Electro P Transparencies Fundamentals

Fundamentals of Electropneumatics Collection of Transparencies
3 2 1 2
3 1
095011 GB
Order No.: Description: Designation: Edition: Author: Graphics: Layout:
095011 EL-PN.FOLIEN-GS D:OT-TP201-GB 02/2000 Frank Ebel Doris Schwarzenberger 10.05.2000, Beatrice Huber
Festo Didactic GmbH & Co., D-73770 Denkendorf, 2000 Internet: www.festo.com/didactic e-mail: did@festo.com 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 registration.
Foreword
The Collection of Transparencies is conceived for the basic material of the TP200 Electropneumatic Technology Package. The transparency collection and technology package form part of the The Learning System for Automation from Festo Didactic GmbH & Co. The transparencies are designed from a didactical and methodological point of view. For each transparency, there is a short accompanying text that provides the speaker with a quick overview of the contents. More information you will find in the textbook Electropneumatics. Syllabus
Physical fundamentals of electropneumatics Function and application of electropneumatic components Designation and drawing of electropneumatic symbols Drawing of pneumatic and electrical circuit diagrams in accordance with standards Presentation of motion sequences and switching conditions Direct and indirect manual controls Direct and indirect direction-dependent controllers Logical AND/OR functions Pressure-dependent controls with pressure switches Troubleshooting in simple electropneumatic control systems
The text pages contain a complete picture of the transparency with some additional explanations and items which the speaker can mark on the transparency during instruction. The advantages of this concept are: The speaker can add to the transparencies step-by-step during instruction. Instruction is livelier. The accompanying texts provided reduce preparation time. New! Electronic presentation The enclosed CD-ROM contains all the overhead transparencies and accompanying text of this edition in an electronically presentable form in the files Electropneumatics _ transparencies.pdf and Electropneumatics _text.pdf. In addition to the screen presentation, which can be made in any order, the contents can be printed out and text and graphics can be used for your own training preparations, insofar as the functionality of the required Adobe Acrobat Reader permits this. This freely distributable software is available on the CD-ROM in the currently valid English version for Windows 95/98/NT for installation in the directory Acrobat_Reader. Please start the file rs405eng.exe and follow the subsequent dialogue.
Festo Didactic GmbH & Co. Electropneumatics
Contents
System Elements Elements of a Control Chain __________________________________ Transparency 1 Pneumatic Components Single-Acting Cylinder _______________________________________ Double-Acting Cylinder ______________________________________ Non-return, Flow Control and Pressure Control Valves_____________ Pressure Regulating Valve____________________________________ One-Way Flow Control Valve __________________________________ Quick Exhaust Valve_________________________________________
Transparency 2 Transparency 3 Transparency 4 Transparency 5 Transparency 6 Transparency 7
Electropneumatic Components Conversion of Electrical Signals into Pneumatic Signals ___________ Transparency 8 Conversion of Pneumatic Signals into Electrical Signals ___________ Transparency 9 Switching Symbols for Valves ________________________________ Transparency 10 Directional Control Valves: Ports and Switching Positions_________ Transparency 11 Function Principle of a Solenoid Coil __________________________ Transparency 12 2/2-Way Solenoid Valve without Pilot Control __________________ Transparency 13 Solenoid Valves with Pilot Control ____________________________ Transparency 14 3/2-Way Single Solenoid Valve with Pilot Control _______________ Transparency 15 5/2-Way Single Solenoid Valve with Pilot Control _______________ Transparency 16 5/2-Way Double Solenoid Valve with Pilot Control_______________ Transparency 17 5/3-Way Solenoid Valve ____________________________________ Transparency 18 Electrical Components Power Supply Units ________________________________________ Transparency 19 Switching Contacts and Types of Actuation _____________________ Transparency 20 Types of Actuation of Switching Elements ______________________ Transparency 21 Switching Symbols for Solenoid Coils and Relays________________ Transparency 22 The Relay ________________________________________________ Transparency 23 Magnetic Proximity Switches (Reed Switches) __________________ Transparency 24 Electrical Output Devices____________________________________ Transparency 25 Logic Functions The AND Logic Function _____________________________________ Transparency 26 The OR Logic Function ______________________________________ Transparency 27
Contents
Electropneumatic Controller Control Chain _____________________________________________ Transparency 28 Direct Actuation of a Single-Acting Cylinder ____________________ Transparency 29 Indirect Actuation of a Double-Acting Cylinder __________________ Transparency 30 Electrical Memory Circuit Dominant Set ______________________ Transparency 31 Electrical Memory Circuit Dominant Reset ____________________ Transparency 32 Electropneumatic Memory Circuit with Double Solenoid Valve _____ Transparency 33 Stroke-Dependent Control___________________________________ Transparency 34 Pressure-Dependent Control _________________________________ Transparency 35 Circuit Diagram Design The Electropneumatic Circuit Diagram _________________________ Transparency 36 Circuit Diagram Structure ___________________________________ Transparency 37 Displacement-Step Diagram _________________________________ Transparency 38 Terminal Connection Diagram Terminal Connection Diagram ________________________________ Transparency 39 Checklist for the Terminal Connection Diagram__________________ Transparency 40 Special Features with the Connection of Solenoid Coils Protective Circuits for Inductive Loads _________________________ Transparency 41 Programmable Logic Controllers Alterable Controls__________________________________________ Transparency 42
Elements of a Control Chain The principle of the control chain is used for the preparation of the circuit diagram. Every element of a control chain has a certain task to perform in the processing and further transmission of signals. This structuring of a system into functional blocks has proven itself in the following tasks: Arrangement of the elements in the circuit diagram Definition of the nominal sizes, nominal current and nominal voltage of components Set-up and commissioning of the controller Identification of the components for maintenance work
Pneumatics/ Hydraulics Cylinders Motors Components
Electrics/ Electronics Electric motors Solenoids Linear motors Power contactors Power transistors Power thyristors
Working elements
Directional control valves
Control elements
Directional control valves Isolating valves Pressure valves Switches Push button actuators Limit switches Program module Sensors
Processing elements (Control elements)
Contactors Relays Electronic modules
Input elements
Switches Push button actuators Limit switches Program module Sensors Indicators/generators
Elements of a Control Chain
Pneumatics/ Hydraulics Cylinders Motors Components Directional control valves Directional control valves Isolating valves Pressure valves Switches Push button actuators Limit switches Program module Sensors Working elements
Electrics/ Electronics Electric motors Solenoids Linear motors Power contactors Power transistors Power thyristors Contactors Relays Electronic modules Switches Push button actuators Limit switches Program module Sensors Indicators/generators
Control elements
Processing elements (Control elements)
Input elements
Festo Didactic GmbH & Co.
TP 201, Transparency 01
Single-Acting Cylinder Compressed air is applied to only one side of the single-acting cylinder. The piston rod side of the cylinder is vented to atmosphere. Single-acting cylinders can perform work in only in the advance direction of travel. The piston rod is driven inwards by the force of a built-in spring or by external forces.
Piston End cap Reset spring Bearing cap Piston rod
Sealing ring Supply port Cylinder barrel
Exhaust port
Single-Acting Cylinder
Double-Acting Cylinder The double-acting cylinder is actuated in both directions with compressed air. It can perform work in both directions of movement. The force transmitted to the piston rod is greater during the advance stroke than during the return stroke.
Cylinder barrel Scraper ring
Bearing cap Piston End cap Piston rod
Double-Acting Cylinder
Non-return, Flow Control and Pressure Control Valves Non-return valves block the flow in one direction and release it in the opposite direction. A distinction is made between: Non-return valves Shuttle valves (OR) Dual pressure valves (AND) One-way flow control valves Quick exhaust valves Pressure control valves influence the pressure or are controlled through the size of the pressure. A distinction is made between: Pressure regulating valves Pressure relief valves Pressure sequence valves Sloping arrow the valve is adjustable
Non-return valves
Non-return valve (check valve) Non-return valve, spring-loaded Shuttle valve (OR function)
Dual pressure valve (AND function)
Quick exhaust valve One-way flow control valve Flow control valve Flow control valve (throttle valve), adjustable Pressure control valve Adjustable pressure regulating valve without relief port
1
2 3
Adjustable pressure regulating valve with relief port

