assembly unit
2A
1A
1S1
2B1
Fig. 13/3:
2B2
3B1
1S2
3B2
3A
2Y1
4
1Y1
2Y2
1
1Y2
1
3Y1
0Z2
0Z1
3Y2
1
S2
4
32
36
40
K1
A2
2B1
K2
5
6
A2
12
A1
11
14
14
13
13
K5
K11
S1
24
23
K1
12
11
K2
14
11
A2
A1
24
21
19 7
29
K3
K2
K4
K7
K3
1S2
8
9
A2
12
A1
11
14
4
11
7
K4
14
11
K5
A2
A1
24
21
4 11
33
K4
9
2B2
10
K6
K9
K5
12
13
A2
12
A1
11
24
21
11
K6
14
11
12
Fig. 13/4:
(1)
A1
14
13
24 V- 1
C-70
Solution 13
S1 = OFF/ON
S2 = MAN/AUT

K7
K8
K11
K7
BK
42
A1
41
24
21
16
17
28
BU
BN
15
7 15
37
3B2
14
A2
A1
24
21
13
A2
K6
24 V-
K8
14
11
16
K9
A2
A1
24
21
11 19
31
39
K8
17
BU
3B1 BN
18
K10
K3
K9
1S1
BK
20
22
23
A2
22
A1
21
24
4
21
19
K10
14
13
20
K12
42
41
21
K11
A2
A1
24
23
15 4
35
K10
22
C-71
Solution 13
Fig. 13/5:
(2)
K12
K13
S5
S4
S3
A1
32
32
31
14
31
13
32 30
14
13
21 24
K12
A2
A1
34
33
24
A2
K10
23
25
K14
36 34
A2
A1
42
14
41
32
13
31
26
K15
40 38
A2
A1
14
42
13
42
41
41
27
H1
28
1Y1
34
31
1A+
K3
29
K13
14
13
30
1Y2
34
31
1A-
K9
31
K13
K1
42
41
22
21
32
Fig. 13/6:
(3)
24 V-
C-72
Solution 13
MAN
2Y1
34
31
33
2A+
K5
24 V-
K14
14
13
34
2Y2
24
23
2A-
K11
35
K14
K1
42
41
32
31
36
3Y1
34
31
3A+
K7
37
K15
14
13
38
3Y2
42
41
3A-
K9
39
K15
K1
42
41
42
41
40
C-73
Solution 13
Fig. 13/7:
(4)
C-74
Solution 13
When the MAN/AUT switch S2 or relay K1 is not actuated, voltage is

applied at line 1 (MANUAL mode). The cylinder can be extended individually via push buttons S3, S4 and S5.
Cylinder 1A extends and remains in the extended position for as long as
push button S3 is actuated or an additional push button is pressed.
Movement is prevented if two or three push buttons are pressed simultaneously.
To ensure that there is no interference with AUTOMATIC mode, the
lines to the normally closed contacts of relays K13, K14 and K15 are
each interrupted by a normally closed contact of K1.
As soon as line 2 (AUTOMATIC mode) is supplied with current, selflatching is set via the normally closed contact K12 in current path 12. At
the same time, when K10 goes into self-latching, relay K12 is switched
via a normally open contact K10. This also goes into self-latching and
the normally closed contact K12 in current path 21 opens. Thus, the last
step which is normally required as a start condition can be activated
without the use of a SET button.
Components list
Quantity
Designation
Relay, 3-off
Manifold
C-75
Solution 14
Moulding press
Fig. 14/3:
1A
1B1
2B1 2B2
1B2
2B3
3A
3S1
2A
1Y
2Y
1
3Y
1
0Z2
0Z1
* For the purposes of this exercise, the double-acting cylinder is replaced by a singleacting cylinder.
3S2
K3
K1
S1
A2
42
A1
41
14
13
S2
14
13
K2
K1
A2
14
A1
13
K3
K2
K5
K14
7
30
A2
42
A1
42
41
14
41
24
11
24
23
23
4
1B2
K4
24 7
9
A2
A1
K5
K11
K3
K4
8
10
31
A2
12
A1
11
14
14
13
13
7
K5
14
13
K6
K4
10
A2
A1
24
23
K7
A2
24
A1
23
18
17
31 11
13
K5
K6
10
K7
14
13
11
Fig. 14/4:
(1)
24 V- 1
C-76
Solution 14
S1, S2 = START-button
1B1
24 V- 12

