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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.

TP202 Festo Didactic

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 Part B Part C Part D Course Fundamentals Solutions Appendix Exercises Reference to the text book Function diagrams, circuits, descriptions of solutions and quipment lists Storage tray, mounting technology and datasheets

TP202 Festo Didactic

Table of contents
Introduction 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 Designation of components 9 11 13 15 18 20 21 22

TP202 Festo Didactic

Part A Course
Basic exercises Exercise 1: Exercise 2: Exercise 3: Exercise 4: Exercise 5: Exercise 6: Exercise 7: Bench drill Feed unit for sheet metal strip Filling device Stamping device Drilling jig Clamping unit for grinding Forming press A-3 A-5 A-7 A-9 A-11 A-15 A-19

Consolidating exercises Exercise 8: Exercise 9: Exercise 10: Exercise 11: Exercise 12: Exercise 13: Exercise 14: Exercise 15: Exercise 16: Exercise 17: Exercise 18: Exercise 19: Exercise 20: Embossing device Handling device Drilling and reaming machine Loading station Internal grinding machine Assembly unit Moulding press Pick-and-place unit Galvanising process Loading station Rotary indexing station Checking station Handling device A-21 A-23 A-25 A-29 A-33 A-37 A-41 A-45 A-49 A-53 A-57 A-63 A-67

Part B Fundamentals

TP202 Festo Didactic

Part C Solutions
Solution 1: Solution 2: Solution 3: Solution 4: Solution 5: Solution 6: Solution 7: Solution 8: Solution 9: Solution 10: Solution 11: Solution 12: Solution 13: Solution 14: Solution 15: Solution 16: Solution 17: Solution 18: Solution 19: Solution 20: Bench drill Feed unit for sheet metal strip Filling device Stamping device Drilling jig Clamping unit for grinding Forming press Embossing device Handling device Drilling and reaming machine Loading station Internal grinding machine Assembly unit Moulding press Pick-and-place unit Galvanising process Loading station Rotary indexing station Checking station Handling device C-3 C-9 C-17 C-21 C-27 C-35 C-41 C-45 C-49 C-55 C-59 C-63 C-69 C-75 C-81 C-87 C-95 C-103 C-111 C-117

Part D Appendix
Storage tray Mounting technology Plastic tubing Data sheets D-2 D-3 D-5 ...

TP202 Festo Didactic

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.).

TP202 Festo Didactic

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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.

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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.

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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

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14

List of training aims

Exercise 1 2 3 4 5 6

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. To teach the student how to realise a control system with an alternative program by means of program switching. To teach the student to program repetition using an additional movement. To familiarise the student with step repetition using the preselect counter. 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. 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. To teach the student how to develop a latching sequence with marginal conditions. 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. Consolidating the students knowledge. Program section repetition. To familiarise the student with parallel program division. To familiarise the student with the use of a timer with delayed switch-on as a delayed starting element. Familiarisation with an alternative solution to electropneumatics.

8 9 10 11 12 13

14 15 16

17 18 19 20

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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 Relay, 3-off* Signal input plate, electrical * Indicator/distributor plate, electrical * Plastic tubing, 10 m, silver metallic Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right Pneumatic-electric converter 3/2-way solenoid valve, normally closed 5/2-way solenoid valve 5//2-way double solnoid valve Order No. 162241 162242 162244 151496 152887 152888 152894 152896 167060 183322 183345 177459 167073 167074 167076 Quantity 1 1 2 1 1 2 1 1 2 1 1 1 1 2 1

Equipment set for the basic level (TP201) (Order No.: 080243)

* These components can be attached to the profile plate by means of 4 adapters (Order No. 323571).

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Symbols of the equipment set

Signal input plate, electrical

Indicator/distributor, electrical

Relay, 3-off

Single-acting cylinder

Double-acting cylinder

On/off valve with filter regulator

Manifold

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Proximity sensor with cylinder mounting

Pneumatic-electric converter

Symbols of the equipment set

Limit switch, electrical, Actuation from left or right*

3/2-way solenoid valve, normally closed

5/2-way solenoid valve

5/2-way double solenoid valve

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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 Relay, 3-off* Signal input plate, electrical* Time relay, 2-off* Preselect counter, electrical, incrementing* 5/2-way double solenoid valve Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor, optical EMERGENCY-STOP button Order No. 162241 162242 162243 162355 167076 178574 178575 178577 183347 Quantity 4 1 1 1 2 1 1 1 1

* These components can be attached to the profile plate by means of 4 adapters (Order No. 323571).

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Signal input plate, electrical

Symbols of the equipment set advanced level

Relay, 3-off

Time relay, 2-off with switch-on delay with switch-off delay

Preselect counter, electrical, incrementing

EMERGENCY-STOP button

Proximity sensor, inductive

Proximity sensor, capacitive

Proximity sensor, optical

5/2-way double solenoid valve

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20

Component and exercise allocation (table)


Exercise Designation Relay, 3-off* Signal input module, electrical * Time relay, 2-off Preselet counter, electrical, incrementing Distributor plate, electrical Single-acting cylinder Double-acting cylinder On-off valve with filter regulator Manifold EMERGENCY-STOP button Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor, optical Proximity sensor with cylinder mounting Limit switch, electrical, Actuation from the left Limit switch, electrical, Actuation from the right Pneumatic-electric converter 3/2-way solenoid valve, normally closed 5/2-way solenoid valve 5/2-way double solenoid valve 1 2 2 1 2 3 1 2 2 2 1 1 2 1 1 1 1 2 1 1 1 1 2 1 1 2 1 1 2 1 1 1 1 2 2 1 2 1 2 1 2 2 1 1 1 1 2 1 1 2 1 1 2 1 1 1 1 1 1 2 1 1 2 1 1 1 2 1 1 2 1 1 1 1 2 1 1 1 2 1 2 3 1 3 3 1 1 1 2 1 2 1 1 1 1 2 1 1 2 1 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 3 1 2 1 2 1 2 1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 2 2 2 3 1 2 1 2 2 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 1 4 4 1 5 5 2 6 5 2 7 2 1 1 1 2 1 2 1 1 1 2 1 2 1 1 2 1 2 1 1 2 1 2 1 1 2 1 2 1 1 1 1 1 8 2 2 9 5 2 10 11 12 13 14 15 16 17 18 19 20 3 1 4 1 5 2 5 2 5 1 1 6* 6* 6* 6* 6* 6* 2 1 1 1 1 1 2 1 2 1 1 2 1 1 1 1 2 1 2 1 1 2 1

3* 3* 3* 3* 1 1 1 1 1 1 1 1 2 1 1 1 2 1 1 1 1 1 1 1 1 2

2* 2* 2* 1 1 1

* Components which are not available in full quantity in equipment sets 201 and 202.

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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 Problem description Positional sketch Displacement-step diagram

sowie

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

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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: Valves: Signal detecter: Accessories: Electrical sensors: Pressure lines: 1A, 2A1, 2A2, ... 1V1, 1V2, 1V3, 2V1, 2V2, 3V, ... 1S1, 1S2, ... 0Z1, 0Z2, 1Z, ... 1B1, 1B2, ... P1, P2, ...

TP202 Festo Didactic

A-1

Part A Course
Basic exercises Exercise 1: Exercise 2: Exercise 3: Exercise 4: Exercise 5: Exercise 6: Exercise 7: Bench drill Feed unit for sheet metal strip Filling device Stamping device Drilling jig Clamping unit for grinding Forming press A-3 A-5 A-7 A-9 A-11 A-15 A-19

Consolidating exercises Exercise 8: Exercise 9: Exercise 10: Exercise 11: Exercise 12: Exercise 13: Exercise 14: Exercise 15: Exercise 16: Exercise 17: Exercise 18: Exercise 19: Exercise 20: Embossing device Handling device Drilling and reaming machine Loading station Internal grinding machine Assembly unit Moulding press Pick-and-place unit Galvanising process Loading station Rotary indexing station Checking station Handling device A-21 A-23 A-25 A-29 A-33 A-37 A-41 A-45 A-49 A-53 A-57 A-63 A-67

TP202 Festo Didactic

A-2

TP202 Festo Didactic

A-3
Aufgabe 1

Electropneumatics Bench drill

Subject Title

To teach the student the principle of a latching sequence. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.

Training aim Exercise

TP202 Festo Didactic

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: Displacement-step diagram

1 1

5=1

1S2 1S1 2B2 2B1

1A
0

2A
0

TP202 Festo Didactic

A-5
Aufgabe 2

Electropneumatics Feed unit for sheet metal strip

Subject Title

To teach the student the principle of a resetting sequence (with reliable switching reversal). Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.

Training aim

Exercise

TP202 Festo Didactic

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. 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.

Operating condition

Fig. 2/1: Positional sketch

1A

2A

Fig. 2/2: Displacement-step diagram

1 1

6=1

1B2 1B1 2S2 2S1

1A
0

2A
0

TP202 Festo Didactic

A-7
Exercise 3

Electropneumatics Filling device

Subject Title

To familiarise the student with the procedure for skipping program steps. To familiarise the student with the use of a timer with switch-on delay. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.

Training aim

Exercise

TP202 Festo Didactic

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. 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.

Operating condition

Fig. 3/1: Positional sketch

1A

3A

2A

TP202 Festo Didactic

A-9
Aufgabe 4

Electropneumatics Stamping device

Subject Title

To teach the student how to realise a stroke-dependent sequence control with a resetting sequence. Drawing the displacement-step diagram and the pneumatic and electrical circuit diagram. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.

Training aim

Exercise

TP202 Festo Didactic

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: Displacement-step diagram

1 1

7=1

1S2 1S1 2B2 2B1 3B2 3B1

1A
0 1

2A
0 1

3A
0

TP202 Festo Didactic

A-11
Exercise 5

Electropneumatics Drilling jig

Subject Title

To teach the student how to realise multiple movements of a cylinder. To familiarise the student with the use of an incrementing preselect counter. Drawing the pneumatic and electrical circuit diagrams. Drawing the pneumatic and electrical circuits. Checking the circuit sequence.