2 1
Pressure sequence valve with external supply line
12 2 1
Pressure-relief valve
2 2
Pressure sequence valve-combination

1 12 3
Non-return, Flow Control and Pressure Control Valves

Non-return valves Non-return valve (check valve) Non-return valve, spring-loaded Shuttle valve (OR function) Dual pressure valve (AND function)
Quick exhaust valve One-way flow control valve Flow control valve Flow control valve (throttle valve), adjustable Pressure control valve Adjustable pressure regulating valve without relief port Adjustable pressure regulating valve with relief port
1
2 3
Pressure sequence valve with external supply line
1
12
2 1
Pressure-relief valve
2 2
Pressure sequence valve-combination

1 12
Pressure Regulating Valve Pressure regulators have the function of keeping the output pressure mainly constant, independent of variations in the input pressure and the air consumption. If the pressure rises at the outlet, the diaphragm moves against the spring force and the flow cross-section at the valve seat is reduced or closed. If the pressure drops at the outlet, the spring presses against the diaphragm and the passage cross-section at the valve seat is enlarged or opened. The output pressure is adjustable. The input pressure must be higher than the output pressure.
P1
P2
1
P1
P2
Pressure Regulating Valve
P1
P2
1
P1
P2
One-Way Flow Control Valve The check element blocks the flow of air in one direction, so that it flows across an adjustable throttle in this direction. The air flow from the opposite direction lifts the seal of the check element from the seat. The compressed air can flow almost unrestricted in this direction. The valve should be installed as close as possible to the cylinder.
1A
1V2
1V3
1V1
1Y1
1Y2
5 1 3
One-Way Flow Control Valve

1A
1V2
1V3
1V1
1Y1
1Y2
Quick Exhaust Valve Quick exhaust valves are used to achieve the maximum advance and retract speed of pneumatic cylinders. To increase the effectiveness of the valve, it should be mounted directly on the cylinder or in the immediate vicinity of the supply or exhaust ports of the cylinder.
1
1V2
1
1A
1A
2 3 1
1V2
3
1V1 1Y1
1V1 1Y2
Quick Exhaust Valve