K8
15
16
27
33
24 13
15
32
K9
24
A1
A2
24
A1
K10
24
A1
21
7 19
K11
K10
3S1
33 17
18
25
14
11
18
A2
K10
17
A2
24
A1
21
K9
21
K8
3S2
23
11
4
K9
16
14
2B3
15
14
11
14
A2
K7
K8
13
K11
24
21
19
BU
2B1 BN
20
K12
BK
27 26
A2
A1
21
C-77
Solution 14
Fig. 14/5:
(2)
2B2
24 V-
BU
BN
22
K13
BK
4
25
24
42
A1
41
32
31
14
11
A2
K14
K4
K8
K13
24
A2
A1
23
K10
K14
34
31
24
21
25
K12
14
11
26
K15
K12
K9
28
29
A2
22
A1
21
34
31
27
K15
14
11
28
H1
K15
24
21
29
1Y
24
23
1A+
K3
30
K7
K5
42
41
34
33
31
2Y
44
41
2A+
K8
32
3Y
42
41
44
41
3A+
K10
K9
33
C-78
Solution 14
Fig. 14/6:
(3)
Vacuum generator
C-79
Solution 14
The two-hand safety control is realised in current paths 1 to 4. Relay K2

serves here as a delaying element. The maximum time duration allowable between the actuation of S1 and S2 is dependent on the switching
time of this relay.
If the two push buttons S1 and S2 are activated simultaneously, cylinder 1A extends. These buttons must remain depressed until the cylinder
has reached its forward end position.
The start condition is decided by the connections in current paths 24 26. It has been established that the signal from signal generator B5 only
becomes effective when the extractor unit leaves the working area, i.e.
on the return stroke of cylinder 2A.
Relay K15 starts the operation of the vaccum generator which must be
specially stored as the sequence is set before the retraced end position
of cylinder 2A is reached.
Quantity
Designation
Relay, 3-off
Time relay, 2-off
Manifold
Components list
C-80
Solution 14
C-81
Solution 15
Pick-and-place unit
Fig. 15/3:
1A
1S1
2B1
1S2
2B2
3A
3B1
2A
1Y
2Y
1
3Y
1
0Z2
0Z1
* For the purposes of carrying out this exercise on the profile plate, cylinder 3A is
replaced by a single-acting cylinder.
3B2
S3
S2
K1
K15
S1
2
4
22
A2
12
A1
11
14
13
14
14
13
13
K1
14
13
H1
24
23
K2
K15
K1
K3
1S2
5
7
40
A2
22
A1
21
24
42
23
41
4
K2
14
13
BU
2B1 BN
K4
K3
K2
BK
8
10
36
A2
24
A1
23
12
11
7
K3
14
13
8
3B2
K4
A2
24
A1
23
12
11
7 11
41 13
K3
K5
10
K4
24
21
11
Fig. 15/4:
(1)
24 V- 1
C-82
Solution 15
Magazine
S1 = START-button
S2 = Gear housing
S3 = Magazine
3B1
24 V- 12
K5
A2
13 16
17
42
10 14
15
38
A1
A1
K6
34
34
K5
31
11
31
K7
1S1
12
24
21
15
12
K5
14
A2
K4
K6
11
13
K6
24
21
16
K7
A2
A1
34
31
12
15 18
36 20
K6
K8
11
17
K7
24
21
18
K7'
42
A2
A1
19
K8
A2
A1
34
31
12
17 21
38 22
K7
K9
11
20
K8
24
21
21
K9
A2
A1
34
31
34
12
33
11
20 23
25
37
K8
K1
K10
22
K9
24
21
23
K9'
43
A2
A1
24
C-83
Solution 15
Fig. 15/5:
(2)
K10
31
A2
25 28
31
39
22 26
43 27
A1
A1
K11
34
34
K10
31
41
42
K12
42
41
24
27
A2
K9
K11
K10
21
26
K11
14
13
28
K11'
40
A2
A1
29
BU
2B2 BN
30
K12
A2
A1
24
23
14
27 31
32
44
K11
BK
K12
13
31
K13
A2
A1
24
23
14
44 32
33
K12
K13
11
32
K14
A2
K15
A2
A1
24
21
32
31
34
1
4
K14
S2
A1
24
21
14
39 33
34
K13
K14
11
33
H2
24
23
35
Fig. 15/6:
(3)
24 V- 25
C-84
Solution 15
Gear
housing

