551150 Leseprobe En

WorkbookTP 601

CD-ROM included

Festo Didactic

551150 EN

ElectrohydraulicsBasic Level

1A1

0V10Z1

1V1 A

TP

B

1M1

1A1

1Z2

1V2

A

B

1Z1

K1 1M1

24 V 1 2

0 V

S113

14

A1

A2

K114

11

12

12

22

32

42

.214

24

34

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11

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Order no.: 551150

Date: 05/2011

Author: Renate Aheimer, Eberhard Bauer, Frank Ebel,

Christine Löffler, Dieter Merkle, Helmut Werner

Graphics Doris Schwarzenberger

Layout: 09/2011, Beatrice Huber, Susanne Durz

© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2013

Internet: www.festo-didactic.com

E-mail: [email protected]

The purchaser shall receive a single right of use which is non-exclusive, non-time-limited and limited

geographically to use at the purchaser's site/location as follows.

The purchaser shall be entitled to use the work to train his/her staff at the purchaser's site/location and

shall also be entitled to use parts of the copyright material as the basis for the production of his/her own

training documentation for the training of his/her staff at the purchaser's site/location with

acknowledgement of source and to make copies for this purpose. In the case of schools/technical colleges

and training centres, the right of use shall also include use by school and college students and trainees at

the purchaser's site/location for teaching purposes.

The right of use shall in all cases exclude the right to publish the copyright material or to make this available

for use on intranet, Internet and LMS platforms and databases such as Moodle, which allow access by a

wide variety of users, including those outside of the purchaser's site/location.

Entitlement to other rights relating to reproductions, copies, adaptations, translations, microfilming and

transfer to and storage and processing in electronic systems, no matter whether in whole or in part, shall

require the prior consent of Festo Didactic GmbH & Co. KG.

© Festo Didactic GmbH & Co. KG 551150 III

Table of contents

Use for intended purpose __________________________________________________________________ V

Preface _________________________________________________________________________________ VI

Introduction ____________________________________________________________________________ VIII

Work instructions and safety precautions _____________________________________________________ IX

Training package for electro-hydraulics, basic level (TP 601) ____________________________________ XI

Learning objectives, electro-hydraulics ______________________________________________________ XII

Allocation of learning objectives to exercises __________________________________________________ XIV

Equipment set _________________________________________________________________________ XVII

Allocation of components to exercises _______________________________________________________ XXI

Notes for the teacher/trainer ______________________________________________________________ XXII

Structure of the exercises ________________________________________________________________ XXIII

Component designations _________________________________________________________________ XXIII

CD ROM contents _______________________________________________________________________ XXIV

Exercises and solutions

Exercise 1: Setting up a hydraulic workstation ________________________________________________ 1

Exercise 2: Commissioning a two-column hydraulic press ____________________________________ 11

Exercise 3: Feeding pressings ___________________________________________________________ 19

Exercise 4: Sorting out crates ___________________________________________________________ 35

Exercise 5: Actuating a lifting platform ____________________________________________________ 51

Exercise 6: Clamping valve manifolds _____________________________________________________ 65

Exercise 7: Clamping engine blocks ______________________________________________________ 83

Exercise 8: Bending metal tubing ________________________________________________________ 95

Exercise 9: Press fitting a gear unit bearing _______________________________________________ 107

Exercise 10: Chamfering workpieces ______________________________________________________ 123

Exercise 11: Opening and closing a hardening furnace door ___________________________________ 135

Exercise 12: Deep drawing sheet metal parts _______________________________________________ 151


Exercise 14: Transporting containers _____________________________________________________ 177

Exercise 15: Eliminating a malfunction at a container handling unit _____________________________ 191

IV © Festo Didactic GmbH & Co. KG 551150

Exercises and worksheets Exercise 1: Setting up a hydraulic workstation ________________________________________________ 1















© Festo Didactic GmbH & Co. KG 551150 V

Use for intended purpose

The training package for basic level electro-hydraulics may only be used:

• For its intended purpose in teaching and training applications

• When its safety functions are in flawless condition

The components included in the training package are designed in accordance with the latest technology, as

well as recognised safety rules. However, life and limb of the user and third parties may be endangered, and

the components may be impaired, if they are used improperly.

The training system from Festo Didactic has been developed and manufactured exclusively for training and

vocational education in the fields of automation and technology. The respective training companies and/or

trainers must ensure that all trainees observe the safety precautions which are described in this workbook.

Festo Didactic hereby excludes any and all liability for damages suffered by trainees, the training company

and/or any third parties, which occur during use of the equipment set in situations which serve any purpose

other than training and/or vocational education, unless such damages have been caused by Festo Didactic

due to malicious intent or gross negligence.

VI © Festo Didactic GmbH & Co. KG 551150

Preface

Festo Didactic’s training system for automation and technology is geared towards various educational

backgrounds and vocational requirements. Correspondingly, the training system is broken down as follows:

• Technology oriented training packages

• Mechatronics and factory automation

• Process automation and control technology

• Mobile robotics

• Hybrid learning factories

The training system for automation and technology is continuously updated and expanded in accordance

with developments in the field of education, as well as actual professional practice.

The technology packages deal with various technologies including pneumatics, electro-pneumatics,

hydraulics, electro-hydraulics, proportional hydraulics, programmable logic controllers, sensor technology,

electrical engineering, electronics and electric drives.