Training aim

Exercise

TP202 Festo Didactic

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.

TP202 Festo Didactic

A-13
Exercise 5

Fig. 5/1: Positional sketch

1 4

2 3

Fig. 5/2: Displacement-step diagram


1 1 2 3 4 5 6 7 8 9 10 11 12 13=1

1B2 1B1 2B2 2B1 3S2 3S1

1A
0

2A
0

3A
0

TP202 Festo Didactic

A-14
Exercise 5

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A-15
Exercise 6

Electropneumatics Clamping unit for grinding

Subject Title

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). Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.

Training aim

Exercise

TP202 Festo Didactic

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.

TP202 Festo Didactic

A-17
Exercise 6

Fig. 6/1: Positional sketch

1A

3A

2A

1 1

9=1

1S2 1S1 2B2 2B1 3B2 3B1

Fig. 6/2: Displacement-step diagram

1A
0

2A
0

3A
0

TP202 Festo Didactic

A-18
Exercise 6

TP202 Festo Didactic

A-19
Aufgabe 7

Electropneumatics Forming press

Subject Title

To teach the student how to realise a control system with specified EMERGENCY-STOP conditions. To teach the student how to realise a two-hand safety control via a timer with switch-on delay. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.

Training aim

Exercise

TP202 Festo Didactic

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. 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.

Operating condition

Fig. 7/1: Positional sketch

1A

Fig. 7/2: Displacement-step diagram

1 1

5=1

1S2 1S1 2B2 2B1

1A
0

2A
0

TP202 Festo Didactic

A-21
Exercise 8

Electropneumatics Embossing device

Subject Title

To teach the student how to incorporate step repetitions and manual step mode into a sequence. Drawing the pneumatic and electrical circuits. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.

Training aim

Exercise

TP202 Festo Didactic

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. 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.

Operating condition

Fig. 8/1: Positional sketch

Fig. 8/2: Displacement-step diagram

1 1

5=1

1B2 1B1 2S2 2S1

1A
0

2A
0

TP202 Festo Didactic

A-23
Exercise 9

Electropneumatics Handling device

Subject Title

To teach the student how to incorporate EMERGENCY-STOP and marginal conditions in a latching sequence. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuits sequence.

Training aim

Exercise

TP202 Festo Didactic

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. 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.

Operating condition

Fig. 9/1: Positional sketch

Fig. 9/2: Displacement-step diagram

1 1

5=1

1S2 open

1A
0

Gripper
1S1 closed 2B2

2A
0

Linear drive
2B1

TP202 Festo Didactic

A-25
Exercise 10

Electropneumatics Drilling and reaming machine

Subject Title

To teach the student how to realise a control system with an alternative program by means of program switching step jump. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.

Training aim

Exercise

TP202 Festo Didactic

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.

TP202 Festo Didactic

A-27
Exercise 10

Fig. 10/1: Positional sketch

Fig. 10/2: Displacement-step diagram Program 1


1 1 2 3=1

Program 2
1 2 3 4 5 6 7=1

1S2

1S2 1S1 2B2 2B1 3B2 3B1

1A
0

1A
1S1 2B2
0

2A
0

2A
2B1 3B2
0

3A
0

3A
3B1
0

TP202 Festo Didactic

A-28
Exercise 10

TP202 Festo Didactic

A-29
Exercise 11

Electropneumatics Loading station

Subject Title

To teach the student to program repetition using an additional movement. To familiarise the student with the use of an incrementing preselect counter. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.

Training aim

Exercise

TP202 Festo Didactic

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.

TP202 Festo Didactic

A-31
Exercise 11

Fig. 11/1: Positional sketch

Conveyor belt Plate

Position 2

Position 1

Fig. 11/2: Displacement-step diagram


1 1 2 3 4 5 6 7 8 9 10 11 12 13=1

1S2 1S1 2B2 2B1 3B2 3B1

1A
0

2A
0

3A
0

Position 1

Position 2

TP202 Festo Didactic

A-32
Exercise 11

TP202 Festo Didactic

A-33
Exercise 12

Electropneumatics Internal grinding machine

Subject Title

To familiarise the student with step repetition using the preselect counter. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuit diagrams. Checking the circuit sequence.

Training aim

Exercise

TP202 Festo Didactic

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.

TP202 Festo Didactic

A-35
Exercise 12

Fig. 12/1: Positional sketch

3A

2A 1A

Fig. 12/2: Displacement-step diagram


1 1 2 3 4 5 6 22 23 24 25 26=1

1B2 1B1 2S2 2S1 3B3 3B2 3B1

1A
0

2A
0

3A
0

TP202 Festo Didactic

A-36
Exercise 12

TP202 Festo Didactic

A-37
Exercise 13

Electropneumatics Assembly unit

Subject Title

To teach the student how to set up manual activation of a cylinder including precautions with protection against collision. To familiarise the student with automatic setting conditions. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.

Training aim

Exercise

TP202 Festo Didactic

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.

TP202 Festo Didactic

A-39
Exercise 13

Fig. 13/1 Positional sketch

1 1

6=1

1S2 1S1 2B2 2B1 3B2 3B1

Fig. 13/2: Displacement-step diagram

1A
0

2A
0

3A
0

TP202 Festo Didactic

A-40
Exercise 13

TP202 Festo Didactic

A-41
Exercise 14

Electropneumatics Moulding press

Subject Title

To teach the student how to construct a two-handed safetystart-up control with relay. To familiarise the student with restart before the end of the cycle. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.

Training aim

Exercise

TP202 Festo Didactic

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.

TP202 Festo Didactic

A-43
Exercise 14

Fig. 14/1: Positional sketch

1 1

7=1

1B2 1B1 2B3 2B2 2B1 3S2 3S1

Fig. 14/2: Displacement-step diagram

1A
0

2A
0

3A
0

TP202 Festo Didactic

A-44
Exercise 14

TP202 Festo Didactic

A-45
Exercise 15

Electropneumatics Pick-and-place unit

Subject Title

To teach the student how to develop a latching sequence with marginal conditions. Drawing the pneumatic and electrical circuit diagrams.. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.

Training aim

Exercise

TP202 Festo Didactic

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. 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-.

Operating condition

TP202 Festo Didactic

A-47
Exercise 15

Fig. 15/1: Positional sketch

2A 1A

3A

Fig. 15/2: Displacement-step diagram

down up Vaccuum generator on Vaccuum generator off Vaccuum generator on Vaccuum generator off

TP202 Festo Didactic

A-48
Exercise 15

TP202 Festo Didactic

A-49
Exercise 16

Electropneumatics Galvanising process

Subject Title

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. To teach the student how to realise a pressure-dependent control system. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.

Training aim

Exercise

TP202 Festo Didactic

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.

TP202 Festo Didactic

A-51
Exercise 16

Fig. 16/1: Positional sketch

Bath 1

Bath 2

Bath 3

Fig. 16/2: Displacement-step diagram START Bath 1


2 3 4 5 6 7 8 9

Bath 2
10 t2 11 12 13

Bath 3
14 15 16 17=1

1
1

1B3 1B2

1A
0

1B1
t1 t1 t1 t1

S1

TP202 Festo Didactic

A-52
Exercise 16

TP202 Festo Didactic

A-53
Exercise 17

Electropneumatics Loading station

Subject Title

Consolidating the students knowledge. Program section repetition. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.

Training aim

Exercise

TP202 Festo Didactic

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. 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).

Operating condition

Fig. 17/1: Positional sketch

4M

3A

1A 2A

The loading station shown here is not in the initial position.

TP202 Festo Didactic

A-55
Exercise 17

1B2

1B1

2B2

2B1

3S2

3S1

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25=1

Fig. 17/2: Displacement-step diagram 1

4B
1

4M

1A

2A

3A

4S

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

TP202 Festo Didactic

A-56
Exercise 17

1B2

2B2

3S2

1B1

2B1

Fig. 17/3: Displacement-step diagram 2

3S1

4B
1

21

21

22

23

24

25=1

1A

3A

Abbreviated notation

1A+ 3A+
Main program

4M+ 4M- 2A- 3A- 2A+ 3A+


3 x Subroutine

4M

2A

4S

4M+ 4M- 3A- 1AMain program

TP202 Festo Didactic

A-57
Exercise 18

Electropneumatics Rotary indexing station

Subject Title

To familiarise the student with parallel program division. Drawing the pneumatic and electrical circuit diagram. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.

Training aim Exercise

TP202 Festo Didactic

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.

TP202 Festo Didactic

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.

TP202 Festo Didactic

A-60
Exercise 18

Fig. 18/1: Positional sketch

Discharge Conveyor 2

9A
Counter 2

1A

8A
Counter 1 Rotary indexing table

Conveyor 1

7A
Drilling 1

TP202 Festo Didactic

A-61
Exercise 18

7=1

Transfer 1

1S2 (1B2) 1S1 (1B1) 2S2 (2B2) 2S1 (2B1)


1 2 3 4 5 6 7=1

Fig. 18/2: Displacement-step diagram

1A
0 1

2A
0

Transfer 2

3S2 3S1 4S2 4S1


1 2 3 4 5 6 7=1

3A
0 1

4A
0

1 Rotary indexing table 5A 0 1 2 3 4 5 6 7=1

5S2 5S1

Drilling 1

6S2 (6B) 6S1 (6S) 7S2 7S1 8S2 8S1 9S2 9S1 10S2 10S1 11S2 11S1

6A
0

Drilling 2

7A
0 1

Counterboring 1

8A
0 1

Counterboring 2

9A
0 1

Deburring 1

10A
0 1

Deburring 2

11A
0

TP202 Festo Didactic

A-62
Exercise 18

TP202 Festo Didactic

A-63
Exercise 19

Electropneumatics Checking station

Subject Title

To familiarise the student with the use of a timer with delayed switchon as a delayed starting element. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.

Training aim

Exercise

TP202 Festo Didactic

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.