3 3
2 1 3
1
1V2
1
1A
1A
2 3
1V2
3
1V1
1V1
1Y1
1Y2
Conversion of Electrical Signals into Pneumatic Signals If control systems are using compressed air and electricity as working mediums, converter systems must be used. Solenoid valves convert electrical signals into pneumatic signals. Solenoid valves consist of: A pneumatic valve A coil which switches the valve
3 2 1 unactuated actuated 2
3 1
Conversion of Electrical Signals into Pneumatic Signals

2 1 3
3 2 1 unactuated
3 2 1 actuated
Conversion of Pneumatic Signals into Electrical Signals The PE converter is actuated with compressed air. When the pressure reaches a preset value, an electric signal is generated. The pressure of a pneumatic signal works against an adjustable spring. If the pressure working against the diaphragm overcomes the spring force, a stem actuates an electrical switch contact. The electrical switching element can be normally closed, normally open or changeover contact.
14
14 actuated
14 unactuated
Conversion of Pneumatic Signals into Electrical Signals

14
14 actuated
14 unactuated
10
Switching Symbols for Valves Pneumatic components are normally shown in the deenergized condition in circuit diagrams. Valve switching positions are represented by a square. The number of squares corresponds to the number of switching positions. Functions and modes of operation are drawn inside the square: Lines indicate the flow paths. Arrows indicate the flow direction. Closed ports are represented by two lines drawn at right angles to one another. The connecting lines are drawn outside on the square.
The valve switching position is shown by a square.
The number of squares corresponds to the number of switching positions.
Lines indicate the flow paths, arrows indicate the direction of flow.
Closed ports are shown by two lines drawn at right angles to one another.
The connecting lines for supply and exhaust air are drawn outside the square.
Switching Symbols for Valves

The valve switching position is shown by a square.
The number of squares corresponds to the number of switching positions.
Lines indicate the flow paths, arrows indicate the direction of flow.
Closed ports are shown by two lines drawn at right angles to one another.
The connecting lines for supply and exhaust air are drawn outside the square.
11
Directional Control Valves: Ports and Switching Positions Information about the type of valve can be established from the following features: Number of ports Number of switching positions Port numbering The following applies to the numbering of the ports: Air supply port 1 Exhaust ports 3, 5 Working or outlet ports 2, 4
Number of ports Number of switching positions

2
2/2-way valve, normally open position

1 2
3/2-way valve, normally closed position

1 2 3

1 3 2
4/2-way valve flow from 1 2 and from 4 3 5/2-way valve flow from 1 2 and from 4 5
4
1 4
3 2
5 2
5/3-way valve, mid-position closed

5 1 3
Directional Control Valves: Ports and Switching Positions

Number of ports Number of switching positions
2

1 2
3/2-way valve, normally closed position

1 2 3

1 3 2
4/2-way valve flow from 1 2 and from 4 3 5/2-way valve flow from 1 2 and from 4 5
4
1 4
3 2
5 2
5/3-way valve, mid-position closed

5 1 3
12
Function Principle of a Solenoid Coil When an electric current flows through a coil, a magnetic field is generated. The following applies to the strength of the magnetic field: Increasing the number of windings increases the field. Increasing the strength of the current increases the field. Lengthening the coil reduces the field. A soft iron core (armature) is drawn into a coil through which a current is flowing.
Coil winding
Soft iron core
Function Principle of a Solenoid Coil

Coil winding
Soft iron core
13
2/2-Way Solenoid Valve without Pilot Control Normally-closed position, spring return Solenoid coil deenergized Port 1 is blocked. Port 2 is blocked. Exhausting is not possible. Solenoid coil energized The armature is raised. Compressed air flows from port 1 to port 2.
2/2-Way Solenoid Valve without Pilot Control
2
14
Solenoid Valves with Pilot Control Solenoid valves with pilot control consist of: An electromagnetically-actuated pilot control valve. A pneumatically-actuated main valve. In comparison with solenoid valves without a pilot control, solenoid valves with a pilot control are distinguished by: Lower force required to actuate the armature. Smaller dimensions of the coil head. Lower power consumption. Less heat generated.
An electrical signal is applied to the solenoid coil The solenoid coil actuates the pilot control valve
The pilot control actuates the valve
Solenoid Valves with Pilot Control
An electrical signal is applied to the solenoid coil
15
3/2-Way Single Solenoid Valve with Pilot Control Normally-closed position, spring return, manual override Solenoid coil deenergized Port 1 is blocked. Port 2 is vented to port 3. The pilot control channel is blocked by the armature seal on the valve side. The space above the valve piston is vented through the armature guide tube. Solenoid coil energized The armature is lifted and the armature seal on the coil side blocks the vent hole in the armature guide tube, while the armature seal on the valve side opens the pilot control channel. Compressed air from port 1 flows through the pilot control channel and actuates the valve piston. Port 3 is blocked. Compressed air flows from port 1 to port 2.
3 2 1 2
3 1
3/2-Way Single Solenoid Valve with Pilot Control