The modular design of the training system allows for applications which go above and beyond the

limitations of the individual training packages. For example, PLC actuation of pneumatic, hydraulic and

electric drives is possible.

© Festo Didactic GmbH & Co. KG 551150 VII

All training packages are comprised of the following elements:

• Hardware

• Media

• Seminars

Hardware Hardware included in the training packages consists of industrial components and systems that are

specially designed for training purposes. The selection and design of the components encompassed by the

training packages are especially well matched to the projects included in the accompanying media.

Media The media provided for the individual groups of topics are allocated to the teachware and software

categories. The practically oriented teachware includes:

• Technical books and textbooks (standard works for imparting basic knowledge)

• Workbooks (practical exercises with supplementary instructions and sample solutions)

• Lexicons, manuals and technical books

(which provide technical information on groups of topics for further exploration)

• Transparency sets and videos (for easy-to-follow, dynamic instruction)

• Posters (for clear-cut representation of facts)

From the software category, programmes are made available for the following applications:

• Digital training programmes (didactically and medially prepared learning content)

• Simulation software

• Visualisation software

• Software for measurement data acquisition

• Project engineering and design engineering software

• Programming software for programmable logic controllers

The teaching and learning media are available in several languages. They are intended for use in classroom

instruction, but are also suitable for self-study.

Seminars Comprehensive seminar offerings covering the contents of the training packages round out the programme

for training and vocational education.

Do you have suggestions or criticism regarding this manual?

If so, send us an e-mail at [email protected].

The authors and Festo Didactic look forward to your feedback.

VIII © Festo Didactic GmbH & Co. KG 551150

Introduction

This workbook is part of the training system for automation technology from Festo Didactic GmbH & Co. KG.

The system provides a solid basis for practice oriented training and vocational education. Training packages

TP 601 and TP 602 include electro-hydraulic controllers only.

The TP 601 basic level is suitable for fundamental training in the field of electro-hydraulic control

technology. On the basis of practically oriented problems, the workbook imparts knowledge regarding the

basic physical principles of electro-hydraulics, function and use of electro-hydraulic components and typical,

basic electrical circuits. Simple electro-hydraulic controllers can be set up with the equipment set. Basic

knowledge of hydraulic device technology is a prerequisite. The TP 602 advanced level is targeted at

vocational training in the field of electro-hydraulic control technology. More advanced electro-hydraulic

circuits can be set up with this equipment set.

Technical prerequisites for setting up the controllers include:

• A Learnline or Learntop-S workstation equipped with a Festo Didactic slotted profile plate. The slotted

profile plate has 14 parallel T-slots at 50 mm intervals.

• A hydraulic power unit (operating voltage: 230 V, 50 Hz, operating pressure: 6 MPa (60 bar),

volumetric flow: 2 l/min.)

• A power pack with short-circuit protection (input: 230 V, 50 Hz, output: 24 V, max. 5 A)

• Laboratory safety cables

Each of the circuits for all 15 exercises is set up using the TP 601 equipment set. The theoretical

fundamentals for understanding these exercises are included in the textbooks:

• Hydraulics, basic level

• Electro-hydraulics, basic level

Data sheets for the individual components are also available (cylinders, valves, sensors etc.).

© Festo Didactic GmbH & Co. KG 551150 IX

Work and safety instructions

General • Trainees should only work with the circuits under the supervision of a trainer.

• Observe specifications included in the technical data for the individual components, and in particular all

safety instructions!

• Faults which may impair safety must not be generated in the training environment and must be

eliminated immediately.

Mechanical system • Only reach into the setup when it is at a complete standstill.

• Mount all of the components securely onto the slotted profile plate.

• Limit switches may not be actuated frontally.

• Danger of injury during troubleshooting!

Use a tool to actuate the limit switches, for example a screwdriver.

• Set all components up so that activation of switches and disconnectors is not made difficult.

• Adhere to the instructions regarding positioning of the components.

• Always set up cylinders together with the appropriate cover.

Electrical specifications • Use extra-low voltage only (max. 24 V DC).

• Electrical connections may only be established in the absence of voltage.

• Electrical connections may only be interrupted in the absence of voltage.

• Only use connecting cables with safety plugs for electrical connections.

• Pull the plug only when disconnecting connector cables – never pull the cable.

Hydraulics • Limit system pressure to 6 MPa (60 bar).

• Maximum permissible pressure for all devices included in the training package is 12 MPa (120 bar).

• In the case of double-acting cylinders, pressure could be increased relative to surface area ratio due to

pressure boosting. With a surface area ratio of 1:1.7 and a system pressure of 6 MPa (60 bar), this may

result in a pressure value of greater than 10 MPa (100 bar).

• All valves, devices and hose lines are equipped with self-sealing quick-release couplings.

X © Festo Didactic GmbH & Co. KG 551150

• Danger of injury when switching on the hydraulic power unit!

Cylinders may advance and retract automatically.

• Hose line couplings

– Never connect or disconnect hose lines when the hydraulic power unit is running, or while under

pressure!

Couplings must be connected in the unpressurised state.

– Set the coupling socket vertically onto the coupling nipple!

The coupling socket and the coupling nipple must not be fitted askew.