TP202 Festo Didactic

A-65
Exercise 19

Fig. 19/1: Positional sketch

1A

4A

3A

1 1

6=1

1B2 1B1 2B2 2B1 3B1 3S1 4S2 4S1

Fig. 19/2: Displacement-step diagram

1A
0

2A
0

3A
0

4A
0

TP202 Festo Didactic

A-66
Exercise 19

TP202 Festo Didactic

A-67
Exercise 20

Electropneumatics Handling device

Subject Title

Familiarisation with an alternative solution to Electropneumatics. Drawing the pneumatic and electrical circuit diagrams. Construction of the pneumatic and electrical circuits. Checking the circuit sequence.

Training aim Exercise

TP202 Festo Didactic

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) 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.

Operating condition

TP202 Festo Didactic

A-69
Exercise 20

Fig. 20/1: Positional sketch

Fig. 20/2: Displacement-step diagram


1 1 2 3 4 5 6 7 8 9 10 11 12 13=1

1S2 1S1 2B2 2B1 3B2 3B1 4B 4S

1A
0

2A
0

3A
0

4A
0

TP202 Festo Didactic

A-70
Exercise 20

TP202 Festo Didactic

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

TP202 Festo Didactic

B-2

TP202 Festo Didactic

C-1

Part C Solutions
Solution 1: Solution 2: Solution 3: Solution 4: Solution 5: Solution 6: Solution 7: Solution 8: Solution 9: Solution 10: Solution 11: Solution 12: Solution 13: Solution 14: Solution 15: Solution 16: Solution 17: Solution 18: Solution 19: Solution 20: Bench drill Feed unit for sheet metal strip Filling device Stamping device Drilling jig Clamping unit for grinding Forming press Embossing device Handling device Drilling and reaming machine Loading station Internal grinding machine Assembly unit Moulding press Pick-and-place unit Galvanising process Loading station Rotary indexing station Checking station Handling device C-3 C-9 C-17 C-21 C-27 C-35 C-41 C-45 C-49 C-55 C-59 C-63 C-69 C-75 C-81 C-87 C-95 C-103 C-111 C-117

TP202 Festo Didactic

C-2

TP202 Festo Didactic

C-3
Solution 1

Bench drill

Fig. 1/3: Circuit diagram, pneumatic

**

* 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.

TP202 Festo Didactic

C-4

Solution 1

Fig. 1/4 Circuit diagram, electrical

24 V- 1
1 33 33 13 13

2 K2
4 14

3 K3 BN
14 34

4 K1 BN BK BU
34

5 K2

10

11 K3

12
33 34

13

13

S 2B2 2B1

K1

1S2

14 1

14

1S1 BK BU

41

23

23

23

41

K4
24 A1 24 A1

K1

K2

K3
24 A1

K3
42

42 A1

K1
A2 A2

K2

K3

K4
A2

1Y 1A+

2Y 2A+
1

3Y

A2

3Z
11 7 9

TP202 Festo Didactic


4 5 11

2 3 10

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.

Solution description

24 V- 1
13

2
13

10
33

Fig. 1/5: Step 1, Cylinder 1A+

S
14 1

K1
14

K1
34

1S1
4

41

K4
42 A1

K1
A2

1Y 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.

TP202 Festo Didactic

C-6
Solution 1

Fig. 1/6: Step 2, Cylinder 2A+

24 V- 1
13

2
13

3
1

4
13

10
33

11
33

S
14 1

K1
14

1S2
4

K2
14

K1
34

K2
34

1S1
4

41

23

41

K4
42 A1

K1
24 A1

K3
42

K1
A2

K2
A2

1Y 1A+

2Y 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.

TP202 Festo Didactic

C-7
Solution 1

Quantity 2 1 1 2 1 1 2 1 1 1 2 1 1

Designation Relay, 3-off Signal input plate, electrical Indicator/distributor plate, electrical Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 3/2-way solenoid valve, normally closed 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V

Components list

TP202 Festo Didactic

C-8
Solution 1

TP202 Festo Didactic

C-9
Solution 2

Feed unit for sheet metal strip

1B1 1A

1B2 2A

2S1

2S2

Fig. 2/3: Circuit diagram, pneumatic

1Y1
5 1 3

1Y2

2Y1
5 1 3

2Y2

0Z2

0Z1

1 3

Simplified representation of on/off valve with filter regulator

TP202 Festo Didactic

Solution 2

C-10

Fig. 2/4: Circuit diagram, electrical (1)

24 V- 1 6
13 23 1 13

2 7 K3 2S1
24 4 13 14

3 8 K5
14

4 9 K3

10
23

13

13

23

S1 K1
14 13 14 22

K1 1B1 BN BK BU
13

K5
24

S2 K4
14 1

14

2S2
4 11 14

K2

K8
14 41 41 21

K4
42 A1 A1 42 A1

K6
A1

K8
22 A1 A1

K1
A2 A2

K2

K3
A2

K4
A2

K5
A2

K6
A2

TP202 Festo Didactic


2 3 12 5 17

6 7

8 18

9 10

5 12 16 19

24 V- 11
11 23 23 23 33 31

12 K7 K7
24 24 24 24 34 34

13 SET 13 K6 K2 K4 K6 K8
14 21

14

15

16

17

18

19

20

TP202 Festo Didactic


14 13 14

1B2

BN

BK BU K6

41

K2
42 A1 A1

K7 H1
A2

K8 1Y1 1A13 15 8 1 20 A2

2Y1 2A-

1Y2 1A+

2Y2 2A+

Fig. 2/5: Circuit diagram, electrical (2)

C-11
Solution 2

C-12
Solution 2

Solution description

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

2
13

3
23

17
23

S1
14 13

K1
14

K1
22

K2
24

S2
14 1

2S2
4 11

K8
14 41

K4
42 A1 A1

K1
A2

K2
A2

1Y1 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.

TP202 Festo Didactic

C-13
Solution 2

Fig. 2/7: Step 2, Cylinder 2A24 V- 1


13

2
13

3
23

5 K3

6
13

7
23

17
23

18
23

S1
14 13

K1
14

K1
22

K3
14 24

K2
24

K4
24

1B1 BN BK BU K2

S2
14 1

13 14

2S2
4 11

K8
14 41 41

K4
42 A1 A1

K6
42 A1 A1

K1
A2

K2
A2

K3
A2

K4
A2

1Y1 1A-

2Y1 2A-

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.

TP202 Festo Didactic

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 13 13 23 23

S1
14 13

K1
14

K2 1B1 BN BK BU K1
23 24 14

K1
24

K2
24

S2
14 1

2S2
4 11

K8
14 41 41

K2
42 A1

K4
42 A1

K1
A2

K3
A2

1Y1 1A-

2Y1 2A-

TP202 Festo Didactic

C-15
Solution 2

Quantity 3 1 2 2 1 1 2 1 1 2 1 1

Designation Relay, 3-off Signal input plate, electrical Indicator/distributor plate, electrical Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 5/2-way double solenoid valve Cable set with safety plug Electrical power supply unit, 24 V

Components list

TP202 Festo Didactic

C-16
Solution 2

TP202 Festo Didactic

C-17
Solution 3

Filling device

Fig. 3/2: Circuit diagram, pneumatic

1S1 1A

1S2 2A

2B1

2B2

3A

3B1

3B2

1Y
5 1 3

2Y
5 1 3

3Y
1 3

0Z2

0Z1

1 3

TP202 Festo Didactic

Solution 3

C-18

Fig. 3/3: Circuit diagram, electrical (1)

24 V1 BN K1 BK S1 13 S2
13 14 13 14 4 14 14 4 13 1 13 13 1

2 2B2 BN BK BU 1S1 K2 1S2 K3

10 K4

11
13 14

3B1

BU
14

S3 13 S4
14 35 14

S1 = Single cycle S2 = Continuous cycle K6


36 41 23 23

23

K7
42 A1 24 A1

K1

K2
24 A1

K3
24 A1

st S3 = 1 interrogation S4 = 2nd interrogation

K1
A2

K2
A2

K3
A2

K4
A2

TP202 Festo Didactic


4 5 18

18 6 7

8 10 19

19 11 13 17

24 V2B1 BN K5 BK
13 14 13

12 2B2 BN S6 BK BU
14 34 34 34 13 33 33 33

13 K1 K3 K5

TP202 Festo Didactic 14 15 16 17 18 19 20 BU S5


14
rd S5 = 3 interrogation S6 = Idle cycle without filling

23

23

33 41

41

K4 K2
34 A1 42 24 A1 24 A1

K5

K4

K4
42

K5
A2 A2 A2

K6

K7

1Y

2Y

3Y

1A14 16 20 2 2

2A+

3A+

Fig. 3/4: Circuit diagram, electrical (2)

C-19
Solution 3

C-20
Solution 3

Solution description

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 3 1 1 1 1 2 1 1 1 1 2 1 1 1 2 1 1 Designation Relay, 3-off Signal input plate, electrical Time relay, 2-off Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, capacitive Proximity sensor, optical Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 3/2-way solenoid valve, normally closed 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V

Components list

TP202 Festo Didactic

C-21
Solution 4

Stamping device

2B1 2A 1A 1S1 1S2

2B2

Fig. 4/3: Circuit diagram, pneumatic

3A

3B1

3B2

2Y1
5 4 2 1 3

2Y2
4 2

1Y1
5 1 3

1Y2

3Y1
5 1 3

3Y2

0Z2

0Z1

1 3

TP202 Festo Didactic

Solution 4

C-22

Fig. 4/4: Circuit diagram, electrical (1)

24 V- 1 6
13 23

2 7 2B2 BN BK BU K3
14 24

3 8 9
13 23 13

4 K1 K2
24 1 14

5 K3

10
13

3B1 K1
14 11

K5
14

K12 1S2
14 13 4

13

S
14

K4
14

41

41

11

K4
42 A1 A1 42 A1

K6
A1

K8
12 A1

K1
A2 A2

K2

K3
A2

K4
A2

K5
A2

TP202 Festo Didactic


3 4 20 5 23

6 7

9 24

10 11

24 V- 11
23

12 2B1 BN K7 K7 1S1
24 4 21 14 24 14 13 11 21 11 21 1

13 K9 K9

14

15

16

17

18

K5
24

TP202 Festo Didactic

BK BU K6
14 24

K8

11

21

K10
A1 12 A1 A1

K12
24 A1 A1

K6
A2 A2

K7

K8
A2

K9
A2

K10
A2

5 13 25

14 15

6 7

9 24

9 24

Fig. 4/5: Circuit diagram, electrical (2)