2 1 3
3 2 1 2
3 1
16
5/2-Way Single Solenoid Valve with Pilot Control Spring returned, manual override Solenoid coil deenergized Compressed air flows from port 1 to 2. Port 4 is vented to 5. Port 3 is blocked. The pilot control channel is blocked. The space above the valve piston is vented through the armature guide tube. Solenoid coil energized The armature is lifted and the armature seal on the coil side blocks the vent in the armature guide tube, while the armature seal on the valve side opens the pilot control channel. Compressed air from port 1 flows through the pilot control channel and actuates the valve piston. Port 5 is blocked. Compressed air flows from port 1 to port 4. Port 2 is vented to port 3.
4 14 84 5 1
14 84 5 4 1 2 3
14 84 5 1 3 4 2
14 84 5 4 1 2 3
5/2-Way Single Solenoid Valve with Pilot Control

4 2
14
84 5
1
14 84 5 4 1 2 3
14
84 5
1
14 84
3
17
5/2-Way Double Solenoid Valve with Pilot Control Manual override Solenoid coil Y1 energized, solenoid coil Y2 deenergized The valve switches over. Port 3 is blocked. Compressed air flows from Port 1 to Port 2. Port 4 is vented to Port 5. Both solenoid coils deenergized The valve retains its previous switching position. Solenoid coil Y2 energized, solenoid coil Y1 deenergized The valve switches over. Port 5 is blocked. Compressed air flows from port 1 to port 4. Port 2 is vented to port 3.
4 14 84 5 1
2 12 3 82
14 84 5 4 1 2 3 82
12
4 14 84 5 1 3 82 2 12
14 84 5 4 1 2 3 82
12
5/2-Way Double Solenoid Valve with Pilot Control

4 2
14
84 5
1
12
3 82
14 84 5 4 1 2 3 82
12
4 2
14
84 5
1
12
3 82
14 84
12 5 4 1 2 3 82
18
5/3-Way Solenoid Valve The three switching positions of an electrically-actuated pilot-controlled 5/3-way valve: 1. In the normal position, the solenoid coils are deenergized and the piston is centered in its mid-position by the two springs. Ports 2 and 3 as well as 4 and 5 are connected. Port 1 is blocked. 2. If current is applied to the lefthand solenoid coil, the piston moves to the right. Ports 1 and 4 as well as 2 and 3 are connected with each other. 3. If current flows through the righthand solenoid coil, the piston moves to the left. In this position, Ports 1 and 2 as well as 4 and 5 are connected. Each of the two actuated switching positions is held as long as current flows through the corresponding solenoid coil. If the flow of current is interrupted, the piston switches back to the mid-position.
4 14 84 5
2 12 13 82
14 84 5 4 1 2 3 82
12
4 14 5 84 1 3 82 2 12
14 84 5 4 1 2 3 82
12
14 84
2 12
1 3 82
14 84 5 4 1 2 3 82
12
5/3-Way Solenoid Valve

4 14 14 84 5 13 82 2 12
14 84 5 4 1 2 3 82
12
4 14 14 5 84 13 82 2 12
14 84 5 4 1 2 3 82
12
14 14 84
2 12
13 82
14 84 5 4
12 1 2 3 82
19
Power Supply Units It is necessary to distinguish between an alternating current and a direct current power supply. Alternating current
Is supplied from the mains 3-phase or single-phase form Sinusoidal-shaped voltage of fixed frequency Relatively constant amplitude Voltage change through transformers
Direct current
Is supplied by power supply devices

Modules of direct current power supply devices Mains transformer Rectifier Stabilization Batteries and rechargeable batteries Used for buffering in case of mains failure. Used in portable devices.
Alternating current
Direct current
Battery
+
Transformer
Rectifier Power supply unit
Stabilizer
Power Supply Units

Alternating current Direct current Battery
+
Transformer
Rectifier Power supply unit
Stabilizer
20
Switching Contacts and Types of Actuation The following switch contact designs are used as input and processing elements: Normally-open contact Normally-closed contact Changeover contact Types of actuation for switching elements are: Manual Mechanical Relay Magnet field
Normally-open contacts
Normally-closed contacts
Changeover switch
Mechanically connected contacts
Push-button with normally open contacts manually actuated by pushing
Rotary switch with normally open contacts manually actuated by turning
Limit switch with normally open or normally closed contacts, mechanically actuated
Switching Contacts and Types of Actuation

Normally-open contacts Normally-closed contacts Changeover switch Mechanically connected contacts
Push-button with normally open contacts manually actuated by pushing
Rotary switch with normally open contacts manually actuated by turning
Limit switch with normally open or normally closed contacts, mechanically actuated
21
Types of Actuation of Switching Elements Frequently used types of actuation are Pushbuttons Roller levers Roller lever with idle return Two types of actuation are shown Pushbutton, as changeover switch Latching rocker switch, as normally-open contact Identifying letters in electrical circuit diagrams: S (S1, S2, ...)
Type of actuation (push-button)

1
Switching element
Connection (normally-closed contact) Connection (normally-open contact)

3
3
4
Types of Actuation of Switching Elements

2 4
Type of actuation (push-button) Switching element Connection (normally-closed contact) Connection (normally-open contact)
4
4
22
Switching Symbols for Solenoid Coils and Relays In electropneumatics, the solenoid coil is the element that switches the valves. Identifying letters in electrical circuit diagrams: Y (Y1, Y2, ...) A relay switches 1, 2 or more contacts. The relay can also be a time or temperaturecontrolled element. Identifying letters in electrical circuit diagrams: K (K1, K2, ...)
Electro-magnetically actuated on both sides
Electro-magnetically actuated on one side, with spring return
Representation in electrical circuit diagrams