• Setting up hydraulic circuits

– The hydraulic power unit and the electrical power pack must be switched off when assembling the

circuit.

– Before commissioning, make sure that all tank lines have been connected and that all couplings

have been securely fitted.

– Make sure that hose lines connected to the cylinder are rinsed with oil if the volume of oil

accommodated by the cylinder is less than the volume which can be contained by the hose lines.

• Commissioning

– Cylinders may only be commissioned with their covers in place.

– Switch on the electrical power pack first, and then the hydraulic power unit.

• Dismantling hydraulic circuits

– Assure that pressure has been relived before dismantling the circuit.

– Switch off the hydraulic power unit first, and then the electrical power pack.

• If connections are decoupled while under pressure, pressure is trapped in the device by the non-return

valve in the coupling. This pressure can be vented with the pressure relief unit.

Mounting technology The mounting boards for the components are equipped with mounting variant A, B or C:

• Variant A, snap-in system

Lightweight devices which cannot be subjected to loads (e.g. directional control valves and sensors).

Simply clip the components into the slots on the slotted profile plate. Release the components from the

slots by actuating the blue lever.

• Variant B, bolt system

Components with medium load capacity (e.g. hydraulic cylinders). These components are clamped to

the slotted profile plate with T-head bolts. The blue, knurled nut is used for clamping and loosening.

• Variant C, screw system

For devices with high load capacity and devices which are seldom removed from the slotted profile plate

(e.g. the hydraulic power unit). These devices are fastened with socket head screws and T-head nuts.

Required accessories A digital multimeter is required in order to ascertain the contact ratings of pushbuttons.

Current is measured with the digital multimeter.

© Festo Didactic GmbH & Co. KG 551150 XI

Training package for electro-hydraulics, basic level (TP 601)

The TP 601 training package consists of a multitude of individual training materials. The subject matter of

this package is electro-hydraulic controllers. Individual components from training package TP 601 may also

be included in other packages.

Important TP 601 components • Permanent workstation with Festo Didactic slotted profile plate

• Equipment sets or individual components (e.g. cylinders, valves and pressure gauges)

• Complete laboratory setups

Media The teachware for the TP 601 training package consists of a textbook and a workbook. The textbook imparts

fundamental electrical and hydraulics knowledge regarding electro-hydraulic controllers in a vivid, clear-cut

fashion. The workbook includes exercise sheets and worksheets for each of the 15 exercises, the solutions

to each individual worksheet and a CD-ROM. A set of ready-to-use exercise sheets and worksheets is

included in each workbook for all of the exercises.

Data sheets for the hardware components are made available along with the equipment set.

Media

Textbooks Hydraulics, basic level

Electro-hydraulics, basic level

Workbooks Electro-hydraulics, basic level (TP 601)

Electro-hydraulics, advanced level (TP 602)

DVD Electro-pneumatics and electro-hydraulics, basic level

Set of posters Hydraulics

Simulation programme FluidSIM® Hydraulic

Digital training programme Web-based training, hydraulics – basic hydraulics principles

Web-based training, electro-hydraulics – basic electro-hydraulics principles

Web-based training, electrical engineering 1 – basic electrical engineering principles

Web-based training, GRAFCET – introduction to GRAFCET

Overview of media for training packages TP 601 and TP 602

Training programmes including hydraulics, electro-hydraulics and electrical engineering 1 are available as

software for training package TP 601. These training programmes concern themselves in detail with the

basic principles of hydraulics, electro-hydraulics and electrical engineering. The GRAFCET training

programme provides a comprehensive introduction to the new GRAFCET standard. Training content is

elucidated on the basis of practical case studies in a systematic, applications-oriented fashion.

The media are offered in several languages. You will find further training materials in our catalogues and on

the Internet.

XII © Festo Didactic GmbH & Co. KG 551150

Learning objectives

Circuits • Be able to safely commission hydraulic controllers.

• Be able to explain and set up direct actuation.

• Be able to plan and set up load-dependent speed controllers.

• Be able to make use of indirect actuation.

• Be able to select and make use of hydraulic and electrical components in accordance with economic

considerations.

• Become familiar with two ways of storing signals: with double solenoid valves and by means of

electrical self-latching loops.

• Be able to explain and set up signal storage in the hydraulic power section.

• Be able to select solenoid valves based on control technology requirements.

• Be able to depict the motion sequence of a controller as a function diagram.

• Be able to make use of a limit switch for end-position monitoring.

• Become familiar with basic logic functions, and be able to make use of them and set them up.

• Be able to create and make use of a sequence table.

• Be able to plan and set up speed controllers which are independent of load.

• Be able to explain and set up an electrical latching circuit with dominant breaking signal.

• Become familiar with latching circuits with varying performance features.

• Be able to plan and set up pressure dependent speed controllers.

• Be able to plan and set up bypass circuits.

• Be able to lock relay controller signals electrically and mechanically.

• Be able to plan and set up circuits for pulling loads.

• Be able to plan and set up a pressure level controller for two levels.

• Become familiar with various types of end-position control for cylinders and be able to select the

appropriate type.

• Be able to reduce a system’s energy consumption by means of pressure-free pump circulation.

• Become familiar with simple operating modes and be able to take them into consideration in the

controller.