C-23
Solution 4

Solution 4

C-24

Fig. 4/6: Circuit diagram, electrical (3)

24 V- 19
11 23 23 31 31

20 SET 13 K11
14 24 24 24 24 34 14 21 23

21 K2 K4 K6 K8 K10
34

22

23

24

25

26

27 K12

28
31 34

K11

3B2

21 22

K10

41 42 A1 A1

K2

K11
A2 A2

K12 1A+
20 22 16 2 20

1Y1

2Y1 2A+

2Y2 2A-

1Y2 1A-

3Y1 3A+

3Y2 3A-

TP202 Festo Didactic

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 4 1 1 1 2 1 1 1 1 2 1 1 3 1 1 Designation Relay, 3-off Signal input plate, electrical Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, capacitive Proximity sensor, optical Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 5/2-way double solenoid valve Cable set with safety plug Electrical power supply unit, 24 V

Solution description

Components list

TP202 Festo Didactic

C-26
Solution 4

TP202 Festo Didactic

C-27
Solution 5

Drilling jig

Fig. 5/3: Circuit diagram, pneumatic

1B2 1A

1B1 2A

2B1

2B2

3A

3S1

3S2

1Y
5 1 3

2Y
5 1 3

3Y
5 1 3

0Z2

0Z1

1 3

* 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

3S1

3S2

Fig. 5/4: Part of circuit diagram, pneumatic

3Y

TP202 Festo Didactic

Solution 5

C-28

Fig. 5/5: Circuit diagram, electrical (1)

24 V- 1 2B2 K1 3S2 3S1


14 4 14 13 4 14 13 1 11 13 1 11

2 K2 K4
14 11

3 K3

8 K5

9
13 14

S
14

K16
12

11

23

23

K14
12 A1 A1

K1
24 A1 A1

K3
24 A1

K1
A2

K2
A2

K3
A2

K4
A2

K5
A2

TP202 Festo Didactic


3 5 35

5 13 20 27

35 6 8

8 15 22 29

9 11 33

24 V- 10 1B1 K6
14 24 14 24 14 13 21 13 21 13

11 K2 BK BU
14

12 K7 K4 K8 2B1 BN K9
11

TP202 Festo Didactic 13 14 15 16 17 18 19


21

K16
22

23

23

23

23

K5 K7
24 A1 24 A1 24 A1

K6

K8
24 A1

K6
A2 A2 A2

K7

K8

K9
A2

12 13 36

36 14 15

16 18 34

19 20 37

Fig. 5/6: Circuit diagram, electrical (2)

C-29
Solution 5

Solution 5

C-30

Fig. 5/7: Circuit diagram, electrical (3)

24 V- 20
11 31 11

21 1B2 BN K12 BK BU K16


32 42 14 44 14 11 41 11 41

22 K4 K11
34 31 14

23 K2 K13 K4
44 41

24

25

26

27

28

29

30

31 14

K2

K10

34

K16

21

21

21

21

21

K9
24 A1 24 A1

K10

K11

K12
24 A1

K13
24 A1 A1

24 A1

K10
A2

K11

K12
A2

K13
A2

K14
A2

K15
A2

A2

TP202 Festo Didactic


33 23 25

37 21 22

26 27 38

38 28 29

31

24 V- 31
11 33 33 31 31 33 33

32 K5 K8
34 41 41 31 31 34 34 34 34 34

33 K1 K6 K9 K12

34

35

36

37

38

K15
14

TP202 Festo Didactic K3


42 42 32

K7

K10

K13
32

31

K11
A1 32

K16 1Y 1A8 15 22 29

H 2Y 2A3Y
A2

3A+

Fig. 5/8: Circuit diagram, electrical (4)

C-31
Solution 5

C-32
Solution 5

Solution description

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

Kn+1 can be set without acknowledgement 3S1 being activated since current can flow via the self-latching of K3 and Kn.

Fig. 5/9:

24 V3S1 K3 Kn+1

K2 K3

Kn Kn+1

TP202 Festo Didactic

C-33
Solution 5

The signal generators indirectly switched (as in the solution to the exercise).
Fig. 5/10: Alternative circuit (1) K1 K3 K1 Kn+1

24 V3S1

K2 K1 K3

Kn 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) K3 3S2 K4 Kn+1

24 V3S1

K4

K2 K3

K3 K4

Kn Kn+1

TP202 Festo Didactic

C-34
Solution 5

Components list

Quantity 5 2 1 2 1 2 1 1 1 1 2 1 1 1 2 1 1

Designation Relay, 3-off Signal input plate, electrical Preselect counter, electrical, incrementing Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 3/2-way solenoid valve, normally closed 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V

TP202 Festo Didactic

C-35
Solution 6

Clamping unit for grinding

Fig. 6/3: Circuit diagram, pneumatic

1A

1S1

1S2

2A

2B1

2B2

3A

3B1

3B2

1B

P1
4 2

2Y1
5 2 1 3

2Y2
4 2

1Y
1 3

3Y1
5 1 3

3Y2

0Z2

0Z1

1 3

* For the purposes of this exercise, feed unit 2A is replaced by a double-acting cylinder.

TP202 Festo Didactic

Solution 6

C-36

Fig. 6/4: Circuit diagram, electrical (1)

24 V- 1
23 13 23

2 2B2 BN K4
24 14 24 13 23

3 2B1 BN K1 K4 BK BU
24 1 14

4 K2 BK BU K2

10

11 K6

12
13 14

13

13

K1

14

14

1S2
4

1B BN K3 BK BU K5
42 41 14

13

13

1S1

P1

K5
14

P2

K7 K9
11 11

11

K14 K13
A1 A1

K7
12 A1 A1

K9
12 A1

12 A1

K1
A2 A2

K2

K3

K4
A2

K5
A2

K6
A2

A2

TP202 Festo Didactic


4 5 7 29

2 3 28

8 9

4 11 31

12 13

24 V- 13 18
11 21 11

14 19 K10
24 14 24 14

15 20 K10 K12 21 22
11 21

16 K8 K8
14

17

23

3B2

K6
24

TP202 Festo Didactic


21 21 21

K7 K9
24 24 24

K11

11 11

21

K11 K13
12 A1 A1 12 A1 A1

K14
A1 24 A1

K7
A2 A2 A2 A2

K8

K9

K10

K11
A2

K12
A2

7 15 4 33

16 17

11 18 4 30

19 20

15 21 32

27 22 23

Fig. 6/5: Circuit diagram, electrical (2)

C-37
Solution 6

Solution 6

C-38

Fig. 6/6: Circuit diagram, electrical (3)

24 V- 23 29
23 31 23 31 31

24 31 K5
34 24 34 34

25 32 K11 K7 K13 33 34
31 23 33

26 S
34 24 34 24

27 K1 K3 K9

28

30

21

3B1

41 44

K12

K14

24

21

K13

24

11

31

K15
32 A1

K12

A1

12 A1

K13
A2

K14 1A+
25

K15

1Y

2Y1 2A+

2Y2 2A-

3Y1 3A+

3Y2 3A-

A2

A2

TP202 Festo Didactic

18 25 4 34

1 26 21

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 5 2 1 1 2 1 1 1 1 2 1 1 1 1 2 1 1 Designation Relay, 3-off Signal input plate, electrical Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right Pneumatic-electric converter 3/2-way solenoid valve, normally closed 5/2-way double solenoid valve Cable set with safety plug Electrical power supply unit, 24 V

Solution description

Components list

TP202 Festo Didactic

C-40
Solution 6

TP202 Festo Didactic

C-41
Solution 7

Forming press

1A

1S1

1S2 2A

2B1

2B2

Fig. 7/3: Circuit diagram, pneumatic

1Y
5 1 3

2Y
5 1 3

0Z2

0Z1

1 3

TP202 Festo Didactic

Solution 7

C-42

Fig. 7/4: Circuit diagram, electrical (1)

24 V- 1
21 13

2 K1

ES
22

1
11

14

3 2B1 BN BK BU
14 13 23 24 23 24 41

K5
12 13

K4

S1
14 13

S2
14 35

K3 K2
36 A1 42 A1 A1

A1 = 0,5s A2

K1
A2 A2

K2 K3

K4
A2

TP202 Festo Didactic


2 4 14 3

24 V-

8 1
1 21 1 11

9 2B2 BN K2 BK BU
14 34 13 31

TP202 Festo Didactic 10 K6


4 14

11 K6

12

13

14

15

1S2 1S1
24 4

K5

41 31

21

41

K7
42 A1 34 A1

K5

K6
24 A1

K5
42

K5 K6
A2 A2

K7
A2

1Y 1A+

2Y 2A+
8

3 9 14 10 11 13 15

Fig. 7/5: Circuit diagram, electrical (2)

C-43
Solution 7

C-44
Solution 7

Solution description

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

Designation Relay, 3-off Signal input plate, electrical Time relay, 2-off Indicator/distributor plate, electrical Double-acting cylinder On/off valve with filter regulator Manifold EMERGENCY-STOP button Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V

TP202 Festo Didactic

C-45
Solution 8

Embossing device

1A

1B1

1B2

2A

2S1

2S2

Fig. 8/3: Circuit diagram, pneumatic

1Y
5 1 3

2Y
5 1 3

0Z2

0Z1

1 3

TP202 Festo Didactic

Solution 8

C-46

Fig. 8/4: Circuit diagram, electrical (1)

