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Electropneumatics

Basic Level

Workbook TP 201

CD-ROM included

Festo Didactic
541090 en

541090_cover_workbook_tp201_en.indd 1 08.03.2005 13:41:05


Intended use

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

Order No.: 541090


Status: 04/2005
Authors: M. Pany, S. Scharf
Editor: Frank Ebel
Graphics: Doris Schwarzenberger
Layout: 09/2005

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

The copying, distribution and utilisation of this document as well as the


communication of its contents to others without express authorisation is
prohibited. Offenders will be held liable for the payment of damages. All rights
reserved, in particular the right to carry out patent, utility model or ornamental
design registration.
Parts of this documentation may be copied by the authorised user exclusively for
training purposes.

2 © Festo Didactic GmbH & Co. KG • 541090


Contents

Preface ______________________________________________________________ 5
Introduction__________________________________________________________ 7
Notes on safety and operation ___________________________________________ 9
Technology package for electropneumatics (TP200) ________________________ 11
Training aims of Basic Level (TP201) _____________________________________ 13
Allocation of training aims and exercises _________________________________ 15
Equipment set – Basic Level (TP201) _____________________________________ 17
Allocation of equipment and exercises ___________________________________ 21
Methodological help for the trainer ______________________________________ 23
Methodological structure of the exercises_________________________________ 25
Designation of equipment _____________________________________________ 26
Contents of the CD-ROM _______________________________________________ 27
Equipment set – Advanced Level (TP202) _________________________________ 29
Training aims – Advanced Level (TP202) __________________________________ 30

Part A – Exercises

Exercise 1: Realising a sorting device ____________________________________A-3


Exercise 2: Realising a shut-off device___________________________________A-15
Exercise 3: Realising a lid press ________________________________________A-25
Exercise 4: Realising the operation of a hinged lid _________________________A-35
Exercise 5: Realising a diverting device __________________________________A-43
Exercise 6: Actuation of a stacking magazine _____________________________A-53
Exercise 7: Sorting of packages ________________________________________A-65
Exercise 8: Actuation of a sliding platform _______________________________A-73
Exercise 9: Expanding a diverting device _________________________________A-81
Exercise 10: Designing a stamping device________________________________A-91
Exercise 11: Realising a pallet loading station __________________________ A-101
Exercise 12: Eliminating a fault on the pallet loading station_______________ A-107

© Festo Didactic GmbH & Co. KG • 541090 3


Contents

Part B – Fundamentals

Part C – Solutions

Exercise 1: Realising of a sorting device __________________________________C-3


Exercise 2: Realising a shut-off device___________________________________C-15
Exercise 3: Realising a lid press ________________________________________C-23
Exercise 4: Realising the operation of a hinged lid _________________________C-33
Exercise 5: Realising a diverting device __________________________________C-41
Exercise 6: Actuation of a stacking magazine _____________________________C-49
Exercise 7: Sorting of packages ________________________________________C-59
Exercise 8: Actuation of a sliding platform _______________________________C-67
Exercise 9: Expanding a diverting device _________________________________C-75
Exercise 10: Designing a stamping device________________________________C-85
Exercise 11: Realising a pallet loading station ____________________________C-95
Exercise 12: Eliminating a fault on the pallet loading station _______________C-101

Part D – Appendix

Organiser __________________________________________________________ D-2


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

4 © Festo Didactic GmbH & Co. KG • 541090


Preface

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


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

The technology packages deal with the following technologies: Pneumatics,


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

© Festo Didactic GmbH & Co. KG • 541090 5


Preface

The modular design of the learning system enables applications beyond the limits of
the individual packages. For example, to facilitate PLC actuation of pneumatic,
hydraulic and electrical drives.

All the training packages are of identical structure:


• Hardware
• Teachware
• Software
• Seminars

The hardware consists of didactically designed industrial components and systems.


The didactic, methodological design of the Teachware is harmonised with the
training hardware and comprises:
• Textbooks (with exercises and examples)
• Workbooks (with practical exercises, additional information, solutions and data
sheets)
• Overhead transparencies and videos (to create an interesting and lively training
environment)

Tuition and training media are available in several languages and are suitable for
use both in the classroom and for self-tuition.
Software is available in the form of computer training programs and programming
software for programmable logic controllers.
A comprehensive range of seminars dealing with the topics of the technology
packages completes the range of vocational and further training available.