• Be able to expand existing controllers and revise the respective documentation accordingly.

• Be able to implement sequence control with two cylinders.

• Be able to represent a simple sequence in GRAFCET.

• Be able to detect and eliminate errors in simple electro-hydraulic controllers.

© Festo Didactic GmbH & Co. KG 551150 XIII

Components • Become familiar with the setup and function of a hydraulic pump.

• Become familiar with the most important characteristics of a hydraulic pump.

• Be able to select a hydraulic power unit on the basis of specified requirements.

• Be familiar with the various types and possible uses of pressure-relief valves.

• Become familiar with the setup and function of a double-acting cylinder.

• Become familiar with the setup and function of a 4/2-way solenoid valve.

• Become familiar with the setup and function of electrical pushbuttons and switches.

• Become familiar with the setup and function of a relay.

• Become familiar with the setup and function of 2/2 and 3/2-way solenoid valves.

• Become familiar with the setup and function of a 4/2-way double solenoid valve.

• Become familiar with the setup and function of a limit switch.

• Become familiar with the setup and function of an electronic pressure switch.

• Become familiar with the setup and function of a 4/2-way double solenoid valve.

Measurements and calculations • Be able to measure and calculate electrical current in an electro-hydraulic system.

• Become familiar with contact ratings of electrical signal generators and be able to take them into

consideration in the electrical circuit.

XIV © Festo Didactic GmbH & Co. KG 551150

Allocation of learning objectives to exercises

Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Learning objectives

Become familiar with the setup and function of a

hydraulic pump. •

Become familiar with the most important

characteristics of a hydraulic pump. •

Be able to select a hydraulic power unit on the

basis of specified requirements. •

Be familiar with the various types and possible

uses of pressure-relief valves. •

Be able to safely commission hydraulic

controllers. •


double-acting cylinder. •


4/2-way solenoid valve. •

Become familiar with the setup and function of

electrical pushbuttons and switches. •

Be able to explain and set up direct actuation. •

Be able to plan and set up load-dependent speed

controllers. •


relay. •

Be able to make use of indirect actuation. • •

Be able to measure and calculate electrical

current in an electro-hydraulic system. •

Become familiar with contact ratings of electrical

signal generators and be able to take them into

consideration in the electrical circuit.

•


2/2 and 3/2-way solenoid valves. •

Be able to select and make use of hydraulic and

electrical components in accordance with

economic considerations.

•

© Festo Didactic GmbH & Co. KG 551150 XV

Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Learning objectives


4/2-way double solenoid valve. •

Become familiar with two ways of storing

signals: with double solenoid valves and by

means of electrical self-latching loops.

•

Be able to explain and set up signal storage in

the hydraulic power section. •

Be able to select solenoid valves based on

control technology requirements. •

Be able to depict the motion sequence of a

controller as a function diagram. •


limit switch. •

Be able to make use of a limit switch for end-

position monitoring. • •

Become familiar with basic logic functions, and

be able to make use of them and set them up. • •

Be able to create and make use of a sequence

table. •

Be able to plan and set up speed controllers

which are independent of load. •

Learn to explain and set up an electrical latching

circuit with dominant breaking signal. • •

Become familiar with latching circuits with

varying performance features. •


an electronic pressure switch. •

Be able to plan and set up pressure dependent

speed controllers. •

Be able to plan and set up bypass circuits. •

XVI © Festo Didactic GmbH & Co. KG 551150

Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Learning objectives


various 4/3-way solenoid valves. •

Be able to lock relay controller signals

electrically and mechanically. •

Be able to plan and set up circuits for pulling

loads. •

Be able to plan and set up a pressure level

controller for two levels. •

Become familiar with various types of end-

position control for cylinders and be able to

select the appropriate type.

•

Be able to reduce a system’s energy

consumption by means of pressure-free pump

circulation.

•

Become familiar with simple operating modes

and be able to take them into consideration in

the controller.

•

Be able to expand existing controllers and revise

the respective documentation accordingly. •

Learn to implement sequence control with two

cylinders. •

Be able to represent a simple sequence in

GRAFCET. •

Be able to detect and eliminate errors in simple

electro-hydraulic controllers. •

© Festo Didactic GmbH & Co. KG 551150 XVII

Equipment set

The equipment set has been put together for basic training in the field of electro-hydraulic control

technology. It includes all of the components which are necessary for mastering the specified learning

objectives, and can be supplemented with any other equipment sets.

