Neumatica avanzada

Workbook TP 102

CD-ROM included

Festo Didactic

541089 en

PneumaticsAdvanced Level

2 © Festo Didactic GmbH & Co. KG • 541089

The Festo Didactic learning system has been developed and produced solely for

vocational and further training in the field of automation and technology. The

training company and / or instructor need to ensure that trainees observe the safety

precautions specified in this workbook.

Festo Didactic hereby disclaims any legal liability for damages or injury to trainees,

the training company and / or other parties, which may occur during the use/

application of this equipment set other than in a training situation and unless such

damages are caused with intention or through gross negligence on the part of Festo

Didactic.

Order No.: Status: Authors: Editor: Graphics: Layout:

541089 04/2005 W. Haring, M. Metzger, R.-C. Weber Frank Ebel Doris Schwarzenberger 10/2005

© Festo Didactic GmbH & Co. KG, D-73770 Denkendorf, 2005 Internet: www.festo-didactic.de e-mail: [email protected]

The copying, distribution and utilisation of this document as well as the communication of its contents to others without express authorisation is prohibited. Offenders will be held liable for the payment of damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design registration.

Parts of this document may be copied by the authorised user exclusively for training purposes.

Intended use

© Festo Didactic GmbH & Co. KG • 541089 3

Preface______________________________________________________________ 5

Introduction__________________________________________________________ 7

Notes on safety and operation ___________________________________________ 9

Technology package for pneumatics (TP100) ______________________________ 11

Training aims – Advanced Level (TP102) __________________________________ 13

Allocation of training aims and exercises _________________________________ 15

Equipment set – Advanced Level (TP102) _________________________________ 17

Allocation of equipment and exercises ___________________________________ 20

Methodological help for the trainer ______________________________________ 22

Methodological structure of the exercises_________________________________ 24

Designation of equipment _____________________________________________ 25

Equipment set – Basic Level (TP101) _____________________________________ 26

Training aims – Basic Level (TP101)______________________________________ 27

Part A – Exercises

Exercise 1: Opening and closing of an oven door ___________________________A-3

Exercise 2: Separating of drinks bottles __________________________________A-9

Exercise 3: Drilling of valve manifold blocks ______________________________A-17

Exercise 4: Filling of drinks bottles______________________________________A-25

Exercise 5: Cleaning of workpieces _____________________________________A-35

Exercise 6: Printing of mobile phone housings ____________________________A-43

Exercise 7: Packaging of spark plugs ____________________________________A-49

Exercise 8: Sealing of guide bushes_____________________________________A-55

Exercise 9: Hardening of material test specimens__________________________A-63

Exercise 10: Bending of sheet metal strips _______________________________A-69

Contents

Contents


Part B – Fundamentals

Part C – Solutions

Exercise 1: Opening and closing of an over door____________________________C-3

Exercise 2: Separating of drinks bottles __________________________________C-7

Exercise 3: Drilling of valve manifold blocks ______________________________C-11

Exercise 4: Filling of drinks bottles______________________________________C-17

Exercise 5: Cleaning of workpieces _____________________________________C-27

Exercise 6: Printing of mobile phone housings ____________________________C-35

Exercise 7: Packaging of spark plugs ____________________________________C-41

Exercise 8: Sealing of guide bushes ____________________________________C-47

Exercise 9: Hardening of material test specimens__________________________C-53

Exercise 10: Bending of sheet metal strips _______________________________C-59

Part D – Appendix

Organiser __________________________________________________________ D-2

Assembly technology ________________________________________________ D-3

Plastic tubing_______________________________________________________ D-4

Data sheets

Circuit diagrams


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

towards different training and vocational requirements and is therefore structured

into the following training packages:

• Basic packages to provide technology-spanning basic knowledge

• Technology packages to address the major subjects of open and closed-loop

technology

• Function packages to explain the basic functions of automated systems

• Application packages to facilitate vocational and further training based on actual

industrial applications

The technology packages deal with the following technologies: Pneumatics,

electropneumatics, programmable logic controllers, automation using a personal

computer, hydraulics, electrohydraulics, proportional hydraulics and handling

technology.

Preface

Preface


The modular design of the learning system enables applications beyond the limits of

the individual packages. For example, to facilitate PLC actuation of pneumatic,

hydraulic and electrical drives.

All the training packages are of identical structure:

• Hardware

• Teachware

• Software

• Seminars

The hardware consists of didactically designed industrial components and systems.

The didactic, methodological design of the teachware is harmonised with the

training hardware and comprises:

• Textbooks (with exercises and examples)

• Workbooks (with practical exercises, additional information, solutions and data

sheets)

• Overhead transparencies and videos (to create an interesting and lively training

environment)

Tuition and training media are available in several languages and are suitable for

use both in the classroom and for self-tuition.

Software is available in the form of computer training programs and programming

software for programmable logic controllers.

A comprehensive range of seminars dealing with the topics of the technology

packages completes the range of vocational and further training available.