6 © Festo Didactic GmbH & Co. KG • 541090


Introduction

This workbook is a component part of the Learning System for Automation and
Technology of Festo Didactic GmbH & Co. KG. This system provides a solid basis for
practice-oriented vocational and further training. Technology package TP200 is
comprised exclusively of electropneumatic control systems.

Basic Level TP201 is suitable for basic training in electropneumatic control


technology and provides knowledge regarding the physical fundamentals of
electropneumatics and the function and use of electropneumatic equipment. The
equipment set enables you to construct simple electropneumatic control systems.

Advanced Level TP202 focuses on further training in electropneumatic control


technology. The two equipment sets enable you to construct complex combinational
circuits with logic operations of input and output signals and program controls.

Prerequisite for the assembly of control systems is a fixed workstation using a Festo
Didactic profile plate, consisting of 14 parallel T-slots with 50 mm spacing. A short-
circuit protected power supply unit (input: 230 V, 50 Hz, output: 24 V, max. 5 A) is
used for DC voltage supply. A mobile, silenced compressor (230 V, maximum 8 bar =
800 kPa) can be used for compressed air supply.

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

Optimum operational reliability is achieved if the control system is operated


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

The equipment set of Basic Level TP201 is used to construct all of the complete
control systems of the 12 problem definitions. The theoretical fundamentals to help
you understand this collection of exercises can be found in the textbook

• Electropneumatics

Also available are data sheets in respect of the individual devices (cylinders, valves,
measuring devices, etc.).

© Festo Didactic GmbH & Co. KG • 541090 7


Introduction

8 © Festo Didactic GmbH & Co. KG • 541090


Notes on safety and operation

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

• Pressurised air lines that become detached can cause accidents. Switch off
supply immediately.
• Do not switch on compressed air until tubing is securely connected.
• Caution!
Cylinders may advance automatically as soon as the compressed air is switched
on.
• Do not operate an electrical limit switch manually during fault finding (use a
tool).
• Observe general safety regulations.
• With electrical limit switches you need to distinguish between two designs
– Actuation from the left
– Actuation from the right.
• At high piston speeds, limit switches must be approached only in the designated
direction of the trip cam of the cylinder. Limit switches must not be actuated from
the front.
• Do not exceed the permissible working pressure (see data sheets).
• Only use extra-low voltage ≤ 24 V DC.
• All components are equipped with 4 mm safety sockets, i.e. jack plugs. Only use
cables with jack plugs for the electrical connections.
• Pneumatic circuit assembly:
Connect devices using the silver-metallic plastic tubing of 4mm outer diameter,
plugging the tubing into the push-in fitting up to the stop; no need for securing!
• Releasing of push-in fitting:
The tubing can be released by pressing down the releasing ring (disconnection
under pressure is not possible!)
• Switch off compressed air supply and power supply prior to dismantling the
circuit.

© Festo Didactic GmbH & Co. KG • 541090 9


Notes on safety and operation

• The mounting plates of the devices are equipped with mounting variants A to D:
Variant A, latching system
For lightweight non loadable devices (e.g. directional control valves). Simply clip
the device into the slot in the profile plate. Devices can be released by pressing
the blue lever.
Variant B, rotary system
Medium weight loadable devices (e.g. actuators). These devices are clamped
onto the profile plate by means of T-head bolts. Clamping and releasing is
effected by means of the blue knurled nut.
Variant C, screw system
For heavy loadable devices rarely removed from the profile plate (e.g. Start-up
valve with filter control valve). These devices are mounted by means of socket
head screws and T-head bolts.
Variant D, plug-in system
Lightweight non loadable devices with locking pins (e.g. indicating devices).
These devices are attached by means of plug-in adapters.
• The data for the individual devices, as specified in the data sheets in Part D, must
be observed.

10 © Festo Didactic GmbH & Co. KG • 541090


Technology package for electropneumatics (TP200)

The technology package TP200 consists of numerous individual training media as


well as seminars. The subject matter of this package is exclusively electropneumatic
control systems. Individual components from the technology package TP200 may
also form a component part of other packages.