Equipment set for electro-hydraulics, basic level (TP 601) 573037

Designation Order number Quantity

2-way flow control valve 544338 1

4/2-way solenoid valve with spring return 544346 1

4/2-way double solenoid valve, detenting 544352 1

4/3-way solenoid valve, mid-position closed 544347 1

On-off valve 152844 1

Mounting kit for cylinders 544371 1

Double-acting cylinder, 16/10/200, with cover 572746 2

One-way flow control valve 152843 1

Pressure-relief valve 544335 1

Pressure gauge 152841 2

Pressure switch, electronic 548612 1

9 kg weight for cylinder 152972 1

Limit switch, electrical, actuated from the left 183322 1

Limit switch, electrical, actuated from the right 183345 1

Proximity switch, electronic 548589 2

Relay, 3-off 162241 2

Non-return valve with hose, opening pressure: 0.6 MPa (6 bar) 548618 1

Signal input, electrical 162242 1

T-distributor 152847 2

4-way manifold plate with pressure gauge 159395 2

XVIII © Festo Didactic GmbH & Co. KG 551150

Graphic symbols, equipment set

Component Graphic symbol

2-way flow control valve B

A

4/2-way solenoid valve

with spring return

M1

BA

TPM1

4/2-way double solenoid valve,

detenting

M1 M2

BA

TPM1 M2

4/3-way solenoid valve,

mid-position closed

M1 M2

BA

TPM1 M2

On-off valve

Double-acting cylinder,

16/10/200, with cover

© Festo Didactic GmbH & Co. KG 551150 XIX


One-way flow control valve A B

Pressure-relief valve P

T

Pressure gauge

Pressure switch, electronic EN 60617-7 ISO 1219-1

p

2

RD (1)BK1 (4),BK2 (5),WH (2)

BU (3)

p

U

SP1SP2

9 kg weight for cylinder m

Electrical limit switch 42

1

Proximity switch, electronic

RD (1)

BU (3)

BK (4)

XX © Festo Didactic GmbH & Co. KG 551150


Relay, 3-off

1412 2422 3432

32

4442

11 21 31 41

A1

A2

1412 2422 34 4442

11 21 41

A1

A2 31

1412 2422 3432 4442

11 21 31 41

A1

A2

Non-return valve with hose

Opening pressure: 0.6 MPa (6 bar)

Signal input, electrical 13 21

14 22

13 21

14 22

13 21

14 22

13 21

14 22

T-distributor

4-way manifold plate

with pressure gauge

© Festo Didactic GmbH & Co. KG 551150 XXI

Allocation of components to exercises

TP 601 equipment set

Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Component

2-way flow control valve 1 1 1 1 1

4/2-way solenoid valve with spring return 1 1 1 1 1 1 1 1

4/2-way double solenoid valve, detenting 1 1 1 1 1

4/3-way solenoid valve, normally closed 1 1 1 1 1

On-off valve 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Mounting kit for cylinders 1 1 1 1

Double-acting cylinder with cover 1 1 1 1 1 1 1 1 1 1 1 2 2

One-way flow control valve 1 1 1 1 1 1 1 1 1 1

Pressure-relief valve 1 1 1 1 1 1

Pressure gauge 2 2 1 2 2 2 1 2 2 2 2 2 2

Pressure switch, electronic 1 1

9 kg weight for cylinder 1 1 1

Electrical limit switch 1 2 2 2

Proximity switch, electronic 1 2 2 2

Relay, 3-off 1 1 1 1 1 1 2 1 2 2 2 2

Non-return valve, 0.6 MPa (6 bar) 1 1 1

Signal input, electrical 1 1 1 1 1 1 1 1 1 1 1 1 1

T-distributor 2 1 2 2 2 2 2

4-way manifold plate with pressure gauge 2 2 2 2 2 2 2 2 2 2 2 2 2

Required accessories

Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Component

Cover for weight 1 1 1

Digital multimeter 1

Hydraulic power unit 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Power pack, 24 V DC 1 1 1 1 1 1 1 1 1 1 1 1 1

Hose line, 600 mm 3 3 3 2 3 3 4 2 6 4 6 6 7 7

Hose line, 1000 mm 2 2 2 2 2 2 2 2 2 2

Hose line, 1500 mm 2 2 4 2 2 2 2 2 4 4 4 4 4

XXII © Festo Didactic GmbH & Co. KG 551150

Notes for the teacher/trainer

Learning objectives The basic learning objective of this workbook is to understand, plan, set up and safely commission basic

electro-hydraulic circuits. This knowledge is gained by means of theoretical questions and by actually

setting up the circuits on the slotted profile plate. This direct interaction involving both theory and practice

ensures faster progress and longer-lasting learning. The more specific learning objectives are documented

in the matrix. Concrete, individual learning objective are assigned to each exercise.

Required time The time required for working through the exercises depends on the learner’s previous knowledge of the

subject matter. A time of roughly 1 to 1½ hours can be assumed for each exercise.

Equipment set components The textbook, the workbook and the equipment set are matched to each other. Only the components

included in a single TP 601 equipment set are required for all 15 exercises.

Each exercise can be set up on a slotted profile plate with a width of 1100 mm.

Standards The following standards are used in this workbook:

DIN ISO 1219-1 Fluid power systems and components – Graphic symbols and circuit diagrams

EN 60617-2 to EN 60617-8 Graphic symbols for diagrams

EN 81346-2 Industrial systems, installations and equipment and industrial products –

Structuring principles and reference designations

Identification within the workbook Solution texts and supplements in graphics or diagrams appear in red.

Identification within the exercise book Texts which require completion are identified with a grid or grey table cells.

Graphics which require completion include a grid.

Training notes Additional information is provided here regarding the didactic-methodological procedure, the individual

components and the completed controllers. These notes are not included in the exercise book.

© Festo Didactic GmbH & Co. KG 551150 XXIII

Solutions The solutions specified in this workbook result from test measurements. The results of your measurements

may deviate from these.

Learning topics The table below contains an overview of the learning topics offered by educational institutions for selected

professions on the subject matter of “basic electro-hydraulic circuits”.