24 V- 1
13 11

2 S2
14

3 K3
14

10

11 K4

12
11

13

11

S1 1B1 1B2

K1

14

14

14

31

11

41

21

K1
34 14

K2

K1
44

K2
24

S1 = START-button S2 = Manual step mode


21

11

K6
21 21

K3
24 11

12

K1
A1 22 A1 22 A1

K7

K7
12 A1

A1

K1
A2 A2

K1'

K2

K3
A2

K4
A2

A2

TP202 Festo Didactic


18 13 16 7 11 14 17

4 2 6 10

8 10 19

12 13 20

24 V- 13
1 1 13 31 31 11

14 K5 2S1
14 4 14 34 34

15 S3 K3 K4

16

17

18

19

20

2S2
4

TP202 Festo Didactic


11 31 21 41

K1'
14 34 24 44

S3 = Step repetition K2 K1' K2


21 21 31

31

K1
24 A1 24 A1

K5

K1'
32 A1

K5
32

K5
A2 A2

K6

K7
A2

1Y 1A+

2Y

2A+
10

20 15 16

1 6

Fig. 8/5: Circuit diagram, electrical (2)

C-47
Solution 8

C-48
Solution 8

Solution description Manual step mode Step repetition

By pressing the START button, the program is started in accordance with the displacement-step diagram. By pressing push button S2, it is possible to carry out one movement per actuation in accordance with the program or control sequence. 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.
Quantity 2 2 1 2 1 1 1 1 1 1 2 1 1 Designation Relay, 3-off Signal input plate, electrical Indicator/distributor plate, electrical Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V

Components list

TP202 Festo Didactic

C-49
Solution 9

Drilling and reaming machine

2B1 1S1 1A 1S2

2B2

Fig. 9/3: Circuit diagram, pneumatic

*
2A

1Y
5 1 3

2Y1

2Y2

0Z2

0Z1

1 3

* For the purposes of this exercise, linear drive 2A is replaced by a double-acting cylinder.
2A 2B1 2B2

Fig. 9/4: Part of circuit diagram, pneumatic

2Y1
1 3

2Y2
5 1 3

TP202 Festo Didactic

Solution 9

C-50

Fig. 9/5: Circuit diagram, electrical (1)

24 V21 11

7 ES K4
22 1 14

NA 3
13 13 23 23

1 K2 1S2
24 2 14 14 24

2 K1 1B K2

10

11

12
11

13

13

S1

K1

S2

K6
14

14

14

2B1
21

11

BN BK BU
13

K5
24

K5

S1 = Single cycle S2 = Continuous cycle S3 = STOP


31 32 A1 A1 A1 A1

14

K3
14 21

11

K9

S3

K9
24 A1

1B = Sensing of parts ES = EMERGENCY-STOP K3


A2 A2

12 A1

K1

K2

K4
A2

K5
A2

K6
A2

A2

TP202 Festo Didactic


4 6 11 25

2 5

19 8 26

1 3 18

12 13 21

24 V21 11 31 11

19 K10
22 14 32 14

20 K6 K11

21

22

K4 13
1 11 11 31

14 K7 K8 BN
12 34

15 K5

16

17

18

TP202 Festo Didactic 1S1


4 14

2B2

BK BU

S4 = RESET linear drive


11

K12
21 21 21 31 12 13

K6 K8
24 A1 24 A1 24 A1

K7

S4
32 A1

K13
14 A1

K7
A2 A2

K8

K9
A2

K10
A2

K11
A2

30 14 15 29

17 18 23

29 20 30

22 28

Fig. 9/6: Circuit diagram, electrical (2)

C-51
Solution 9

Solution 9

C-52

Fig. 9/7: Circuit diagram, electrical (3)

24 V- 23
31 31 21 23 23 21

24 K12 K3
24 32 24 24 24

25 K4 29
31

26 S5 K11

27

28

K8
34

30
41

K7
34 21

K7
42 31

K10
22

K10
32

S5 = RESET gripper
41

K5
42 23

K13
24 A1 A1

K12
A2

K13
A2

1Y

2Y1

2Y2

1A+
21 24 21 23

TP202 Festo Didactic

2A+

3A-

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.

Solution description

TP202 Festo Didactic

C-54
Solution 9

Components list

Quantity 5 2 1 2 1 1 1 1 2 1 1 1 2 1 1

Designation Relay, 3-off Signal input plate, electrical Indicator/distributor plate, electrical Double-acting cylinder On/off valve with filter regulator Manifold EMERGENCY-STOP button Proximity sensor, capacitive Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 3/2-way solenoid valve, normally closed 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V

TP202 Festo Didactic

C-55
Solution 10

Drilling and reaming machine

Fig. 10/3: Circuit diagram, pneumatic

1A

1S1

1S2 2A

2B1

2B2

3A

3B1

3B2

1Y
5 1 3

2Y
5 1 3

3Y
5 1 3

0Z2

0Z1

1 3

* 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.

TP202 Festo Didactic

C-56

Solution 10

Fig. 10/4: Circuit diagram, electrical (1)

24 V- 1 6
1 33 1 23

2 7 K1
4 34 21

3 8 K3
24

4 9
13

5 K2 1S1
14 4

10
11

13

13

2B1 BN 1S2 BK BU K3 K4
14 13 24 13

K1
14 41 14

K5
14

K2
42

S
14 23

K1
11 24 21 23 31

S = START-button

PS = PROGRAM SELECTION button


11

K4
12 A1 22

K8
A1

K8
12 A1

K2
24 A1

K4
34 A1

K1
A2 A2

K2

K3
A2

K4
A2

K5
A2

TP202 Festo Didactic


2 5 8 1 5 7 19

4 9

4 8 19 9

10 12 20

24 V- 11 19
33 31 31

12 20 K5
34 34 34

13 21 K6
11

14 3B2 K7 K2
14 11

15 3B1

16

17

18

2B2 K6
14

TP202 Festo Didactic


21 21 41 31

BN

BK

BU

21

K5 K4
24 A1 42 24 A1

K6

K7

K7
32

24 A1

K6
A2 A2

K7

K8

1Y

2Y

3Y

A2

1A+
21 16 18 1 5

2A+

3A+

13 15 21

Fig. 10/5: Circuit diagram, electrical (2)

Solution 10

C-57

C-58
Solution 10

Solution description

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 3 1 1 1 2 1 1 1 1 2 1 1 1 2 1 1

Designation Relay, 3-off Signal input plate, electrical Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 3/2-way solenoid valve, normally closed 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V

TP202 Festo Didactic

C-59
Solution 11

Loading station

Fig. 11/3: Circuit diagram, pneumatic

1A

1S1

1S2

2A

2B1

2B2 3A

3B1

3B2

1Y
5 1 3

2Y
5 1 3

3Y
5 1 3

0Z2

0Z1

1 3

* For the purposes of this exercise, cylinder 1A is replaced by a single-acting cylinder.

TP202 Festo Didactic

C-60

Solution 11

Fig. 11/4: Circuit diagram, electrical (1)

24 V11 1 14 4 11 1 11 21 21

1 7 K3 1S1
14 24 24 4

2 8 K4 K5 K6 9 10 11 12 13 K2
14

3 1S2

11 12

S1 2B1

K1

11

11 11

K9 K4
14 21 12 12

K5

2B2

S1 = START button S2 = Sensing of steel parts K1


24 1

41

S2
4 41 21 21 31 31

K10

42

K7 K2
42 24 A1 A1

K3
24 A1 A1

K4
34 A1

K5
34 A1

A1

K1
A2

K2

K3
A2

K4
A2

K4'
A2

K5
A2

K6
A2

A2

TP202 Festo Didactic


5 6 21 22 15 7 22 8

2 4 15

6 9 12 24

25

8 12 13 23

21 13 22 14

14
31 13 31 41 41 41 11

15 K1 3B1
BN BK BK BU BU BN

16 K2 K2
34 44 44 44 14

17 K5 K4 K8

18

19

20

21

22

23

24

25

K1
34 14

TP202 Festo Didactic 3B2


41 11

K5
42

K4'
14

Electromagnet
31 41

21

31

K6 K6
32 A1 A1 R1 A1 32 42

K3

K6

24

A1

K7 H1
A2 A2 R2 A2

K8

K9

K10

1Y

2Y

3Y

A2

4 25 1 16

Electromagnet

1A+

2A+

3A+

Fig. 11/5: Circuit diagram, electrical (2)

Solution 11

C-61

C-62
Solution 11

Solution description

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 4 1 1 2 1 2 1 1 1 1 2 1 1 1 2 1 1

Designation Relay, 3-off Signal input plate, electrical Preselect counter, electrical, incrementing Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 3/2-way solenoid valve, normally closed 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V

TP202 Festo Didactic

C-63
Solution 12

Internal grinding machine

Fig. 12/3: Circuit diagram, pneumatic

3A

1A

1B1

1B2

2A

2S1

2S2

3B1

3B3

3B2

2B

P1

1Y
5 1 3

2Y
5 1 3

3Y
5 1 3

0Z2

0Z1

1 3

* 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.