This workbook is a component part of the Learning System for Automation and

Technology of Festo Didactic GmbH & Co. KG. This system provides a solid basis for

practice-oriented vocational and further training. Technology package TP100 is

comprised exclusively of electropneumatic control systems.

Basic Level TP101 is suitable for basic training in pneumatic control technology and

provides knowledge regarding the physical fundamentals of pneumatics and the

function and use of pneumatic components. The equipment set enables you to

construct simple pneumatic control systems.

Advanced Level TP102 focuses on further training in pneumatic control technology.

The equipment set enables you to construct complex combinatorial circuits with

logic operations of input and output signals as well as control systems with

sequencer modules.

Prerequisite for the assembly of control systems is a fixed workstation using a Festo

Didactic profile plate, consisting of 14 parallel T slots spaced 50 mm apart. A mobile,

silenced compressor (230 V, maximum 8 bar = 800 kPa) can be used for compressed

air supply.

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

Optimal operational reliability is achieved if the control system is operated on

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

The equipment set of Advanced Level TP102 is used to construct complete control

systems for all of the 10 exercise definitions. The theoretical fundamentals to help

you understand this collection of exercises can be found in the textbook

• Pneumatics – Basic Level

Also available are data sheets in respect individual devices ( cylinders, valves,

measuring devices, etc.).

Introduction

Introduction



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

• Pressurised air lines that become detached can cause accidents. Switch off the

supply immediately.

• Do not switch on compressed air until tubing is securely connected.

• Caution!

Cylinders may advance automatically as soon as the compressed air is switched

on.

• Do not operate roller lever valves manually during fault finding (use a tool).

• Observe general safety regulations (DIN 58126).

• Limit switches must always be mounted laterally to the trip cam (not to the

front).

• Do not exceed the permissible operating pressure (see data sheets).

• Pneumatic circuit assembly: Connect the components using the silver-metallic

plastic tubing of 4 mm outer diameter; the tubing is plugged into the push-in

fitting up to the stop, no additional securing required!

• Releasing of push-in fitting: The tubing can be released by pressing down the

releasing ring (disconnection under pressure is not possible!)

• Switch off compressed air supply prior to dismantling the circuit.

• The mounting plates of the devices are in the form of mounting variants A, B or C:

Variant A, latching system

For lightweight non-loadable devices (e.g. directional control valves). Simply clip

the device into the slot in the profile plate. Devices can be released by pressing

the blue lever.

Variant B, rotary system

For medium weight loadable devices (e.g. actuators). These devices are clamped

onto the profile plate by means of T-head bolts. Clamping and releasing is

achieved by means of the blue knurled nut.

Variant C, screw system

For heavy loadable devices rarely removed from the profile plate (e.g. on/off

valve with filter regulating valve). These components are mounted by means of

socket head screws and T-head bolts.

• The data for the individual devices, as specified in the data sheets in Part D, must

be observed.

Notes on safety and operation

Notes on safety and operation


A stop watch is required for the evaluation of the assembled control systems, i.e.:

• To adjust one-way flow control valves such that the cylinder stroke time complies

with the specified values,

• To adjust time delay valves.


The technology package TP100 consists of numerous individual training media as

well as seminars. The subject matter of this package is exclusively pneumatic control

systems. Individual components from the technology package TP100 may also form

a component part of other packages.

• Fixed workstation with Festo Didactic profile plate

• Compressor (230 V, 0.55 kW, maximum 8 bar = 800 kPa)

• Equipment set or individual components (e.g. cylinders, directional control

valves, predetermining counters, stepper modules, logic elements, pneumatic

proximity sensors)

• Optional training aids (e.g. visual displays, 5/3-way valve, pulling/pushing load)

• Practical training models

• Complete laboratory set-ups

Training documentation

Textbooks Basic Level TP101

Fundamentals of pneumatic control technology

Maintenance of pneumatic devices and systems

Workbooks Basic Level TP101

Advanced Level TP102

Optional teachware Sets of overhead transparencies

Magnetic symbols, drawing template

Simulation software FluidSIM®

Pneumatics

WBT Fluid Studio Pneumatics

Cutaway model sets 1 + 2 with storage case

Technology package for pneumatics (TP100)

Important elements of

TP100

Technology package for pneumatics (TP100)


Seminars

P111 Fundamentals of pneumatics and electropneumatics

P121 Maintenance of and fault finding on pneumatic and electropneumatic systems

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

control systems

P-AL Pneumatics for vocational training

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

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

the Internet. The Learning System for Automation and Technology is continually

updated and expanded. The sets of overhead transparencies, films, CD-ROMs and

DVDs as well as technical books are available in several languages.


• To familiarise yourself with different types of end position sensing.

• To familiarise yourself with the options of designing control systems with a

memory function.

• To be able to convert 3/2- and/or 5/2-way valves (normally closed/normally

open).

• To familiarise yourself with displacement-step diagrams and to be able to design

these for a specified circuit.