Y1
Electro-magnetically actuated, with pilot control
Contactor or relay with 3 normally open contacts and 1 normally closed contact
K1
Switching Symbols for Solenoid Coils and Relays

Electro-magnetically actuated on both sides Electro-magnetically actuated on one side, with spring return Representation in electrical circuit diagrams
Y1
Electro-magnetically actuated, with pilot control
Contactor or relay with 3 normally open contacts and 1 normally closed contact
K1
23
The Relay In practice, the construction of a relay can be very different, but the function is nevertheless the same in principle: When a voltage is applied to the relay coil through contacts A1 and A2, an electric current flows through the windings. A magnetic field is built up and pulls the armature against the core of the coil. Switch contact 1 is connected with switch contact 4. After removing the voltage, the armature is brought back into its initial position by a spring. Switching contact 1 is connected with switching contact 2. A relay can have multiple switching contacts which can be actuated simultaneously. There are the following types, for example: Polarised relay Current impulse relay Time relay Thermal relay
12 14 22 24
Return spring Relay coil Armature
A1 A2 11 21
Coil core Insulation Contact
A1 A2
4 2
The Relay
Return spring Relay coil Armature Coil core Insulation Contact
A1 A2 11 21 12 14 22 24
A1 A2
4 2
1
24
Magnetic Proximity Switches (Reed Switches) Reed switches are actuated through a magnetic field. In industrial applications, most reed switches are used with LED displays. The illustration shows a three-wire reed switch. It has three connections: One connection for the positive power supply One connection for the negative power supply One signal or switch output The reed switch is attached directly to the body of a cylinder. It is actuated by a magnetic ring on the cylinder piston. When the magnetic ring moves past the reed switch, the switching contacts are closed as a result of the magnetic field and thus provide an output signal. Identifying letters in electrical circuit diagrams: B (B1, B2, ...)
+24V BN BK
BU 0V
Magnetic Proximity Sensors (Reed Switches)

+24V BN BK
BU 0V
25
Electrical Output Devices Supply acoustic signals: For example, horns, sirens Identifying letters in electrical circuit diagrams: Supply optical signals: For example, lamps, LEDs Identifying letters in electrical circuit diagrams: Do work: For example, electric motors Identifying letters in electrical circuit diagrams:
H (H1, H2, ...)
H (H1, H2, ...)
M (M1, M2, ...)
Signalling device Audible indicator: Horn Siren Bell
Illuminating indicators:
Lamp
Light emitting diode (LED)
Motors DC motor
M
Electrical Output Devices

Signalling device
Audible indicator:
Horn
Siren
Bell
Illuminating indicators:
Lamp
Light emitting diode (LED)
Motors
DC motor
M
26
The AND Logic Function The AND logic function consists of at least two switching elements connected in series: The AND logic function can have two or more inputs. A combination of switches and sensors may be involved. The function is represented through a logic symbol with two inputs and one output. Both input signals must be present to switch the output.
+24V S1 S2
Input 1 (S1) Input 2 (S2)
&
Output (lamp H1)
H1 0V
The AND Logic Function

1 S1 S2 H1 0V
+24V
Input 1 Input 2
&
Output
27
The OR Logic Function The OR logic function consists of at least two switching elements connected in parallel: The OR logic function can have two or more inputs. A combination of switches and sensors may be involved. The function is represented through a logic symbol with two inputs and one output. Only one input signal needs to be present to switch the output.
+24V S1
S2
Input 1 (S1) Input 2 (S2)
Output (lamp H1)
H1 0V
The OR Logic Function

1 S1 S2 2
+24V
Input 1 Input 2
H1 0V
Output
28
Control Chain The structure of the control chain supports: The allocation of components with comparable functions to a group of elements. The avoidance of lines crossing each other in pneumatic and electrical circuit diagrams. The preparation of clearly structured and uniformly designed circuit diagrams. The principle of the control chain should be understood as being only a guideline. The signal flow of the control system defines the structure of the control chain: In the pneumatic circuit diagram, the signal flow is represented from bottom to top. In the electrical circuit diagram, the signal flow is represented from top to bottom.
1A
+24V S1
2 Signal input Signal flow
Signal flow
1V1 1Y1
S2 Signal processing Signal output
K1
K1
1Y1 0V
2
Control Chain
1A
+24V S1
2 Signal input
1V1
S2 K1 K1 1Y1 0V
2
1Y1
5 1 3
Signal processing Signal output
29
Direct Actuation of a Single-Acting Cylinder After actuating S1, current flows through the coil 1Y1, which switches the valve 1.1. Compressed air flows from port 1 to port 2, and the piston rod advances. If S1 is no longer actuated, there is no current through coil 1Y1. Valve 1.1 switches back into the initial position. The cylinder is vented through port 3 of valve 1.1, and the piston rod retracts.
1A
+24V S1
1V1 1Y1
1Y1 0V
Direct Actuation of a Single-Acting Cylinder