Vocation Topic

Mechatronics technician Examination of the flow of energy and information in electrical, pneumatic and hydraulic assemblies

Implementing mechatronic subsystems

Industrial mechanic Installation and commissioning of technical control systems

Electronics engineer for

automation technology

Controllers, analysis and adaptation

Systems implementation and safety testing

Structure of exercises

All 15 exercises have the same methodological layout. The exercises are broken down into:

• Title

• Learning objectives

• Problem description

• Layout

• Assignments

• Work aids

• Worksheets

The workbook includes the solutions for all of the worksheets for all 15 exercises.

Component designations

Components are designated in circuit diagrams in accordance with DIN ISO 1219-2. All of the components

included in any given circuit have the same primary identifying number. Letters are assigned depending on

each respective type of component. Consecutive numbers are assigned if several components of the same

type are included within a single circuit.

Cylinders: 1A1, 2A1, 2A2 ...

Valves: 1V1, 1V2, 1V3, 2V1, 2V2, 3V1 …

Sensors: 1B1, 1B2 ...

Signal input: S1, S2 …

Accessories: 0Z1, 0Z2, 1Z1 …

XXIV © Festo Didactic GmbH & Co. KG 551150

CD-ROM contents

The workbook is included on the CD-ROM as a PDF file. The CD-ROM also provides you with additional

media.

The CD-ROM contains the following folders:

• Operating instructions

• Images

• Data sheets

• FluidSIM® circuit diagrams

• Presentations

Operating instructions Operating instructions for various components in the training package are available. These instructions are

helpful with regard to component use and commissioning.

Images Photos and graphics of components and industrial applications are made available. These can be used to

illustrate individual tasks. Project presentations can also be supplemented with these illustrations.

Data sheets The data sheets for the components included in the training package are supplied along with the equipment

set, and are additionally available as PDF files.

FluidSIM® circuit diagrams The FluidSIM® circuit diagrams for all 15 exercises included in the technology package are contained in this

directory.

Presentations Short presentations for components included in the training package are included in this directory. They can

be used, for example, for the creation of project presentations.

© Festo Didactic GmbH & Co. KG 551150 1

Exercise 1 Setting up a hydraulic workstation

Learning objectives After completing this exercise:

• You will be familiar with the setup and function of a hydro pump.

• You will be familiar with the most important characteristics of a hydro pump.

• You will be able to select a hydraulic power unit on the basis of specified requirements.

Problem description A new hydraulic workstation needs to be set up in the training department. Size NG 4 products are used.

Maximum operating pressure is limited to 6 MPa (60 bar). A 230 V AC electrical outlet is available. A suitable

hydraulic power unit must be selected.

Layout

Hydraulic workstation

Exercise 1 – Setting up a hydraulic workstation

2 © Festo Didactic GmbH & Co. KG 551150

Assignments 1. Describe the setup and function of a hydro pump.

2. Calculate the volumetric flow rate of a hydro pump.

3. Calculate the efficiency of a hydro pump.

4. Select a hydraulic power unit on the basis of specified requirements.

Work aids • Data sheets

• Hydraulics textbook

1. Describing setup and function of a hydro pump

Information

Hydro pumps are displacement pumps which function on the basis of “suction and displacement”.

We differentiate amongst three basic types of hydro pumps on the basis of displacement volume:

• Constant displacement pump: Constant displacement volume

• Variable displacement pump: Adjustable displacement volume

• Control pump: Displacement volume is controlled on the basis of pressure,

flow rate and power

The hydro pump generates volumetric flow (but no pressure). The delivery rate per revolution and the

drive speed dictate the pump’s delivery rate which is specified in litres per minute.

Pressure only occurs as the result of resistance to pump delivery, for example flow resistance, load

resistance and pressure-relief valve settings. Pressure is specified in MPa or bar.



a) Describe the function of the gear pump shown in the figure.

3

2

1

Cutaway view of a gear pump, 1: trapped fluid, 2: pressure chamber, 3: suction chamber

Gear pumps are constant-displacement pumps, because the displaced volume which is determined by

the gear tooth gap is unchangeable.

The gear pump functions on the basis of the following principle:

• One gear wheel is connected to the drive unit, and the other rotates along with it via the toothing.

• As a result of the volume enlargement which occurs when a tooth leaves a gear tooth gap, a

partial vacuum is generated in the suction chamber.

• The hydraulic fluid fills the tooth chambers and is conveyed along the housing wall and into the

pressure chamber.

• Here, the hydraulic fluid is displaced from the tooth chambers and into the hydraulic lines by the

teeth which then enter the tooth gaps.

Training notes

Trapped fluid is located in the tooth gaps between the suction chamber and the pressure chamber. This is

fed to the pressure chamber via a slot, because pressure peaks would otherwise occur due to

compression of the trapped oil which would result in noise and destruction of the pump.

Pump leakage oil quantities are determined by the size of the gap (between housing, tooth crests and the

sides of the teeth), overlapping of the gears, viscosity and speed.



b) Name the circuit symbol shown below and briefly describe the function of its components.

P T

M

1

4

2 3

Circuit symbols for a hydraulic power unit

1. Electric motor with a single direction of rotation

Drive for hydro pumps

2. Hydraulic pump

Pump with constant delivery rate. The volumetric flow rate is dictated by motor speed and

displacement volume per revolution.