Important elements of • Fixed workstation with Festo Didactic profile plate


TP200 • Compressor (230 V, 0.55 kW, maximum 8 bar = 800 kPa )
• Equipment sets or individual components
• Optional training aids
• Practical training models
• Complete laboratory setups

Training documentation

Textbooks Basic Level TP201


Fundamentals of pneumatic control technology
Maintenance of pneumatic devices and systems

Workbooks Basic Lvel TP201


Advanced Level TP202

Optional Teachware Sets of overhead transparencies and overhead projector


Magnetic symbols, drawing template
WBT Fluid Studio Electropneumatics
Cutaway model sets 1 + 2 with storage case
®
Simulation software FluidSIM Pneumatic

© Festo Didactic GmbH & Co. KG • 541090 11


Technology package for electropneumatics (TP200)

Seminars

P111 Fundamentals of pneumatics and electropneumatics

P121 Maintenance of and fault finding on pneumatic and electropneumatic systems

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


control systems

EP-AL Electropneumatics for vocational training

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

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


the Internet. The Learning System for Automation and Technology is continually
updated and expanded. The sets of overhead transparencies, films, CD-ROMs and
DVDs as well as technical books are available in several languages.

12 © Festo Didactic GmbH & Co. KG • 541090


Training aims of Basic Level (TP201)

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


single-acting cylinder.
• To familiarise yourself with the design and mode of operation of a
double-acting cylinder.
• To be able to calculate piston forces according to specified values.
• To familiarise yourself with the design and mode of operation of a 3/2-way
solenoid valve.
• To familiarise yourself with the design and mode of operation of a double
solenoid valve.
• To be able to select solenoid valves according to requirements.
• To be able to identify and draw the various types of actuation of directional
control valves.
• To be able to convert solenoid valves.
• To be able to explain and design an example of direct actuation.
• To be able to explain and design an example of indirect actuation.
• To familiarise yourself with logic functions and to design these.
• To familiarise yourself with different types of end position control and to be able
to select a suitable type.
• To be able to calculate electrical characteristic values.
• To familiarise yourself with latching circuits with different characteristics.
• To be able to explain and design an electrical latching circuit with dominant
switch-off signal.
• To be able to design a pressure-dependent control system.
• To familiarise yourself with the design and mode of operation of magnetic
proximity sensors.
• To familiarise yourself with displacement-step diagrams and to be able to design
these for specified problem definitions.
• To be able to realise a sequence control using two cylinders.
• To be able to identify and eliminate errors in simple electropneumatic control
systems.

© Festo Didactic GmbH & Co. KG • 541090 13


Training aims of Basic Level (TP201)

14 © Festo Didactic GmbH & Co. KG • 541090


Allocation of training aims and exercises

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

Training aims

To familiarise yourself with the design •


and mode of operation of a single-
acting cylinder.

To familiarise yourself with the design • • •


and mode of operation of a double-
acting cylinder.

To be able to calculate piston forces •


according to specified values.

To familiarise yourself with the design •


and mode of operation of a 3/2-way
solenoid valve.

To familiarise yourself with the design • •


and mode of operation of a double
solenoid valve.

To be able to select a solenoid valve •


according to requirements.

To be able to identifiy and draw the •


various types of actuation of
directional control valves.

To be able to convert solenoid valves. •

To be able to explain and design an • •


example of direct actuation.

To be able to explain and design an • • •


example of indirect actuation.

To familiarise yourself with different • •


types of end position control and to be
able to select a suitable type.

To familiarise yourself with logic • •


functions and to be able to design
these.

To be able to calculate electrical •


characteristic values

© Festo Didactic GmbH & Co. KG • 541090 15


Allocation of training aims and exercises

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

Training aims

To familiarise yourself with latching • •


circuits with different characteristics.

To be able to explain and design an •


electrical latching circuit with
dominant switch-off signal.

To be able to design a pressure- •


dependent control system.

To familiarise yourself with the mode •


of operation of magnetic proximity
sensors.

To familiarise yourself with •


displacement step diagrams and to be
able to create these for specified
problem definitions.

To be able to realise a sequence •


control using two cylinders.

To be able to detect and eliminate •


errors in simple electropneumatic
control systems.

16 © Festo Didactic GmbH & Co. KG • 541090


Equipment set – Basic Level (TP201)

This equipment set has been compiled for basic training in electropneumatic control
technology. It contains all the components required to meet the specifed training
aims and can be expanded in any way with other equipment sets. The profile plate
and a compressed air supply are required in addition.