TP202 Festo Didactic

C-64

Solution 12

Fig. 12/4: Circuit diagram, electrical (1)

24 V- 1
23 13

2 K1 K4
p 14 p1 2

3 K3 K5 BK BU
14 1 4 14 24 13 14

4 1B2 2B BN 3B3
13 13

5 BN

10

11

12

13

13

13

S1 K2

K1

2S1

14

14

BK BU

S1 = START-button S2 = Part of the stop S3 = STOP-button


11 23 23

S2

31

S3 K14
14 A1 24 A1

K3

K4
24 A1 A1 A1

32 A1

A1

K1
A2 A2

K2

K3

K4

K5
A2

K5'
A2

K6
A2

A2

A2

TP202 Festo Didactic


5 7 32

2 4

4 29

8 10 33

11 14 22 35

37

20 14 16

C-65
Solution 12

Fig. 12/5: Circuit diagram, electrical (2)

TP202 Festo Didactic

C-66

Solution 12

Fig. 12/6: Circuit diagram, electrical (3)

24 V- 28
21 1 33 33 41 41

29 K13 2S2
24 34 41 31 42 44 31 4 34

30 K3 K4 K13 K5 K5'

31

32

33

34

35

36

37
11 14

1B1

23

K2 K12
42 32

K7

K10
34

24

21

31

41

11

K12 K12
A1 32

K11
42

K12'
12

24 A1

K13
A2

K14

1Y

2Y

3Y

H1

A2

1A+
4

2A+

3A+

Grinding wheel

TP202 Festo Didactic

17 30 31 35

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 5 2 1 2 1 2 1 1 1 1 1 2 1 1 1 1 2 1 1 Designation Relay, 3-off Signal input plate, electrical Preselect counter, electrical, incrementing Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor, optical Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right Pneumatic-electric converter 3/2-way solenoid valve, normally closed 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V

Solution description

Components list

TP202 Festo Didactic

C-68
Solution 12

TP202 Festo Didactic

C-69
Solution 13

Assembly unit

2A 1A

2B1

2B2

Fig. 13/3: Circuit diagram, pneumatic

1S1

1S2 3A

3B1

3B2

2Y1
4 2 5 1 3

2Y2
4 2

1Y1
5 1 3

1Y2

3Y1
5 1 3

3Y2

0Z2

0Z1

1 3

* For the purposes of this exercise, cylinder 1A is replaced by a single-acting cylinder.

TP202 Festo Didactic

C-70

Solution 13

Fig. 13/4: Circuit diagram, electrical (1)

24 V- 1
23 11

13

S2 K1
24

14

1 3
11 21 1 11 21

12

2 K2 K2 1S2
24 4 11 14 24 14

5 K4 K4 2B2

10

11 K6

12
11 14

2B1 K3
13 14

S1 = OFF/ON S2 = MAN/AUT
S1
14 13

21

K5
24

K11
14 11 11 11

K5
12 A1 A1

K7
12 A1 A1

K9
12 A1

A1

K1 K2
A2

K3
A2

K4
A2

K5
A2

K6
A2

A2

TP202 Festo Didactic


5 6

4 32 36 40

19 7 29

8 9

4 11 33

12 13

24 V-

TP202 Festo Didactic 13


21

14 3B2 BN K8 K8 K10 K12


14 42 24 11 21

15 3B1 BN K10 BK BU
21 1 13 41 23

16

17

18

19

20

21

22

K6
24

BK BU

14 24

K7 1S1
24 4 21

K9
24 41 21

K11 K3
42 A1 A1 A1

22 A1

A1

K7 K8
A2 A2 A2

K9

K10
A2

K11
A2

7 15 37

16 17 28

11 19 31 39

20 22 23

15 4 35

Fig. 13/5: Circuit diagram, electrical (2)

Solution 13

C-71

C-72

Solution 13

24 V21

32

Fig. 13/6: Circuit diagram, electrical (3) K1 25 26 27 28 30


22

23
13 13 31 41 31 13

24 S3
14 14 31 32 13 14 41 42 14 42 13 42 41 34

29 K3 K13
14

31
31 41

33

K10

K12

K9
34

K13
42

34

S4
32 31

S5
32

A1 A1 A1 A1

K12 K13 K15


A2 A2

K14

H1
A2

1Y1

1Y2

A2

1A+ MAN
40 38

1A-

TP202 Festo Didactic


32 30 36 34

21 24

24 V31 41

36

40

K1 34
32 42

K1 38

TP202 Festo Didactic 33 37


41 31 13 41 41

35 39 K15
34 14 42 13 23

31

K5 K14
24 42 34 14

K14

K11

K7

K9

K15
42

2Y1

2Y2

3Y1

3Y2

2A+

2A-

3A+

3AFig. 13/7: Circuit diagram, electrical (4)

Solution 13

C-73

C-74
Solution 13

Solution description

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 5 2 2 1 2 1 1 1 1 2 1 1 3 1 1

Designation Relay, 3-off Signal input plate, electrical Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 5/2-way double solenoid valve Cable set with safety plug Electrical power supply unit, 24 V

TP202 Festo Didactic

C-75
Solution 14

Moulding press

Fig. 14/3: Circuit diagram, pneumatic


2B1 2B2 2A 2B3

1A

1B1

1B2

3A

3S1

3S2

1Y
5 1 3

2Y
5 1 3

3Y
5 1 3

0Z2

0Z1

1 3

* For the purposes of this exercise, the double-acting cylinder is replaced by a singleacting cylinder.

TP202 Festo Didactic

C-76

Solution 14

Fig. 14/4: Circuit diagram, electrical (1)

24 V- 1
23

2 1B2 K4
13 24 23 14 13 14 24 13 13 23 17

3 K5 K4 K6
18

10 K7

11
13 14

13

S1

14

S1, S2 = START-button K3
14 14 24 11

S2

K14
14 41

K5
13 42 41 11 23

41

K3
14 A1 42 A1 A1

K1 K2

K11
12 A1 A1

K5
24 A1

42 A1

K1
A2 A2

K2

K3

K4
A2

K5
A2

K6
A2

K7
A2

A2

TP202 Festo Didactic


4 1 7 30

24 7 9

8 10 31

10

31 11 13

24 V- 12
11 1 11 1 21 11

13 K8 2B3 3S1
14 4 24 14 4 14

14 K9 3S2 BK BU K10 K11 2B1 BN

15

16

17

18

19

20

21

TP202 Festo Didactic


23 21 21 21

1B1

K7
24 A1 24 A1 24 A1 24 A1

K8

K9

K10
A1

K8 K9
A2 A2 A2

K10

K11
A2

K12
A2

24 13 15 32

15 16 27 33

33 17 18 25

7 19

27 26

Fig. 14/5: Circuit diagram, electrical (2)

Solution 14

C-77

C-78

Solution 14

Fig. 14/6: Circuit diagram, electrical (3)

24 V11 21 31 11 21 23 33 41 11

22 K14
14 31 31 41 24 34 14 24 24 34 14

23 K12 K9 K15 K15 K3 K5 K8


44

24

25

26

27

28

29

30

31

32 K9

33
41 44

BN

K13

2B2 K10
32 34

BK K7
42

BU

K8

41

21

41

K4
42 A1 22 A1

K12

K10
42

A1

K13
A2 A2

K14

K15

H1

1Y

2Y

3Y

A2

1A+
28 29

2A+

3A+

Vacuum generator

TP202 Festo Didactic


4 25

24

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 5 1 1 2 1 2 1 1 1 1 1 2 1 1 1 2 1 1 Designation Relay, 3-off Signal input plate, electrical Time relay, 2-off Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor, optical Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 3/2-way solenoid valve, normally closed 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V

Solution description

Components list

TP202 Festo Didactic

C-80
Solution 14

TP202 Festo Didactic

C-81
Solution 15

Pick-and-place unit

Fig. 15/3: Circuit diagram, pneumatic


2B1 2A 2B2

1A

1S1

1S2

3A

3B1

3B2

1Y
5 1 3

2Y
5 1 3

3Y
5 1 3

0Z2

0Z1

1 3

* For the purposes of carrying out this exercise on the profile plate, cylinder 3A is replaced by a single-acting cylinder.

TP202 Festo Didactic

C-82

Solution 15

Fig. 15/4: Circuit diagram, electrical (1)

24 V- 1
13 1 13

2 2B1 BN 3B2 K3
14 13 14

3 K2
4

10 K4

11
21 24

13

S1 1S2
14

K1 BK BU

14 13

S2

S1 = START-button S2 = Gear housing S3 = Magazine


23 41 11

14 11

13

S3 K3 K4
42 23 12 24

K5
12

14

K1
24 21 23 23

11

K15
22 A1

K15

K2
24 A1

K3
24 A1

12 A1

K1
A2

H1 K2

K3
A2

K4
A2

A2

Magazine

TP202 Festo Didactic


5 7 40

2 4 22

8 10 36

7 11 41 13

24 V- 12
1 21 21 21 21

13 K6 K9
24 24 4 24 24

14 K7 K8

15

16

17

18

19

20

21

22

23

24

3B1

21

K5

1S1

TP202 Festo Didactic


11 11 11 11

24

11

K6
12 12 12 12 33

K7 K8 K1
34 31 31 31 31

K9

K10

12

31

K4
34 34 A1 A1 A1 A1 34

K5

K6

K7

K8
34 A1 A1

34

A1

K5
A2 A2 A2 A2

K6

K7

K7'

K8

K9
A2

K9'
A2

A2

10 14 15 38 42

13 16 17 42

15 18 36 20

17 21 38 22

20 23 25 37

43

Fig. 15/5: Circuit diagram, electrical (2)

Solution 15

C-83

C-84

Solution 15

Fig. 15/6: Circuit diagram, electrical (3)

24 V- 25
21 13 13 11 11 31

26 K11 S2
14 32 24 14 14 14

27 K12 K13 K14

28

29

30

31

32

33

34

35
23 24

K10

41

41

2B2 BN BK BU

K11
42

K12

42

31

31

23

23

21

21

K9
34 A1 A1

K10

K11
24 A1

K12
24 A1

K13
24 A1

K14
24 A1

34

A1

K10
A2 A2

K11

K11'

K12
A2

K13
A2

K14
A2

K15
A2

H2

A2

Gear housing

TP202 Festo Didactic


25 28 31 39 40

22 26 43 27

27 31 32 44

44 32 33

39 33 34

1 4

24 V- 36
33 41 41 33 33 41 11 33

37 K9 K5
44 44 14 34 44 34 34

38 K11 K2 K6 K9' K12

39

40

41

42

43

44

TP202 Festo Didactic K3


34 41 31 41 31 41 41 11 41 31

K7
42 32 42 32 42 42 12

K13

K8

K14

K11'

K4

K7'

K10
42

K13
32

H3 1Y 2Y

3Y

Vacuum generator 1A-

2A-

3A+

Fig. 15/7: Circuit diagram, electrical (4)

Solution 15

C-85

C-86
Solution 15

Solution description

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 6 2 2 1 2 1 1 1 1 2 1 1 1 3 1 1

Designation Relay, 3-off Signal input plate, electrical Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 3/2-way solenoid valve, normally closed 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V