3. Pressure gauge

Indicates prevailing pressure with a specified tolerance.

4. Pressure-relief valve

Adjustable pressure-relief valve without oil return port. The valve begins to open when an

adjustable pressure level is reached.



c) Match up the individual components of the hydraulic power unit with the corresponding numbers in the

drawing.

10

8

9

1

2

3

4

6

5

11

7

Schematic diagram of a hydraulic power unit

Component Designation

6 Drain screw

3 Suction chamber

2 Suction tube

10 Ventilation with air filter

4 Moderating plate

8 Filling filter

9 Fill-level indicator, maximum fill-level

7 Fill-level indicator, minimum fill-level

1 Motor and pump

11 Return

5 Return chamber



2. Calculating the volumetric flow rate of a hydro pump

Information Displacement volume V (also known as delivery rate or swept volume) is a measure of the size of the

pump. It designates the liquid volume which is delivered by the pump per revolution (or stroke).

The delivered liquid volume per minute is designated volumetric flow rate q. This results from

displacement volume V and speed in RPM n:

q n V= ⋅

– Calculate the volumetric flow rate of a gear pump.

Given Speed n = 1450 RPM

Displacement volume V = 2.8 cubic cm (per revolution)

Desired Flow rate q in l/min.

Calculation

3 33

1 cm dm l1450 2.8 cm = 4060 = 4.06 = 4.06min min min min

= ⋅ =q n V



3. Calculating the efficiency of a hydro pump

Information

Mechanical power is converted to hydraulic power by pumps, during which power losses occur that are

expressed in terms of the pump’s degree of efficiency.

Effective power Phyd generated by the pump depends upon operating pressure p and effective volumetric

flow rate qeff. Effective power is calculated with the equation:

hyd effP p q= ⋅

Volumetric efficiency is the relationship between the pump’s effective volumetric flow rate and its

theoretically calculated volumetric flow rate.

effvol

th

qq

η =

th thq V n= ⋅

eff th volq V n= ⋅ ⋅η

– Calculate the efficiency of a hydro pump.

Given

Speed n = 1450 RPM


Effective volumetric flow rate effl8.6

min=q at 100 bar

Desired Efficiency ηvol

Calculation

3th

1 l6.5 cm 1450 = 9.4min min

q =

effvol

th

l8.6min = 0.92 = 92 %

l9.4min

qq

η = =



4. Selecting a hydraulic power unit

Information

Excerpts from three data sheets for hydraulic power units are included below. Select the power unit

which fulfils the following conditions:

• Drive motor with 230 V nominal voltage

• Frequency: 50 Hz

• Delivery rate at nominal speed: 2.2 l/min.

• Weight without oil: max. 20 kg

General HA-5L-230-50 HA-5L-110-60 HA-20L-400-50

Dimensions

Length

Width

Height

580 mm

300 mm

180 mm

580 mm

300 mm

180 mm

580

300

180 mm

Weight

Empty

With oil

19 kg

24 kg

19 kg

24 kg

19 kg

29 kg

Electrical specifications HA-5L-230-50 HA-5L-110-60 HA-20L-400-50

Motor Alternating current, single-

phase

Alternating current, single-

phase

Alternating current, 3-phase

Nominal power 650 W 550 W 550 W

Nominal voltage 230 V 110 V 400 V

Frequency 50 Hz 60 Hz 50 Hz

Nominal speed 1320 RPM 1680 RPM 1390 RPM

Protection IP 20 IP 20 IP 20

Duty cycle 50% 50% 100%



Hydraulics HA-5L-230-50 HA-5L-110-60 HA-20L-400-50

Medium Mineral oil, recommended: 22 cSt (sq. mm / s)

Pump design External gear pump

Geometric delivery rate 1.6 cubic cm 1.6 cubic cm 1.6 cubic cm

Delivery rate at nominal speed 2.2 l/min. 2.7 l/min. 2.2 l/min.

Operating pressure 0.5 to 6 MPa (5 to 60 bar)

Adjustment Manual

Pressure gauge indicating range 0 to 10 MPa (0 to 100 bar)

Pressure gauge quality class 1.6

Oil tank capacity Approx. 5 litres Approx. 5 litres Approx. 10 litres

Return filter filtration grade 90 μm

Connection One quick coupling socket each for P and T, one coupling for the line to the storage tank, one

connection for the discharge measuring receptacle

– Which hydraulic power unit have you chosen? Give reasons for your selection.

The hydraulic power unit with the designation HA-5L-230-50 was selected. It fulfils the following

specified conditions:





© Festo Didactic GmbH & Co. KG 551150 I

Table of contents Exercises and worksheets Exercise 1: Setting up a hydraulic workstation ________________________________________________ 1
















Exercise 1 Setting up a hydraulic workstation

Learning objectives After completing this exercise:

• You will be familiar with the setup and function of a hydro pump.

• You will be familiar with the most important characteristics of a hydro pump.

• You will be able to select a hydraulic power unit on the basis of specified requirements.

Problem description A new hydraulic workstation needs to be set up in the training department. Size NG 4 products are used.

Maximum operating pressure is limited to 6 MPa (60 bar). A 230 V AC electrical outlet is available. A suitable

hydraulic power unit must be selected.