H3
K7
K3
42
K13
32
31
41
41
44
K9
37
34
33
24 V- 36
1Y
42
41
44
41
1A-
K8
K5
38
K14
K11
32
31
34
33
39
2Y
42
41
34
33
2A-
K11'
K2
40
3Y
42
3A+
K4
41
41
K7'
K6
12
11
44
41
42
K10
K9'
42
41
14
11
43
K13
K12
32
31
34
33
44
C-85
Solution 15
Fig. 15/7:
(4)
Vacuum
generator
C-86
Solution 15
If one of the magazines is empty, then the installation remains stationary

at position 1 or 2 by resetting the START signal, and waits there until the
magazine has been filled and a new START signal is issued (see current
paths 1, 4, 22).
In order to fulfil the gear sensing, it is necessary to establish whether a
gear housing is available (starting precondition). When the assembly has
been completed, the gear housing must be removed. Without this, it will
no longer be possible to start the installation (see current path 1, 4, 34).
Components list
Quantity
Designation
Relay, 3-off
Manifold
C-87
Solution 16
Galvanising process
1B1
1B3
1B2
1A
1Y
5
0B
P1
0Z2
0Z1
1
3
Fig. 16/3:
1B1
BU
BN
K21
BK
K2
22 3
4
26
A1
42
41
14
14
13
11
14
14
11
11
K1
K21
K15
K13
A2
0B
1.2
A2
A1
1.1
K1
14
13
K2
5
6
42
A2
A1
42
41
24
24
23
21
1A+
K5
K1
K15
4
K2
14
13
Bad 1
H1
K3
K2
A2
A1
24
23
K4
9
10
A2
A1
12
11
14
14
13
11
1A-
K7
K3
K18
8
K4
14
13
K5
A2
A1
24
23
4 11
27
K4
10
Fig. 16/4:
(1)
24 V- 1.0
C-88
Solution 16
S = START-button

K6
12
14
44
A2
A1
12
11
14
34
13
1A+
K9
K5
K15
31
24 V- 11
K6
14
13
12
H2
13
K7
A2
K8
A1
24
1A-
16
17
A2
A1
12
11 18
28
A2
K10
44
21
19
21
43
A2
A1
22
1A+
K13
K9
K15
21
K9
K8
41
18
11
14
21
17
24
K8
11
16
24
36
21
35
15
K11
K7
K19
A1
24
8 15
36
K6
23
14
K10
14
11
19
H3
20
C-89
Solution 16
Fig. 16/5:
(2)
Bath 3
Bath 2
1A-
23
25
29
45
A1
42
41
24
24
21
21
15 22
K12
K1
K11
K18
A2
A1
24
21
A2
K11
K10
22
K12
14
11
23
S1
14
13
24
A2
A1
24
21
18 2
37
K13
K12
25
K14
A2
A1
34
33
t1
34 30
45
K1
26
K5
24
23
27
K9
34
31
28
K12
34
K15
K14
31
29
2
4
11
18
A2
A1
18
17
30
1B3
K16
BK
BU
BN
31
33
37
A2
A1
32
Fig. 16/6:
(3)
24 V- 21
C-90
Solution 16
S1 = SET-button
K14
35
A2
A1
14
11
R2
R1
36
35
34
K18
A2
A1
14
11
40 8
22
K17
35
K19
A2
A1
32
t2
15
K7
31
36
K20
A2
A1
12
11
32
31
24
21
42 38
K22
K13
K16
37
K20
14
11
38
1B2 1
39
37
K18
K22
S2
A2
A1
32
31
40
1Y
S2 =
Up/Down
K17
K16
24 V- 33
1A+
14
13
41
K20
K2
22
21
34
33
42
K10
34
31
43
K6
K12
H4
K14
34
33
44
28
44
27
41
45
C-91
Solution 16
Work surface
t1 > tReturn stroke
oscillate
Fig. 16/7:
(4)
C-92
Solution 16
Initial position: Cylinder 1A is retracted and is located above the work