1A
+24V S1
1V1
1Y1
1Y1 0V
30
Indirect Actuation of a Double-Acting Cylinder The use of indirect actuation depends upon: The force which is required for the actuation of the positioner The complexity of the circuit The switching power of the contacts Whether or not the system is remote controlled
1A
+24V S1
1
13 14
2
13 14
K1
1V1 1Y1
A1
K1
A2
1Y1
0V
Indirect Actuation of a Double-Acting Cylinder

1A
+24V S1
1
13 14
1V1
1Y1
1Y1 0V
31
Electrical Memory Circuit Dominant Set A relay can be held in the switched condition if a holding current path is switched in parallel to the ON pushbutton through an internal normally-open contact in the relay. An OFF pushbutton must be built into the memory circuit. The installed position of the OFF pushbutton determines the function of the memory circuit. A memory circuit in which a pushbutton (S2, normally-closed) is connected in series with a relay holding contact (normally-open) is a dominating set memory circuit. In this dominating set memory circuit, the pushbutton S1 dominates the pushbutton S2. If S1 and S2 are pressed simultaneously, current flows through the relay coil K1.
+24V S1
2
13 14
3
23 24
K1 S2
K1
K1 0V
2 3
H1
Electrical Memory Circuit Dominant Set

+24V S1 1 K1 S2 2
13 14
3 K1
23 24
K1 0V
2 3
H1
32
Electrical Memory Circuit Dominant Reset A relay can be held in the switched condition if a holding current path is switched in parallel to the ON pushbutton to the relay coil through an internal normally-open contact in the relay. An OFF pushbutton must be built into the memory circuit. The installed position of the OFF pushbutton determines the function of the memory circuit. A memory circuit in which a pushbutton (S1, normally-open) and a relay holding contact (normally-open) are connected in parallel and then in series with a pushbutton (S2, normally-closed) is a dominating reset memory circuit. In this dominating reset memory circuit, the pushbutton S2 dominates the pushbutton S1. If S1 and S2 are pressed simultaneously, no current flows through the relay coil K1.
+24V S1
2
13 14
3
23 24
K1
K1
S2
K1 0V
2 3
H1
Electrical Memory Circuit Dominant Reset

+24V S1 1 K1 2
13 14
3 K1
23 24
S2 K1 0V
2 3
H1
33
Electropneumatic Memory Circuit with Double Solenoid Valve Double solenoid valves are also called bistable valves or memory valves: The valve illustrated is actuated by two solenoid coils. The valve retains the switched position brought about through energising one of the coils, even when the signal to switch the valve is cancelled. The switched position is reversed only when a signal is applied to the opposite coil or a manual override is operated. To reverse the switched position, a signal only needs to be applied to one coil.
1A
1S2
+24V
S1
1V1 1Y1
5 1 3 4 2
1S2
K1
K2
1Y2
K1
K2
1Y1
1Y2
0V
3 4
Electropneumatic Memory Circuit with Double Solenoid Valve

1A 1S2
+24V S1
1 1S2
2 K1
3 K2
1V1
1Y1
1Y2
K1
K2
1Y1
1Y2
0V
3 4
34
Stroke-Dependent Control Limit switches with roller lever actuation are frequently used to check the position of pneumatic actuators in simple circuits. The use of limit sensors in a control depends upon the required accuracy of the sensor. Decisive factors are: The reliability The safety The complexity of the circuit
1A
1S1
1S2
+24V
S1
1V1 1Y1
5 1 3 4 2
1S2
K1
K2
1S1
1Y2
K1
K2
1Y1
1Y2
0V
3 4
Stroke-Dependent Control
1A 1S1 1S2
+24V S1
1 1S2
2 K1
3 K2
1V1
1Y1
1Y2
1S1 K1 K2 1Y1 1Y2
0V
3 4
35
Pressure-Dependent Control A pneumatic-electric signal converter measures the air pressure in the supply line of cylinder 1A and compares it with a preset value. As soon as this value is reached, the signal converter generates an electrical signal.
1A
1B2
+24V
1 1B2
3 1B1 p
1B1
S1
K1
K2 K3
1V1 1Y1
1Y2
5 1 3
K1
K2
K3
1Y1
1Y2
0V
5 6 6
Pressure-Dependent Control
1A
1B2
+24V S1
1
1B2
3 1B1 p
6 K1 K2 K3
1B1
1V1
1Y1
1Y2
K1
K2
K3
1Y1
1Y2
0V
5 6 6
36
The Electropneumatic Circuit Diagram The pneumatic and electrical parts of an electropneumatic circuit diagram are prepared separately, but their contents are closely related. In the pneumatic part, signal flow is presented from bottom to top. In the electrical part, signal flow is presented from top to bottom. In the electrical circuit diagram, the current paths are numbered consecutively from left to right. The common circuit diagram elements form the interfaces between the pneumatic and the electrical circuits. In this case, they are the coils 1Y1 and 2Y1, as well as the limit sensors 1B1, 1B2, 2S1 and 2S2.
1B1
1A
1B2
2A
2S1
2S2
1V1 1Y1
2V1 2Y1
+24V 1B1
2 1B2
4 Start K1
5 K3
6 K2
7 K4
8 2S2
9 K5
10 2S1
11 K3
12 K4
13
K6 K1 0V
5 7 6 7 12
K3 K4
K4 K5
K5 K6 1Y1 2Y1
K5
K2
K3
8 9 13
13 10 11
The Electropneumatic Circuit Diagram