Equipment set – Basic Level Description Order No. Quantity


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

5/2-way solenoid valve 539777 1

Blanking plug 153267 10

Double-acting cylinder 152888 2

Limit switch, electrical, actuated from the left 183322 1

Limit switch, electrical, actuated from the right 183322 1

Manifold 152896 1

One-way flow control valve 539773 4

Plastic tubing 4 x 0.75, 10 m 151496 2

Pressure sensor 539757 1

Proximity sensor, electronic 540695 2

Proximity sensor, optical 178577 1

Push-in sleeve 153251 10

Push-in T-connector 153128 20

Relay, 3-off 162241 2

Signal input, electrical 162242 1

Single-acting cylinder 152887 1

Start-up valve with filter control valve 540691 1

© Festo Didactic GmbH & Co. KG • 541090 17


Equipment set – Basic Level (TP201)

Equipment set symbols Description Symbol

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

A2 11 21 31 41

12 14 22 24 32 34 42 44
A1

A2 11 21 31 41

12 14 22 24 32 34 42 44
A1

A2 11 21 31 41

Signal input, electrical


13 23 31 41

14 24 32 42

13 23 31 41

14 24 32 42

13 23 31 41

14 24 32 42

3/2-way solenoid valve, 2


normally closed

1M1
1 3

1M1

18 © Festo Didactic GmbH & Co. KG • 541090


Equipment set – Basic Level (TP201)

Description Symbol

5/2-way solenoid valve 4 2

1M1
5 1 3

1M1

5/2-way double solenoid valve 4 2

1M1 1M2
5 1 3

1M1 1M2

Proximity sensor, electronic

Pressure sensor

Proximity sensor, optical

Limit switch, electrical


2 4

One-way flow control valve 1 2

© Festo Didactic GmbH & Co. KG • 541090 19


Equipment set – Basic Level (TP201)

Description Symbol

Single-acting cylinder

Double-acting cylinder

Start-up valve with filter control valve

2
3
Manifold

Connection elements

20 © Festo Didactic GmbH & Co. KG • 541090


Allocation of equipment and exercises

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

Equipment

Cylinder, single-acting 1 1 1 1

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

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

3/2-way double solenoid valve, 1 (1) 1 1


normally closed

5/2-way solenoid valve 1 1 1 1

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

Pressure sensor 1

Limit switch, electrical 1 2

Proximity sensor, normally open 2 2 2 2


conact

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


contact

Pushbutton, electrical, normally 1 1


closed button

Relay 1 1 2 2 3 1 3 3 3 3

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

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

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

© Festo Didactic GmbH & Co. KG • 541090 21


Allocation of equipment and exercises

22 © Festo Didactic GmbH & Co. KG • 541090


Methodological help for the trainer

• Training aims
The overall aim of this collection of exercises is the systematic design of circuit
diagrams and practical assembly of a control system on a profile plate. This
direct interaction of theory and practice ensures quick progress with learning.
The detailed training aims are documented in the table. Actual individual training
aims are allocated to each problem and major training aims are shown in
brackets.
• Time required
The time required to work through a problem depends on the trainee’s prior
knowledge. Skilled workers in the engineering and electrical fields require
approximately 2 weeks. Technicians or engineers require approximately 1 week.
• Components of the equipment set
The book of exercises and equipment set are harmonised. For all 18 exercises
you only require the components of the equipment set of Basic Level TP201.
Each of the Basic Level exercises can be assembled on a profile plate.
• Representation
Abbreviated notation and motion diagrams are used for the representation of
motion sequences and switching statuses.

© Festo Didactic GmbH & Co. KG • 541090 23


Methodological help for the trainer

24 © Festo Didactic GmbH & Co. KG • 541090


Methodological structure of the exercises

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

The exercises are divided into:


• Title
• Training aims
• Problem definition
• Parameters
as well as
• Project task
• Positional sketch
• Worksheets

The proposed solutions in Part C are divided into:


• Circuit diagram
• Solution description
as well as
• Circuit assembly
• Equipment list

© Festo Didactic GmbH & Co. KG • 541090 25


Designation of equipment

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


the DIN-ISO 1219-2 standard. All components of a circuit have the same main code
number. Letters are assigned depending on components. Several components
within a circuit are numbered consecutively. The designation of pressure ports is P
and these are separately consecutively numbered.

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


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

26 © Festo Didactic GmbH & Co. KG • 541090


Contents of the CD-ROM

The CD-ROM supplied provides you with additional media. The contents of Part A –
Exercises and Part C – Solutions are stored in the form of pdf files.

The structure of the CD-ROM is as follows:


• Operating instructions
• Data sheets
• Demo
• Festo catalogue
• FluidSIM® circuit diagrams
• Industrial applications
• Presentations
• Product information
• Videos

Operating instructions Operating instructions are available for the various pieces of equipment of the
technology package to assist you in the use and commissioning of the equipment.