surface and lamp H4 is illuminated. Cylinder 1A can be extended via the
up/down switch (current path 41). Once the initial start position has been
regained, the cycle is started with the start button. Then lamp H4 is
switched off and the time t1 expires. This switches lamp H1 (bath 1
reached) and allows cylinder 1A to extend via relay K2. Counting pulses
are passed on to the counter via 1B3 (current paths 31-34). Additionally,
1B3 reverses the valve so that cylinder 1A retracts as far as 1B2. As a
result, cylinder 1A is switched back to Extend (current paths 37-40).
This oscillating movement of cylinder 1A is repeated until the counter
switches and interrupts the signal of sensor 1B2.
When the cylinder has retracted, time delay t1 is activated once again by
relay K5, which switches relay K6 when it has completed its cycle. Lamp
H2 is illuminated and cylinder 1A extends. Next, the delay period t2 of
the basket in bath 2 is switched via K7. Then, relay K8 switches, cylinder
1A retracts once again and the time t1 is repeated. When the time relay
has switched, the cylinder enters bath 3 and the motion sequence carried out for bath 1 is repeated. Time period t1 is then activated a final
time and signals the initial start position via lamp H4.
The time t1 must be longer than the time which the cylinder requires for
its return stroke.
C-93
Solution 16
Quantity
Designation
Relay, 3-off
Time relay, 2-off
Manifold
Components list
C-94
Solution 16
C-95
Solution 17
Loading station
Fig. 17/4:
1B 1
1A1
1B2
1A2
2B1
2B2
2A
1V1
1Y1
1V2
1Y2
2V
2Y1
2Y2
1
3A
3S1
3S2
4S
4M
3V
3Y1
4V
3Y2
4Y
4B
0Z2
* For the purposes of this

exercise, the rotary actuator
(4M) is replaced by a singleacting cylinder, and the rodless cylinder (1A) by a
double-acting cylinder.
0Z1
1
3
1B1
24 V- 1
3A+
24
A1
21
14
11
1A+
K2
K1
K2
35 5
6
39
1B2
3
5
35
36
14
11
A2
42
A1
41
14
K1
A2
K7
K1
13
K3
K2
K9
7
8
20
A2
24
A1
21
14
13
6
K3
14
11
7
11
K4
A2
24
A1
21
14
11
4M+
20 9
10
44
K3
K18
14
K19
12
K4
14
11
K5
A2
24
A1
21
14
13
4M-
44 11
12
34
K4
K11
10
K5
14
11
11
C-96
Solution 17
Fig. 17/5:
(1)
S = START-button
K7
K6
K8
A2
24
A1
23
14
13
1A-
14
13
3A-
K6
14
A2
24
A1
21
14
13
13
39 13
14
42
K6
K5
K10
24 V- 12
K8
3S1
14
28
A2
A1
15
K9
3S2
6
20
A2
A1
16
K10
4S
12
24
A2
A1
17
4B
18
K11
10
22
A2
A1
19
K12
21
22
33
43
A2
34
A1
22
31
32
21
31
24
23
4M+
K3
K18
K4
K9
20
K12
14
11
21
K13
A2
24
A1
21
24
23
4M-
33 23
43 24
K12
K11
22
K13
14
11
23
C-97
Solution 17
Fig. 17/6:
(2)
K14
24
A1
21
14
11
3A-
K15
K14
K15
2A-
2B1
39 27
28
41
14
11
25
27
37
K14
27
A2
24
A1
21
24
23
26
A2
K13
K10
25
A2
24
A1
21
24
23
2A+
37 29
31
38
K16
K15
K8
28
K16
14
11
29
2B2
30
K17
A2
24
A1
21
14
11
3A+
41 31
32
40
K16
K17
31
K18
A2
A1
24
21
20 8
K17
32
K19
K13
K12
A2
32
A1
31
34
31
33
K5
R2
R1
34
31
34
Fig. 17/7:
(3)
24 V- 24
C-98
Solution 17
1Y1
32
31
34
1A+
K2
K1
31
24 V- 35
1Y2
44
1A+
K1
41
36
2Y1
32
31
34
2A-
K16
K14
31
37
2Y2
44
2A+
K16
41
38
3Y1
42
41
32
44
31
3A+
K6
K15
K2
41
39
K17
34
31
40
3Y2
42
44
41
3A-
K17
K15
41
41
K6
34
33
42
4Y
42
44
41
4M+
K13
K12
41
43
H1
K5
K4
42
44
41
41
44
C-99
Solution 17
Suction
cups
Fig. 17/8:
(4)
C-100
Solution 17
Main program
The loading station is located in step 21 of the subroutine.