1B1 1A 1B2 2A 2S1 2S2
1V1
2V1
1Y1
2Y1
+24V 1B1
2 1B2
4 Start K1 K6
5 K3
6 K2
7 K4
8 2S2
9 K5
10 2S1
11 K3
12 K4
13
K3 K4
K4 K5
K5 K6 1Y1 2Y1
K5
K1 0V
5
K2
K3
6 7 12
8 9 13
13 10 11
37
Circuit Diagram Structure The electropneumatic circuit diagram consists of two parts: Pneumatic Electrical Pneumatic
The arrangement of the components follows the signal flow accordingly from bottom to top. Cylinders and valves are drawn horizontally. The outward travel motion of cylinders should be from left to right. The arrangement of the components follows the signal flow accordingly from top to bottom. The electrical circuit diagram can be subdivided into a control part and a power part.
Electrical
Control section
1A 1S2
Power section 3 4
+24V
S1
1V2
1S2
K1
K2
K2
1V1 1Y1
5 4 2
1Y2 0Z
1 3
K1
K2
1Y1
1Y2
0V
3 4
Circuit Diagram Structure
1A
1S2
+24V S1
1 1S2 K2
2 K1
3 K2
1V2
1V1
1Y1
0Z
5 1 3
1Y2
K1
K2
1Y1
1Y2
0V
3 4
38
Displacement-Step Diagram In a displacement-step diagram, the motion sequences of an actuator in a control system are presented graphically: Movements of the cylinder within a step are represented by a line moving diagonally upwards (advancing) or downwards (retracting). Horizontal lines represent the position of the cylinder in the advanced or retracted end position. If the movements of several actuators are to be represented, they are arranged under each other for every individual step. This arrangement clarifies the relationship between the movements of the individual actuators in every step.
Step 1 1 1A 0 1 2A 0 2 3 4 5=1
Displacement-Step Diagram
Step 1 1A 0 1 2A 0 1 2 3 4 5=1
39
Terminal Connection Diagram The terminal connection diagram shows the physical implementation of the current circuit. The identifications used in the circuit diagram are used in the terminal connection diagram. The terminal points and the cables are numbered. This facilitates the setting-up of the controller as well as troubleshooting and maintenance.
1B1
1A
1S2
Machine
Target
Control cabinet
Target Terminal no. X1 Component code
X1 X1 X1 K2 X1 K1 K2 X1 X1 K1 X1 X1 K1 X1 K2 K2 X1
Component code
Connection code
1Y1
5 1 3
+24V
X1-1 X1-9
2
X1-2 X1-12
3
X1-3 X1-14 3 4 11 14 A1 A2
4
X1-4 1 2 11 14 X1-16
+24V
1B1
S1
X1-13
1S2
X1-15
K2
21 24
0V
K1
X1-11 X1-10 A1 A2
K2
K1
X1-5 X1-6
K2
X1-7
1Y1
X1-17 X1-8
0V
3 4 5
1B1 1B1 1B1 S1 S1 1S2 1S2 1Y1 1Y1
+ 3 4 1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Connection code
1V1
Jumper
9 12 14 21 11 A2 A2 17 1 A1 5 2 11 3 11 24 8
Terminal Connection Diagram

1B1 1A 1S2
Machine
Target
Control cabinet
Target
Terminal no. X1
Component code
Connection code
1Y1
+24V
X1-1 X1-9
2
X1-2 X1-12
3
X1-3 X1-14 3 4 11 14 A1 A2
4
X1-4 1 2 11 14 X1-16
+24V
1B1
S1
X1-13 X1-11 X1-10 A1 A2
1S2
X1-15
K2
21 24
0V
K1
K2
K1
X1-5 X1-6
K2
X1-7
1Y1
X1-17 X1-8
0V
3 4 5
1B1 1B1 1B1 S1 S1 1S2 1S2 1Y1 1Y1
+ 3 4 1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
X1 X1 X1 K2 X1 K1 K2 X1 X1 K1 X1 X1 K1 X1 K2 K2 X1
Connection code
9 12 14 21 11 A2 A2 17 1 A1 5 2 11 3 11 24 8
Component code
1V1
Jumper
40
Checklist for the Terminal Connection Diagram In the preparation of a terminal connection diagram, the structure of the control should be checked once again: Is every current path connected to the positive +24V bus bar through a terminal? Is every current path connected to the negative 0 V bus bar through a terminal? Are all external components, such as switches, sensors and valve coils connected with one terminal per connection to the current circuit? Are all connections to the +24 V and 0 V shown in the terminal connection diagram? Are all external components included in the terminal connection diagram provided with their connection identifications? Check all current paths systematically and complete the terminal connection diagram. Note that not all connections such as the relay contacts, for example must be included in the terminal connection diagram.
Each current path must be connected
Enter all external components with the
to the positive +24 V rail via a terminal.

designation of the connection in the terminal connection diagram.

Systematically check all current paths
to the negative 0 V rail via a terminal. External components, such as switches, sensors and solenoids are each connected via one terminal per unit. Identify the connection point for +24 V and 0 V in the wiring diagram.
and complete the wiring diagram.