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

Demo A demo version of the software package FluidSIM® Pneumatic is stored on the CD-
ROM. This version is suitable for the testing of the control systems developed.

Festo catalogue Pages from the Festo AG & Co. KG catalogue are provided for selected pieces of
equipment. The representation and description of equipment in this form is intended
to illustrate how such equipment is represented in an industrial catalogue. You will
also find additional information here regarding the equipment.

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

© Festo Didactic GmbH & Co. KG • 541090 27


Contents of the CD-ROM

Industrial applications Photos and pictures are provided of industrial applications to enable you to
illustrate your own problem definitions. These can also be added to project
presentations.

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

Product information This directory provides you with the product information and data sheets of Festo
AG & Co. KG regarding the equipment of the technology package and is intended to
explain what information and data are provided for an industrial component.

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

28 © Festo Didactic GmbH & Co. KG • 541090


Equipment set – Advanced Level (TP202)

This Advanced Level equipment set has been compiled for further training in
pneumatic control technology. The two equipment sets (TP201 and TP202) comprise
the components required for the specified training aims and can expanded in any
way with other equipments sets of the Learning System for Automation and
Technology.

Equipment set – Advanced Description Order No. Quantity


Level (TP202
Relay, 3 off 162241 2
Order No.: 540713)
Signal input, electrical 162242 1

Time relay, 2 off 162243 1

Predetermining counter 162355 1

Proximity sensor, inductive 178574 1

Proximity sensor, capacitive 178575 1

EMERGENCY-STOP button 183347 1

Valve terminal with 4 valve slices (MMJJ) 540696 1

Non-return valve, piloted 540715 2

© Festo Didactic GmbH & Co. KG • 541090 29


Training aims of Advanced Level (TP202)

• To describe the design and use of valve terminals


• To solve sequence controls with signal overlap – solution according to group
method
• To solve sequence controls with signal overlap – solution with sequence chain
using spring-return valves
• To solve sequence control with signal overlap – solution with sequence chain
using double solenoid valves (with control step)
• To be able to describe and configure modes of operation (single cycle,
continuous cycle, , ...)
• To describe the function and use of a predetermining counter
• To explain and realise an EMERGENCY-STOP FUNCTION using spring-return
valves
• To realise special EMERGENCY-STOP conditions: Actuators must stop during
EMERGENCY-STOP
• To explain the function and use of a 5/3-way solenoid valve
• To describe and configure the Reset mode of operation
• To carry out fault finding in complex electropneumatic circuits

30 © Festo Didactic GmbH & Co. KG • 541090


Contents

Part A – Exercises

Exercise 1: Realising a sorting device ____________________________________A-3


Exercise 2: Realising a shut-off device___________________________________A-15
Exercise 3: Realising a lid press ________________________________________A-25
Exercise 4: Realising the operation of a hinged lid _________________________A-35
Exercise 5: Realising a diverting device __________________________________A-43
Exercise 6: Actuation of a stacking magazine _____________________________A-53
Exercise 7: Sorting of packages ________________________________________A-65
Exercise 8: Actuation of a sliding platform _______________________________A-73
Exercise 9: Expanding a diverting device _________________________________A-81
Exercise 10: Designing a stamping device________________________________A-91
Exercise 11: Realising a pallet loading station __________________________ A-101
Exercise 12: Eliminating a fault on the pallet loading station_______________ A-107

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


Contents

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


Exercise 1: Realising a sorting device

Training aims • To familiarise yourself with the design and mode of operation of a single-acting
cylinder.
• To familiarise yourself with the design and mode of operation of a 3/2-way
solenoid valve.
• To be able to identify and draw various types of actuation of directional control
valves.
• To be able to explain and design an example of direct actuation.

Problem definition A sorting device is to be used to sort water samples according to the size of the
sample bottle. Design a control system whereby this process can be carried out.

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


• The control of the cylinder is to be effected by means of a pushbutton.
• In the event of a power failure the cylinder piston rod is to return into the
retracted end position.

Project task 1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
2. Draw the pneumatic and electrical circuit diagram.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile an equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.

© Festo Didactic GmbH & Co. KG • 541090 A-3


Exercise 1: Realising a sorting device

Positional sketch

Sorting device

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


push the sample bottle off the conveyor.
2. When the pushbutton is released, the piston rod is to return into the retracted
end position.