When the START button has been pressed, K1 causes cylinder 1A to
extend. Then cylinder 3A is extended via K2 and cylinder 3A is switched
to the unpressurised condition.
Next, the jump from K3 to K12 into the subroutine takes place. When the
subroutine has run through, the return jump through K18 and K19 to K4
in the main program takes place. Cylinder 4M advances and is retracted
by K5. The, cylinder 3A is retracted by K6 and cylinder 1A by K7.
Subroutine
Movements 4M+, 4M-, 2A- (with every 2A- movement, cylinder 1A which
has been switched unpressurised, is pushed back by a partial stroke),
3A-, 2A+, 3A+ are executed in the subroutine and repeated three times
via a counter. When the counter has reached the preselected figure, the
return jump to the main program is carried out.
Comment
In the case of this motion sequence, costs make it necessary to realise

this by means of a repetition of a program section (subroutine).
Increased expenditure on planning is justified here by a considerable
saving on relays and very much simpler circuitry, so that in this case, the
solution shown is more economical than a solution with the full sequence
which requires less planning.
C-101
Solution 17
Quantity
Designation
Relay, 3-off
Manifold
Components list
C-102
Solution 17
C-103
Solution 18
3
5
2
4
8Y
8A
3
5
7Y
7A
2
4
7S2
7S1
2Y1
3
1
5
1Y2
1Y1
3
1
8S1
3
5
2
4
2Y2
8S2
9Y
9A
9S1
3
1
5
3Y1
2A
2
4
10Y
10A
9S2
4Y1
3Y2
2
4
2S2
2S1
(2B1) (2B2)
1A
3
5
10S1 10S2
4A
4Y2
2
11Y
11S1 11S2
11A
5Y1
4S2
4S1
3S2
3S1
3A
1S2
1S1
(1B1) (1B2)
12Y
3
5
3
5
5A
5S1
5Y2
5S2
6Y
6A
(6S)
6S1
(6B)
6S2
Fig. 18/3:
For the purposes of this exercise, cylinders 3A and 4A are not constructed. Feed units 6A to 11A are represented in the construction by a
single-acting cylinder. The on/off valve with filter regulator and manifold
are not represented.
24 V-
36
35
K1
1 3
6
A2
A1
32
31
24
18
17
4
2B1
H2
S1 = ON
S3 = Sensing of parts
S2 = AUTO/MANUELL
S4 = OFF
H1
K1
S4
23
13
14
32
14
K1
31
K2
K1
A2
28
A1
42
27
41
14
14
11
4
13
36 7
8
34
K6
K16
S3
6S
6
K2
14
13
K3
A2
A1
24
23
28 11
44
57
K2
8
1B2
K4
11
24
34
A2
A1
10
K5
K9
K3
K4
13
14
A2
12
A1
11
14
13
14
13
11
K17
14
11
12
K5
14
13
13
K6
A2
A1
24
23
6 17
46
K5
14
Fig. 18/4:
(1)
S1
S2
13
C-104
Solution 18
START
Pump
1B1
24 V-
15
K7
18
19
52
17
28
51
12
A1
11
14
13
14
13
A2
K8
K11
K6
K7
17
A2
A1
16
K8
14
11
18
K9
A2
A1
24
21
11 21
36
49
K8
19
2B2
22
23
A2
12
A1
11
24
4
21
21
K13
K9
5S2
BK
K10
BU
BN
20
K10
14
11
22
K11
A2
A1
24
21
17 24
45
53
K10
23
K12
A2
22
A1
21
24
4
21
24
23
34 25
26
K16
K11
5S1
K4
24
K12
14
11
25
K13
A2
A1
24
21
21 28
47
55
K12
26
6B
27
K14
K3
K13
K7
29
31
33
A2
42
A1
41
24
24
21
23
28
C-105
Solution 18
Fig. 18/5:
(2)
K14
14
11
29
24 V-
K15
12
11
30
K15
S5 = EMERGENCY-Stop
S6 = RESET
K16
K14
A1
34
24 6