Note:
Not all of the connections have to be entered in the wiring diagram (e.g. relay connections are exempt).
Checklist for the Terminal Connection Diagram

Each current path must be connected Enter all external components with the
to the positive +24 V rail via a terminal.
designation of the connection in the terminal connection diagram. and complete the wiring diagram.
to the negative 0 V rail via a terminal. sensors and solenoids are each connected via one terminal per unit. and 0 V in the wiring diagram.
Systematically check all current paths Note:
External components, such as switches,
Identify the connection point for +24 V
Not all of the connections have to be entered in the wiring diagram (e.g. relay connections are exempt).
41
Protective Circuits for Inductive Loads If the current flowing to an inductive load, for example, a solenoid coil, is interrupted, the magnetic field collapses. A high induction voltage can be generated which can have the following effects: Damage to the coil insulation Burning of contacts This can be avoided through protective circuits using diodes.
I1
I1 = 0
IM = I1 +24V 0V
ID = 0
IM +24V 0V
ID = IM
Protective Circuits for Inductive Loads
I1
I1 = 0
IM = I1 +24V 0V
ID = 0
IM +24V 0V
ID = IM
42
Alterable Controls Relay-controlled systems are hard wired. The relay control can be replaced in whole or in part by a programmable controller. The structure of a system that is controlled via a programmable logic controller (PLC) is similar to that of a relay-controlled system. Both systems can be subdivided as follows: Signal input Signal processing Signal output The signal processing part is the part that can be hard wired or freely programmable.
Signal input
Switch S1 S2 S3 S4
Signal processing
Relays K1 K2 K3 K4 K3 K4 Contacts K1 K2
Signal output
H1
H2
S1 S2 S3 S4
E1 E2 E3 E4
Program: WHEN THEN OTHERWISE WHEN THEN OTHERWISE
AND SET RESET
E0.1 E0.2 A0.1 A0.1 E0.3 E0.4 A0.2 A0.2
A1
H1
AND SET RESET
A2
H2
Processor
Inputs
Outputs
Alterable Controls
Signal input
Switch S1 S2 S3 S4
Signal processing
Relays K1 K2 K3 K4 K3 K4 Contacts K1 K2
Signal output
H1
H2
S1 S2 S3 S4
E1 E2 E3 E4
Program: WHEN
AND
E0.1 E0.2 A0.1 A0.1 E0.3 E0.4 A0.2 A0.2
A1
H1
THEN SET OTHERWISE RESET WHEN AND
THEN SET OTHERWISE RESET
A2
H2
Inputs
Processor
Outputs

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Fundamentals of Electropneumatics Collection of Transparencies

Order No.: Description: Designation: Edition: Author: Graphics: Layout:

Festo Didactic GmbH & Co. Electropneumatics

Transparency 2 Transparency 3 Transparency 4 Transparency 5 Transparency 6 Transparency 7

Festo Didactic GmbH & Co. Electropneumatics

Festo Didactic GmbH & Co. Electropneumatics

Pneumatics/ Hydraulics Cylinders Motors Components

Directional control valves

Processing elements (Control elements)

Contactors Relays Electronic modules

Festo Didactic GmbH & Co. Electropneumatics

Elements of a Control Chain

Processing elements (Control elements)

Festo Didactic GmbH & Co.

Piston End cap Reset spring Bearing cap Piston rod

Sealing ring Supply port Cylinder barrel

Festo Didactic GmbH & Co. Electropneumatics

Festo Didactic GmbH & Co.

Cylinder barrel Scraper ring

Bearing cap Piston End cap Piston rod

Festo Didactic GmbH & Co. Electropneumatics

Festo Didactic GmbH & Co.

Dual pressure valve (AND function)

Adjustable pressure regulating valve with relief port

Pressure sequence valve with external supply line

Pressure sequence valve-combination

Festo Didactic GmbH & Co. Electropneumatics

Non-return, Flow Control and Pressure Control Valves

Pressure sequence valve with external supply line

Pressure sequence valve-combination

Festo Didactic GmbH & Co. Electropneumatics

Pressure Regulating Valve

Festo Didactic GmbH & Co.

Festo Didactic GmbH & Co. Electropneumatics

One-Way Flow Control Valve

Festo Didactic GmbH & Co.

Festo Didactic GmbH & Co. Electropneumatics

Quick Exhaust Valve

Festo Didactic GmbH & Co.

Festo Didactic GmbH & Co. Electropneumatics

Conversion of Electrical Signals into Pneumatic Signals

Festo Didactic GmbH & Co. Electropneumatics

Conversion of Pneumatic Signals into Electrical Signals

The valve switching position is shown by a square.

The number of squares corresponds to the number of switching positions.

Festo Didactic GmbH & Co. Electropneumatics

Switching Symbols for Valves

The number of squares corresponds to the number of switching positions.

Festo Didactic GmbH & Co.

Number of ports Number of switching positions

2/2-way valve, normally open position

3/2-way valve, normally closed position

3/2-way valve, normally open position

5/3-way valve, mid-position closed

Festo Didactic GmbH & Co. Electropneumatics

Directional Control Valves: Ports and Switching Positions

2/2-way valve, normally open position

3/2-way valve, normally closed position

3/2-way valve, normally open position

5/3-way valve, mid-position closed

Festo Didactic GmbH & Co.

Soft iron core