TP202 Festo Didactic

C-87
Solution 16

Galvanising process

1B1 1A

1B3

1B2

Fig. 16/3: Circuit diagram, pneumatic

1Y
5

0B

P1
0Z2

0Z1

1 3

TP202 Festo Didactic

C-88

Solution 16

Fig. 16/4: Circuit diagram, electrical (1)

24 V- 1.0 0B K1 K2
24 23 24 14 14 13 14 13 23 21 13 11 13 23

1.1 K15 K2 K18 K4


14 11

1.2 K4
24

10

BN

1B1 K1
24 14

BK K3 K13
14 11

S = START-button K15
14 11

BU

K21
14 13

S
14 41 41 11

K2 K5
42 42 A1 A1

K7
12 A1 A1 A1

A1

K21
A2

K1

K2
A2

H1

K3
A2

K4
A2

K5
A2

A2

22 3 4 26

5 6 42

Bad 1

9 10

4 11 27

TP202 Festo Didactic 1A+

1A-

24 V- 11
31 35 11 21 41 11 13 23

12 K6 K8
36 21 14 24 44 21 14

13 K6 K19
24

14 K8 K15 K10

15

16

17

18

19

20

K15
34 13 14

K5 K9
24 24 14

TP202 Festo Didactic K7


11 11 21

K9
12 A1 A1 A1 12 A1

K11

K13
22 A1

K6
A2 A2 A2

H2 Bath 2
8 15 36 16 17

K7

K8

K9
A2

K10
A2

H3 Bath 3

12 14 44

11 18 28

19 21 43

1A+

1A-

1A+ Fig. 16/5: Circuit diagram, electrical (2)

Solution 16

C-89

C-90

Solution 16

Fig. 16/6: Circuit diagram, electrical (3)

24 V- 21
11 17 13 21 33 23 31 31

22 1B3 BN BK BU S1 K12
14 34 24 34 34 18 24

23 K1 K5 K9 K12 K14

24

25

26

27

28

29

30

31

32

21 14

21

K10

K18

K12

24

24 21

K11

S1 = SET-button
A1 A1 A1

24

41

K1
A1

42

A1

A1

K11
A2

K12

K13

K14
A2

K15
A2

K16
A2

A2

A2

15 22

23 25 29 45

18 2 37

34 30 45

2 4 11 18

33 37

TP202 Festo Didactic t1

1A-

24 V- 33
31 21 11

34 K16
32 34 34 3 31 21 28 44 27 24 14 4 34

35 K20 K2 K10 K6 K12 1B2 1


33 31 33 41

36

37

38

39

40

41

42

43

44

45

11

11

K16 K7

K17

14

14

TP202 Festo Didactic K14 K13


32 22

K20

S2 = Up/Down

35 11 31

13

K14 K22
12 A1 A1 A1 32 14

K18

S2

36

A1

R1

A1

K17
A2 A2 A2

K18

K19

K20

K22

1Y

H4

A2

R2

A2

Work surface

oscillate

t1 > tReturn stroke

35

40 8 22

15

42 38

37

t2

1A+

Fig. 16/7: Circuit diagram, electrical (4)

Solution 16

C-91

C-92
Solution 16

Solution description

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.

TP202 Festo Didactic

C-93
Solution 16

Quantity 6 1 1 1 1 1 1 1 1 1 2 1 1 1 1

Designation Relay, 3-off Signal input plate, electrical Time relay, 2-off Preselect counter, electrical, incrementing Indicator/distributor plate, electrical Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor with cylinder mounting Pneumatic-electric converter 5/2-way solenoid valve Cable set with safety plug Electrical power supply unit, 24 V

Components list

TP202 Festo Didactic

C-94
Solution 16

TP202 Festo Didactic

C-95
Solution 17

Loading station

Fig. 17/4: Circuit diagram, pneumatic


1B 1 1A1

1B2

1A2

2B1

2B2

2A

1V1

1Y1

1V2

1Y2

2V

2Y1

2Y2
5 1 3 5 1 3 5 1 3

3A

3S1

3S2 4M

4S

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 2

TP202 Festo Didactic

C-96

Solution 17

Fig. 17/5: Circuit diagram, electrical (1)

24 V- 1
11 13 11 11 11 13 11

2 K1 K4
11 14 12 14 14

3 1B2 K11
14 14 14 14 14

4 K2 K9 K3 K19 K5

10

11
11 14

1B1

13 14

K18

S = START-button
41 21 21 21

21

K7
42 A1 24 A1 24 A1

K1

K2

K3
24 A1

K4
24 A1

K1
A2 A2

K2

K3
A2

K4
A2

K5
A2

3 5 35 36

35 5 6 39

7 8 20

20 9 10 44

44 11 12 34

TP202 Festo Didactic 1A+ 3A+

4M+

4M-

24 V- 12
13 11 23 11 1 1 1

13 3S1 3S2 4B
4 14 24 14

14 4S K12 K11 K13


4

15

16

17

18

19

20

21

22

23

13 14 4

13

K10

K6

K8

TP202 Festo Didactic


23

14

14

K9
24 31

K4
32 21

K18
23 22 31 21

21

K5 K3
24 A1 A1 A1 A1 A1 34 A1

K6

K12
24 A1

24 A1

K6 K11
A2 A2

K7 K12
A2 A2 A2

K8

K9

K10

K13
A2 A2

A2

39 13 14 42

14 28

6 20

12 24

10 22

21 22 33 43

33 23 43 24

3A-

1A-

4M+

4MFig. 17/6: Circuit diagram, electrical (2)

Solution 17

C-97

C-98

Solution 17

Fig. 17/7: Circuit diagram, electrical (3)

24 V- 24
11 11 11 21 31 11 23

25 2B1
14 14 24 14 14 24

26 K15 K8 K16 2B2 K17 K17 K12


34

27

28

29

30

31

32

33 K5

34
31 34

23

K10

K14

24

21

21

21

21

31

K13
24 A1 24 A1

K14

K15

K16
24 A1 A1

K13
32 A1 R1

24 A1

K14
A2 A2

K15

K16

K17
A2

K18
A2

K19
A2 R2

A2

25 27 37

39 27 28 41

37 29 31 38

41 31 32 40

20 8

TP202 Festo Didactic 3A2A+

2A-

3A+

24 V- 35
31 41 41 31 41 33 41 41

36 K16 K17
44 31 34 44 41 44 41 34 44 41

37 K2 K15 K6 K12 K4
44

38

39

40

41

42

43

44

31 34

41

K1

K1

K14

TP202 Festo Didactic K15


32 42 42 42

34

44

K17

K13

K5

31

31

41

K2
32 42

K16

K6

32

1Y1

1Y2

2Y1

2Y2

3Y1

3Y2

4Y

H1

Suction cups

1A+

1A+

2A-

2A+

3A+

3A-

4M+

Fig. 17/8: Circuit diagram, electrical (4)

Solution 17

C-99

C-100
Solution 17

Solution description 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. 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.

Comment

TP202 Festo Didactic

C-101
Solution 17

Quantity 6 1 1 2 1 3 1 1 1 1 1 2 1 1 1 2 2 1 1

Designation Relay, 3-off Signal input plate, electrical Preselect counter, electrical, incrementing Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor, optical Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 3/2-way solenoid valve, normally closed 5/2-way solenoid valve 5/2-way double solenoid valve Cable set with safety plug Electrical power supply unit, 24 V

Components list

TP202 Festo Didactic

C-102
Solution 17

TP202 Festo Didactic

C-103
Solution 18

Rotary indexing station


Fig. 18/3: Circuit diagram, pneumatic
2 3 2 1 4 5 4 5 5 1 3 5 1 3 1 3

6A

(6S) 6S1

(6B) 6S2

11S1 11S2

5S2

5S1

5Y2

5A

5Y1

11A

10S1 10S2

4S2

4S1

4Y2

11Y

4A

4Y1

10A

3S2

3Y2

3S1

9S1

9S2

3A

3Y1

9A

2S2

2Y2

2S1

8S1

8S2

9Y

(2B1) (2B2)

2A

2Y1

8A

(1B1) (1B2)

1S2

1S1

1Y2

7S1

7S2

1A

1Y1

7A

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.

TP202 Festo Didactic

7Y

8Y

10Y

12Y

6Y

Solution 18

C-104

Fig. 18/4: Circuit diagram, electrical (1)

24 V-

13

31

S2 4 2B1 K2 K2
14 1 24 13 14 13 23

14

32

3 1B2 K4 K17
14 13 11

10

11

12 K5

13
13

14
23

13

23

17

S1

K1

K5
14 24

14

24

18

6S
4 13

K3
14

S3
14 11

K16
14 41

S1 = ON S3 = Sensing of parts S2 = AUTO/MANUELL S4 = OFF K6


42 27

35

31

S4 K1
28 A1 A1

11

K1

36

32

K9
A1 12 A1 A1

A1

H1
A2

K1

H2

K2

K3
A2 28 11 44 57

K4
A2 11 24 34

K5
A2 13 14

K6
A2 6 17 46

A2

Pump
36 7 8 34

START

TP202 Festo Didactic

1 3 6

24 V-

15

16
11 21

17 2B2 BN K10 BK BU 5S2


4 21 4 21 1 1 23 14 24 24 14 24 11 21 23 11 21

18 6B K8 K10 K4 K12 K12


14 24

19

20

21

22

23

24

25

26

27

28

1B1

13

TP202 Festo Didactic 5S1 K7


24 21

K7

K8

14

13

K6

14

K9
24 24

K11

K13
24

11

11

21

41

K11
A1 A1 12 A1 22 A1

K13

K16
A1

K3
42 A1

A1

12 A1

K7
A2 A2 A2

K8

K9

K10

K11

K12
A2

K13
A2

K14
A2

A2

A2

17 28 51

18 19 52

11 21 36 49

22 23

17 24 45 53

34 25 26

21 28 47 55

29 31 33

Fig. 18/5: Circuit diagram, electrical (2)