50
24
30 32
K15
31
33
A2
A1
24
21
32
A2
K14
21
31
K17
A2
32
A1
31
34
33
34
44 12
35
43
K12
K4
K2
33
K17
24
21
35
K18
K2
K9
37
56
A2
42
A1
41
34
31
36
K18
14
11
37
K19
S6
48
51
54
A2
A1
14
13
38
K20
56
A2
A1
24
23
39
S5
22
21
40
K21
50 42
A2
A1
32
31
14
13
41
K21
14
11
42
Fig. 18/6:
(3)
34
C-106
Solution 18
H3
K17
24 V-
34
31
43
1Y1
42
41
24
23
1A+
K17
K3
44
K11
24
23
46
1A-
K6
1Y2
34
31
45
K13
34
31
47
K19
44
41
49
2A+
K9
2Y1
14
11
48
2Y2
22
21
34
31
2A-
K21
K16
50
K7
K19
34
31
52
5A+
K8
5Y1
34
33
24
21
51
5Y2
44
41
5A-
K11
53
K19
34
31
54
6Y
K18
K20
44
41
6A+
K13
55
K3
12Y
18
17
24
21
56
34
33
57
C-107
Solution 18
Air blast
Fig. 18/7:
(4)
Vacuum generator
C-108
Solution 18
Current paths 1 to 3 fulfill the following functions: START and STOP via
push buttons, display of the start signal and simulation of the central
lubrication system.
Power to the installation is switched off with the EMERGENCY-STOP in
order to add a memory and secure the movement 2A-. Otherwise,
cylinder 2A would retract as a result of the automatic setting condition if
cylinder 1A is already located in its initial start position.
The status of the vacuum generator is stored by current paths 33 and
34. After EMERGENCY-STOP, the unit is reset and a restart can be
made. If the fact that the vacuum generator is active has now been
stored, steps 1 and 2 (1A+, 1A-) are now skipped because a workpiece
has already been collected.
In manual mode, the initial start position of the machining station can be
achieved via the RESET button, cylinder 2A only being able to retract
when cylinder 1A is in its initial position. In addition, processing is started
via the RESET key if memory K18 reports that no processing has yet
been carried out. Memory K21 (EMERGENCY-STOP actuated) is reset.
In order to limit the cost incurred through additional equipment, relay
K21 can be replaced by the counter (preselected figure 1).
C-109
Solution 18
40
Fig. 18/8:
(3)
Addition with counter
41
21
13
22
14
S5
38
39
13
23
31
14
24
32
S6
A1
K19
A1
K20
A2
A2
S5 = EMERGENCY-STOP
S6 = RESET
A1
R1
A2
R2
K21
C-110
Solution 18
Components list
Quantity
Designation
Relay, 3-off
Time relay, 2-off
Manifold
C-111
Solution 19
Checking station
Fig. 19/3:
2A
1B1
2B1
2B2
1B2
4A
3A
3S
4S1
3B
1A
2Y
4
4Y
1
3Y
1Y1
1Y2
0Z2
0Z1
* For the purposes of this exercise, cylinder 4A is to be replaced by a single-acting

cylinder.
4S2
S1 = START-button
K1
S2
K3
K2
S1
A1
1
5
K2
3S
2
5
14
A2
K1
13
A2
32
A1
31
14
14
13
14
13
13
K3
4S1
1
5
A2
K3
K2
K1
K4
K19
A1
6
9
37
39
A2
18
A1
17
24
24
23
24
23
23
5
K4
14
11
BU
1B2 BN
K5
BK
A2
A1
A2
24
A1
21
14
37 10
16
38
K6
K4
K5
11
9
K6
14
11
10
BU
1B1 BN
11
K7
BK
15
A2
A1
12
Fig. 19/4:
(1)
24 V- 1
C-112
Solution 19
S2 = STOP-button
2B1
24 V- 13
K8
S3 = Tolerance check