A-4 © Festo Didactic GmbH & Co. KG • 541090


Exercise 1: Realising a sorting device

Exercise 1: Realising the operation of a sorting device

Name: Date:

Fundamentals: Function of pneumatic working components Sheet 1 of 7

Pneumatic working components can be divided into two groups:


• Working components using linear movement
• Working components using rotary movement

– Describe the function of the working components shown.

Symbol 1 Symbol 2 Symbol 3

Description of function

Symbol 1:

Symbol 2:

Symbol 3:

© Festo Didactic GmbH & Co. KG • 541090 A-5


Exercise 1: Realising a sorting device

Exercise 1: Realising the operation of a sorting device

Name: Date:

Fundamentals: Completing solenoid valve symbols Sheet 2 of 7

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

Description Symbol

Directly actuated 3/2-way


2
solenoid valve, normally open,
with manual override, with
spring return 1 3
Pilot actuated 3/2-way solenoid
2
valve, normally closed, with
manual override, with spring
return 1 3

A-6 © Festo Didactic GmbH & Co. KG • 541090


Exercise 1: Realising a sorting device

Exercise 1: Realising the operation of a sorting device

Name: Date:

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

An electrically actuated 3/2-way solenoid valve has two switching positions. It can
be in the normal position (unactuated) or in the switching position (actuated). In the
normal position the valve can be open or closed.

– Describe the effects on the motion sequence of the following application arising
as a result of the different normal positions. The single-acting cylinder shown is
controlled by an electrically actuated 3/2-way solenoid valve.

2 2

1M1 1M1
1 3 1 3

Description: Normal position closed Description: Normal position open

© Festo Didactic GmbH & Co. KG • 541090 A-7


Exercise 1: Realising a sorting device

Exercise 1: Realising the operation of a sorting device

Name: Date:

Fundamentals: Direct and indirect actuation Sheet 4 of 7

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

– Describe the difference with the help of the following application: Electrical
actuation of a spring-returned 3/2-way solenoid valve using a pushbutton.

Description: Direct actuation Description: Indirect actuation

A-8 © Festo Didactic GmbH & Co. KG • 541090


Exercise 1: Realising a sorting device

Exercise 1: Realising the operation of a sorting device

Name: Date:

Design and function of an electrical switch Sheet 5 of 7

Switches are basically divided into pushbutton and control switch designs and
perform the function of a normally open or normally closed contact or changeover
switch.

– Describe the design and function of the switches shown.

Symbol 1 Symbol 2 Symbol 3

3 1 2 4

4 2 1

Description: Design/Function

© Festo Didactic GmbH & Co. KG • 541090 A-9


Exercise 1: Realising a sorting device

Exercise 1: Realising the operation of a sorting device

Name: Date:

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

Electrically actuated directional control valves are switches with the help of
solenoids. Basically, these can be divided into two groups:
• Spring-return solenoid valves
• Double solenoid valves

– Describe the differences between the two groups with regard to function and
behaviour in the event of power failure.

Valve type Mode of operation

Spring-return valve

Double solenoid valve

A-10 © Festo Didactic GmbH & Co. KG • 541090


Exercise 1: Realising a sorting device

Exercise 1: Realising the operation of a sorting device

Name: Date:

Fundamentals: Port designations of valves Sheet 7 of 7

In order to prevent incorrect tubing up of directional control valves, the valve ports
(working and pilot lines) are identified in accordance with ISO 5599, both on the
valve itself and in the circuit diagram.

– Describe the meaning and function of the designations below.

Designation Meaning, function

12

10

© Festo Didactic GmbH & Co. KG • 541090 A-11


Exercise 1: Realising a sorting device

Exercise 1: Realising the operation of a sorting device

Name: Date:

Completing the pneumatic and electrical circuit diagram Sheet 1 of 1

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

1 3

Pneumatic circuit diagram

+24 V 1

0V

Electrical circuit diagram

A-12 © Festo Didactic GmbH & Co. KG • 541090


Exercise 1: Realising a sorting device

Exercise 1: Realising the operation of a sorting device

Name: Date:

Compiling the equipment list Sheet 1 of 1

Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.

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

Quantity Description

Equipment list

© Festo Didactic GmbH & Co. KG • 541090 A-13


Exercise 1: Realising a sorting device

A-14 © Festo Didactic GmbH & Co. KG • 541090