Layout

Hydraulic workstation


2 Name: __________________________________ Date: ____________ © Festo Didactic GmbH & Co. KG 551150

Assignments 1. Describe the setup and function of a hydro pump.

2. Calculate the volumetric flow rate of a hydro pump.

3. Calculate the efficiency of a hydro pump.

4. Select a hydraulic power unit on the basis of specified requirements.

Work aids • Data sheets

• Hydraulics textbook

1. Describing setup and function of a hydro pump

Information

Hydro pumps are displacement pumps which function on the basis of “suction and displacement”.

We differentiate amongst three basic types of hydro pumps on the basis of displacement volume:

• Constant displacement pump: Constant displacement volume

• Variable displacement pump: Adjustable displacement volume

• Control pump: Displacement volume is controlled on the basis of pressure,

flow rate and power

The hydro pump generates volumetric flow (but no pressure). The delivery rate per revolution and the

drive speed dictate the pump’s delivery rate which is specified in litres per minute.

Pressure only occurs as the result of resistance to pump delivery, for example flow resistance, load

resistance and pressure-relief valve settings. Pressure is specified in MPa or bar.


© Festo Didactic GmbH & Co. KG 551150 Name: __________________________________ Date: ____________ 3

a) Describe the function of the gear pump shown in the figure.

3

2

1

Cutaway view of a gear pump, 1: trapped fluid, 2: pressure chamber, 3: suction chamber



b) Name the circuit symbol shown below and briefly describe the function of its components.

P T

M

1

4

2 3

Circuit symbols for a hydraulic power unit



c) Match up the individual components of the hydraulic power unit with the corresponding numbers in the

drawing.

10

8

9

1

2

3

4

6

5

11

7

Schematic diagram of a hydraulic power unit

Component Designation

Drain screw

Suction chamber

Suction tube

Ventilation with air filter

Moderating plate

Filling filter

Fill-level indicator, maximum fill-level

Fill-level indicator, minimum fill-level

Motor and pump

Return

Return chamber



2. Calculating the volumetric flow rate of a hydro pump

Information Displacement volume V (also known as delivery rate or swept volume) is a measure of the size of the

pump. It designates the liquid volume which is delivered by the pump per revolution (or stroke).

The delivered liquid volume per minute is designated volumetric flow rate q. This results from

displacement volume V and speed in RPM n:

q n V= ⋅

– Calculate the volumetric flow rate of a gear pump.

Given Speed n = 1450 RPM


Desired Flow rate q in l/min.

Calculation



3. Calculating the efficiency of a hydro pump

Information

Mechanical power is converted to hydraulic power by pumps, during which power losses occur that are

expressed in terms of the pump’s degree of efficiency.

Effective power Phyd generated by the pump depends upon operating pressure p and effective volumetric

flow rate qeff. Effective power is calculated with the equation:

hyd effP p q= ⋅

Volumetric efficiency is the relationship between the pump’s effective volumetric flow rate and its

theoretically calculated volumetric flow rate.

effvol

th

qq

η =

th thq V n= ⋅

eff th volq V n= ⋅ ⋅η

– Calculate the efficiency of a hydro pump.

Given

Speed n = 1450 RPM


Effective volumetric flow rate effl8.6

min=q at 100 bar

Desired Efficiency ηvol

Calculation



4. Selecting a hydraulic power unit

Information

Excerpts from three data sheets for hydraulic power units are included below. Select the power unit

which fulfils the following conditions:





General HA-5L-230-50 HA-5L-110-60 HA-20L-400-50

Dimensions

Length

Width

Height

580 mm

300 mm

180 mm

580 mm

300 mm

180 mm

580

300

180 mm

Weight

Empty

With oil

19 kg

24 kg

19 kg

24 kg

19 kg

29 kg

Electrical specifications HA-5L-230-50 HA-5L-110-60 HA-20L-400-50

Motor Alternating current, single-

phase

Alternating current, single-

phase

Alternating current, 3-phase

Nominal power 650 W 550 W 550 W

Nominal voltage 230 V 110 V 400 V

Frequency 50 Hz 60 Hz 50 Hz

Nominal speed 1320 RPM 1680 RPM 1390 RPM

Protection IP 20 IP 20 IP 20

Duty cycle 50% 50% 100%



Hydraulics HA-5L-230-50 HA-5L-110-60 HA-20L-400-50

Medium Mineral oil, recommended: 22 cSt (sq. mm / s)

Pump design External gear pump

Geometric delivery rate 1.6 cubic cm 1.6 cubic cm 1.6 cubic cm

Delivery rate at nominal speed 2.2 l/min. 2.7 l/min. 2.2 l/min.

Operating pressure 0.5 to 6 MPa (5 to 60 bar)

Adjustment Manual

Pressure gauge indicating range 0 to 10 MPa (0 to 100 bar)

Pressure gauge quality class 1.6

Oil tank capacity Approx. 5 litres Approx. 5 litres Approx. 10 litres

Return filter filtration grade 90 μm

Connection One quick coupling socket each for P and T, one coupling for the line to the storage tank, one

connection for the discharge measuring receptacle

– Which hydraulic power unit have you chosen? Give reasons for your selection.

551150 Leseprobe En

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