16
15
A1
K9
K6
K10
= 3s
14
14
13
13
A2
K9
K8
K7
15
A2
A1
14
17
21
23
33
A2
A1
24
21
18
17
16
K10
14
11
17
39
K10'
A2
A1
18
2B2
19
K11
23
A2
A2
A1
24
21
14
13
21
41 22
40
K12
K10
S3
A1
20
K12
14
11
22
C-113
Solution 19
Fig. 19/5:
(2)
K13
K10
K11
31
K15
A1
14
13
28
29
K14
A1
4S2
24
29
40
41
3B
27
A2
14
11
26
A2
K13
25
A2
A1
34
31
14
11
24
K16
K14
A2
A1
14
11
28
K17
A2
A1
24
21
24
21
40 32
33
36
K13
K14
29
K17'
41
A2
A1
30
K15
14
11
31
K17
14
11
32
Fig. 19/6:
(3)
24 V- 23
C-114
Solution 19
S4
K17
= Interrogate container
K18
A1
22
21
35 34
K19
14
11
35
A2
44
A1
41
K18
34
A2
K18
K10
14
24
13
21
24 V- 33
H1
K17
34
31
36
1Y1
32
31
34
31
1A+
K6
K4
37
1Y2
44
41
1A-
K6
38
2Y
12
11
44
41
2A-
K10'
K4
39
3Y
42
41
24
34
21
31
3A+
K17
K12
K13
40
4Y
12
11
32
44
31
41
4A+
K17'
K12
K13
41
C-115
Solution 19
Fig. 19/7:
(4)
Conveyor belt
C-116
Solution 19
In this solution, end position sensing is indirectly interconnected. The

START and STOP conditions for continuous cycle using one push
button each, are both realised by means of relay K1.
Selection between tolerance conditions Good/Reject is made with the
switch S4 (K12), with the result that either cylinder 3A or 4A extends.
Parts are counted by 3B (position C+) indirectly via K14.
The conveyor belt is started by the final step (K17) and does not stop
until the timer which resets the sequence has run through. The time
delay is not started until the control is in the final step and a container
(S4) has been signalled as being present.
The time element with switch-on delay is activated immediately after
power supply has been switched on, meaning that interruption of this
causes delayed start-up behaviour. That is, the time element switches to
its normal position when the time has expired. However, for this purpose
it is necessary to store the interruption signal (see K18).
Components list
Quantity
Designation
Relay, 3-off
Time relay, 2-off
Manifold
C-117
Solution 20
Handling device
1A
1S1
2B1
1S2
2B2
Fig. 20/3:
2A
1Y
2Y
1
4M
*
3A
3B1
4S
3B2
4B
3Y
4Y1
4Y2
4Y3
0Z2
0Z1