C-105
Solution 18

Solution 18

C-106

Fig. 18/6: Circuit diagram, electrical (3)

34
21 13

35 S5
22 14

36 K21

40

41

42
11 14

24 V-

38
13 23 24

39
31 32

29 37
14 33 31 11 21 21 31

30 K14 K9
24 34 14

31 K2 K18
34 33 34

32 K17

33

S6

11 24

11

21

K14

K15

K14

K15

14

12

24

K4
34

S5 = EMERGENCY-Stop S6 = RESET
31 41

K12
A1 32 A1 42 A1

K2
A1 A1 A1

A1

K15
A2 A2

K16

K17

K18
A2

K19
A2

K20
A2

K21
A2

A2

TP202 Festo Didactic


24 6 50 44 12 35 43

30 32

37 56

48 51 54

56

50 42

43

24 V48
11 21 31

51 K19
24 33 31 41 41 21 33

54 K19
34

56

TP202 Festo Didactic 47


14 41 31

44 50 K16 K8
34 17 34 44 44 24

45 52 K11 K13 K18 K3


34

46 53 55 57
31

K19 49 K9 K7
34 21

31 34 44

23

31

23

K17

K3

K11

K6

K13

34

24

34

24

41

K17
22

K21

K20
18

42

Air blast

Vacuum generator 2Y1 2Y2 5Y1 5Y2 6Y 12Y 2A+ 2A5A+ 5A6A+

H3

1Y1

1Y2

1A+

1A-

Fig. 18/7: Circuit diagram, electrical (4)

C-107
Solution 18

C-108
Solution 18

Solution description

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).

TP202 Festo Didactic

C-109
Solution 18

40
21

41
13 14

S5
22

Fig. 18/8: Circuit diagram, electrical (3) Addition with counter

38
13

39
23 24 31 32

S6
14

A1

A1

A1

R1 R2

K19
A2

K20
A2

K21
A2

S5 = EMERGENCY-STOP S6 = RESET

TP202 Festo Didactic

C-110
Solution 18

Components list

Quantity 6 2 1 2 1 3 1 1 1 1 1 1 2 2 1 2 3 1 1

Designation Relay, 3-off Signal input plate, electrical Time relay, 2-off Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold EMERGENCY-STOP button Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor, optical Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 5/2-way solenoid valve 5/2-way double solenoid valve Cable set with safety plug Electrical power supply unit, 24 V

TP202 Festo Didactic

C-111
Solution 19

Checking station

Fig. 19/3: Circuit diagram, pneumatic


2A 1B1 1A 1B2 2B1 2B2 3A 3S 3B 4A

4S1

4S2

2Y
4 2 5 1 3 4 2

4Y
5 1 3

3Y 1Y1
5 1 3

1Y2
0Z2

0Z1

1 3

* For the purposes of this exercise, cylinder 4A is to be replaced by a single-acting cylinder.

TP202 Festo Didactic

Solution 19

C-112

Fig. 19/4: Circuit diagram, electrical (1)

24 V- 1
1 1 23 11

2 1B2 BN K5
14 11 11

3 1B1 BN BK BU K1 K6
14 14 4 24 23

4 K4 BK BU

10

11

12

13

13

S1 3S
4

K1 4S1

14 13

14

K2
24 23

K2

S1 = START-button K3
24 17 21

14 13

K3

14

31

S2
A1 A1 18 A1

K19
A1

K4
24 A1 A1

32 A1

S2 = STOP-button K2
A2 A2 A2

K1

K3

K4

K5
A2

K6
A2

K7
A2

A2

TP202 Festo Didactic


1 5 1 5 6 9 37 39

2 5

37 10 16 38

15

24 V- 13 2B1 K7 K12
14 14 14 13 18 14 13 17 11

14 2B2 S3
13 11

15 K9 K10

TP202 Festo Didactic 16 17 18 19 20 21 22 K8


14 21 21

S3 = Tolerance check K6
A1 A1

K10
24 A1 A1 A1 24 A1

= 3s K10 K10'
A2 A2

K8
A2 A2

K9

K11
A2

K12
A2

15

16

17 21 23 33

39

23

41 22 40

Fig. 19/5: Circuit diagram, electrical (2)

C-113
Solution 19

Solution 19

C-114

Fig. 19/6: Circuit diagram, electrical (3)

24 V- 23
11 11

24 3B 4S2
14 14 14 24 13 11 21 11

25 K14 K14 K15


14

26

27

28

29

30

31 K17

32
11 14

K11
14

K13

31

21

K10
34 A1 A1 A1 A1

K13
24 A1 A1

K13
A2 A2

K14

K15
A2

K16
A2

K17
A2

K17'
A2

TP202 Festo Didactic


24 29 40 41 28 29

31

40 32 33 36

41

24 V- 33
21 11 21 31 31 41 41 31 41

34 K18 K18
14 22 34 34 44 44 34 21 44 31

35 K17 K6 K4 K13 K13 K4

36

37

38

39

40

41

K17
24 13

TP202 Festo Didactic K12 K12


24 32 14 41 31 11 41 11

S4

= Interrogate container K6
44 A1 A1 32

K10 K10'

K17
12 42

K17'
12

K18 1Y1 1Y2


A2 A2

K19

H1

2Y

3Y

4Y

1A+

1A-

2A-

3A+

4A+

Conveyor belt

35 34

Fig. 19/7: Circuit diagram, electrical (4)

C-115
Solution 19

C-116
Solution 19

Solution description

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 6 1 1 1 2 1 3 1 1 1 1 1 2 2 1 1 2 1 1 1

Designation Relay, 3-off Signal input plate, electrical Time relay, 2-off Preselect counter, electrical, incrementing Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor, optical Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 3/2-way solenoid valve, normally closed 5/2-way solenoid valve 5/2-way double solenoid valve Cable set with safety plug Electrical power supply unit, 24 V

TP202 Festo Didactic

C-117
Solution 20

Handling device

1A

1S1

1S2 2A

2B1

2B2

Fig. 20/3: Circuit diagram, pneumatic

1Y
5 1 3

2Y
5 1 3

*
3A 3B1 3B2

4M

4S

4B

3Y

4Y1

4Y2
0Z2

4Y3

4Y4

0Z1

1 3

* For the purposes of this exercise, cylinder 1A is replaced by a single-acting cylinder. Rotary actuator 4M is replaced by a double-acting cylinder.

TP202 Festo Didactic

Solution 20

C-118

Fig. 20/4: Circuit diagram, electrical (1)

24 V- 1

10

21

11

S6

K1

22

14 13

31

S2 7 5
23 17 13 13 13

14

32

8 9 3B1 K6
14 23 14 13

4 K4
11 24 41 18 14 14

6 S5 K10 K5 K15

11

12

13

14
21

15
13

16
1

17
13

13

S1 = START-button S2 = MAN/AUT S3 = Sensing of parts K7


24 14

S1

1S2
4

K8
14

14 11

13

K18 K15 K2
14 42

K2 K2
24

14 13

14

S3

14 31 11 11 23 23

S4 K16
12 A1 R1 A1 A1

32 11

K13
12 A1

K6
24 A1

K7
24 A1

S4 = STOP S5 = RESET S6 = EMERGENCY-STOP K4


A2 R2 A2 7 50

K3

A1

12 A1

K1

K2

H1

K3

K5
A2 22 10 30

K6
A2 13 14 42

K7
A2 15 16 41

K8
A2 42 17 19

A2

A2

START

TP202 Festo Didactic


2

46 2 48 45

3 12

2A+

1A+

2A-

24 V-

18
41 21 27 21 11 21 31 11 1

19 1B2 BN BK BU K5 K16
42 24 28 24 14 24 34 23 14 4

20 K10 K11 1S1 K12 K18 K9 K14

21

22

23

24

25

26

27

28

29

30

31

32

33

1B1

TP202 Festo Didactic K5


11 24 21

BN

11

K9

BK

14

BU

K17
14 22

K17

23

11

21

31

21

31

K8 K11
12 A1 A1 A1 A1 A1 A1 24 34 24

K9

K11

K12

K12
32 A1 A1

24

A1

K9
A2 A2 A2 A2 A2

K9'

K10 K11 K12 K12'

K13

K14
A2 A2

K15
A2

A2

20 24 30 44

45

9 24

22 25 41 26

30 27 44 29

45 47 49

12

31 43

5 14

3A+ 4M+

1A-

3A- 4M-

Fig. 20/5: Circuit diagram, electrical (2)

C-119
Solution 20

Solution 20

C-120

Fig. 20/6: Circuit diagram, electrical (3)

24 V-

46

48

40
31 41

50
23 42 21

34
32 33 33 21 41 21

35 K7
34 34 24 44 24 11

36 K6 K14 K9 K1 K12'

37

38

39

41

42

43

44

45

K1 47

K1

49
31

K4
24

3B2

4B

4S

K12'
24 34

K9'
14 11

K12'
12

41

41

41

K11
42 42

K8 2Y 3Y

K12
42

A1

A1

A1

K16 H2 H3

K17

K18

1Y

4Y1

4Y2

4Y3

4Y4

A2

A2

A2

MAN

AUTO

9 23

30 22

2 29

TP202 Festo Didactic 1A+ 2A+

3A+

4M+

4M+

4M-

4M-

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 6 2 1 1 2 1 3 1 1 1 1 1 1 2 2 1 2 2 1 1 Designation Relay, 3-off Signal input plate, electrical Time relay, 2-off Preselect counter, electrical, incrementing Indicator/distributor plate, electrical Single-acting cylinder Double-acting cylinder On/off valve with filter regulator Manifold EMERGENCY-STOP button Proximity sensor, inductive Proximity sensor, capacitive Proximity sensor, optical Proximity sensor with cylinder mounting Limit switch, electrical, actuation from the left Limit switch, electrical, actuation from the right 5/2-way solenoid valve 5/2-way double solenoid valve Cable set with safety plug Electrical power supply unit, 24 V

Solution description

Components list

TP202 Festo Didactic

C-122
Solution 20

TP202 Festo Didactic