Rotary actuator 4M is replaced by a double-acting cylinder.
4Y4
S6
S1 = START-button
S2 = MAN/AUT
S3 = Sensing of parts
S4 = STOP
S5 = RESET
S6 = EMERGENCY-STOP
3
12
46 2
48 45
A2
K2
12
A1
32
11
14
31
14
13
14
11
13
14
14
13
A2
K1
K3
S4
K18
S3
A1
K1
11
K2
14
13
32
31
H1
K3
K15
A2
A1
14
11
K2
R2
R1
42
24
41
23
6
K4
K4
14
S5
13
7
50
A2
A1
14
K5
A2
A1
12
11
18
17
22 10
30
K16
K10
13
K5
14
13
10
3B1
11
K6
1A+
A2
A1
24
23
24
2A+
K7
K6
K15
14
21
14
15
16
41
A2
A1
12
11
24
K6
13
13
13
14
42
K13
K2
23
12
K7
A2
A1
24
23
16
2A-
42 17
19
K7
K8
14
1S2
13
15
K8
14
13
17
Fig. 20/4:
(1)
S1
S2
22
21
24 V- 1
C-118
Solution 20
START
1B1
K9'
A2
45
A2
20
24
30
44
K10
11
14
11
42
K16
41
9
24
A2
A1
A1
K11
K17
K5
22
A1
3A+ 4M+
K9
14
11
21
12
K9
20
24
23
19
BK
K8
BU
BN
18
24 V-
24
K11
A2
A1
24
21
28
27
24
1A-
22 25
41 26
K9
K11
K10
21
23
K12
A2
A1
34
31
26
30 27
44 29
K11
K12
24
1S1
21
25
K12'
14
11
27
45 47
49
A2
A1
28
12
K12
A2
31
43
A2
A1
32
31
22
24
21
34
23
K14
31
30
K17
K5
K9
K14
A1
24
21
24
21
3A- 4M-
K13
K12
K18
29
14
11
31
1B2
5
14
A2
A1
33
BK
K15
BU
BN
32
C-119
Solution 20
Fig. 20/5:
(2)
3B2
K16
4S
30 22
K18
9 23
K17
A1
37
A2
4B
36
A2
A1
35
2
29
A2
A1
38
H2
39
H3
40
1Y
42
2Y
2A+
42
41
41
K8
34
K6
33
42
34
1A+
K11
K7
33
41
3Y
24
3A+
K14
21
43
42
41
44
4M+
4Y1
K12
K9
41
44
4Y2
12
14
11
24
11
4M+
K12'
K9'
K1
21
45
K1
4Y3
24
21
47
4M-
K12'
32
31
46
K1
4Y4
34
31
49
4M-
K12'
42
41
48
K4
24
23
50
Fig. 20/6:
(3)
34
24 V-
C-120
Solution 20
MAN
AUTO
C-121
Solution 20
The continuous cycle is introduced via the START button. The handling
device then runs until a STOP is actuated at the end of the cycle or until
the counter has reached the preselected figure or no parts are reported
as being present.
At this point, lamp H1 indicates whether the start signal is still stored.
Memories K5 and K14 cause cylinder 3A to move every second cycle.
Lamp H2 indicates that the installation is operating in AUTOMATIC
mode. H3 lights up when MANUAL mode is operating (RESET).
Quantity
Designation
Relay, 3-off
Time relay, 2-off
Manifold
Components list
C-122
Solution 20

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Learning System for Automation and Technology

Authorised applications and liability

Copyright by Festo Didactic GmbH & Co., D-73770 Denkendorf 2002

Basic packages which convey basic knowledge spanning a wide

Technology packages which deal with important subjects of open and

Function packages to explain the basic functions of automated systems

Application packages to facilitate practice-orientated vocational and

The technology packages deal with the technologies of pneumatics,

TP202 Festo Didactic

The modular design of the Learning System permits applications beyond

The hardware consists of industrial components and systems which

Textbooks (with exercises and examples)

Workbooks (with practical exercises, explanatory notes, solutions and

Transparencies and videos (to create a lively training environment)

The training and learning media is available in several languages, which

TP202 Festo Didactic

Latest information about the technology package pneumaticTP 202

Industrial components on the profile plate.

Fostering of key qualifications:

Training of team skills, willingness to co-operate, willingness to learn,

Aim Professional competence

Reference to the text book

Function diagrams, circuits, descriptions of

Storage tray, mounting technology

TP202 Festo Didactic

Notes on safety and operation

Training contents of basic level and advanced level

Equipment set for the basic level (TP201)

Equipment set for the advanced level (TP202)

Component and exercise allocation (table)

Methodical structure of the exercises

TP202 Festo Didactic

Feed unit for sheet metal strip

Clamping unit for grinding

Drilling and reaming machine

Internal grinding machine

Rotary indexing station

TP202 Festo Didactic

Feed unit for sheet metal strip

Clamping unit for grinding

Drilling and reaming machine

Internal grinding machine

Rotary indexing station

TP202 Festo Didactic

Also available are data sheets on the various components (cylinders,

TP202 Festo Didactic

TP202 Festo Didactic

Notes on safety and operation

Pressurised air lines that become detached can cause accidents.

Lines must be connected up and secured before the compressed air

Do not operate the electrical limit switches manually during fault

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

Distinction is to be made between the two different designs of the

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

Only use extra-low voltage 24 V.

All components are provided with 4 mm safety sockets respectively

Pneumatic circuit design:

Releasing of the QS straight push-in fitting:

TP202 Festo Didactic

The profile plate for the assembly of components is equipped for

Please observe the data sheets in Part D for information regarding

TP202 Festo Didactic

Training contents of basic level and advanced level