• To be able to realise circuits with parallel movements in push-pull mode.

• To be able to use pneumatic decrementing counters.

• To be able to design indirect cylinder actuation.

• To be able to select appropriate sensors for applications and adjust such

sensors.

• To familiarise yourself with the design and function of stepper modules.

• To be able to design the basic „continuous cycle“ stepper control system.

• To be able to install one-way flow control valves dependent on given parameters.

• To be able to realise the OR function of feedback signals.

• To be able to set time delays according to specifications.

• To familiarise yourself with circuits in order to cancel time delays via signal input.

• To be able to realise the following input commands:

EMERGENCY-STOP, acknowledge EMERGENCY-STOP, START, RESET, STOP at

CYCLE END and AUTOMATIC/MANUAL.

• To be able to design a stepper control with idle step.

• To familiarise yourself with the option of facilitating variable step repetitions

within a motion sequence and to assemble this circuit.

• To be able to develop input circuits with self-latching loop

• To familiarise yourself with the option of realising the double stroke of a cylinder

and to be able to assemble this circuit.

• To familiarise yourself with circuits in order to realise the reversal of a cylinder

movement in the partial stroke range.

• To be able to develop an input circuit for a stepper control with protected pilot

air.

• To be able to stop a double-acting cylinder in the partial stroke range.

• To understand how valve output signals can be inverted.

• To be able to realise a control system with control behaviour in combination with

a sequence control in stepper design.

Training aims of Advanced Level (TP102)

Training aims of Advanced Level (TP102)



Exercise 1 2 3 4 5 6 7 8 9 10

Training aims

To familiarise yourself with different types of end position

sensing.

•

To familiarise yourself with the options of designing

control systems with a memory function.

•

To be able to convert 3/2- and/or 5/2-way valves

(normally closed/normally open).

•

To familiarise yourself with displacement-step diagrams

and to be able to design these for a specified circuit.

•

To be able to realise circuits with parallel movements in

push-pull mode.

•

To be able to use pneumatic decrementing counters. •

To be able to design indirect cylinder actuation. • •

To be able to select appropriate sensors for applications

and adjust such sensors.

• • • •

To familiarise yourself with the design and function of

stepper modules.

•

To be able to design the basic „continuous cycle“ stepper

control system.

•

To be able to install one-way flow control valves

dependent on given parameters.

•

To be able to realise the OR function of feedback signals. •

To be able to set time delays according to specifications. •

To familiarise yourself with circuits in order to cancel time

delays via signal input.

•

To be able to design a stepper control with the input

commands AUTOMATIC/MANUAL, START and RESET.

•

To be able to realise the following input commands:

EMERGENCY-STOP, acknowledge EMERGENCY-STOP,

START, RESET, STOP at CYCLE END and

AUTOMATIC/MANUAL.

•

Allocation of training aims and exercises

Allocation of training aims and exercises


Exercise 1 2 3 4 5 6 7 8 9 10

Training aims

To be able to develop an input circuit with self-latching

loop, that enables the following inputs:

AUTOMATIC/MANUAL, START, STOP at CYCLE END and

RESET.

•

To be able to design a stepper control with idle step. •

To familiarise yourself with the option of facilitating a

variable motion sequence and to be able to design this

circuit.

•

To familiarise yourself with the option of realising the

double stroke of a cylinder and to be able to assemble this

circuit.

•

To familiarise yourself with circuits in order to realise the

reversal of a cylinder movement in the partial stroke

range.

•

To be able to develop an input circuit for a stepper control

with protected pilot air with the inputs START,

AUTOMATIC/MANUAL and RESET.

•

To be able to stop a double-acting cylinder in the partial

stroke range.

•

To be able to adjust proximity sensors in the end positions

and in the partial stroke range.

To understand how valve output signals can be inverted. •

To be able to realise a control system with control

behaviour in combination with a sequence control in

stepper design.

•


This equipment set for the advanced level has been compiled for further training in

pneumatic control technology. The two equipment sets (TP101 and TP102) contain

all the components required to meet the specified training aims and can be

expanded as desired with other equipment sets of the Learning System for

Automation and Technology.

Description Order No. Quantity

3/2-way roller lever valve with idle return, normally closed 152867 1

3/2-way pneumatic valve, convertible 539768 4

3/2-way valve with pushbutton, normally closed 152860 2

3/2-way valve with mushroom actuator, normally open

(EMERGENCY-STOP)

152864 1

5/2-way pneumatic double pilot valve 539769 2

Back pressure valve 152868 1

Double-acting cylinder 152888 2

Dual pressure valve, 3-fold 152883 1

Non-return valve, piloted 540715 2

One-way flow control valve 539773 2

Plastic tubing 4 x 0.75, 10 m 151496 2

Predetermining counter, pneumatic 152877 1

Push-in sleeve 153251 10

Push-in T-connector 153128 20

Shuttle valve 539771 1

Shuttle valve, 3-fold 152882 1

Stepper module 152886 1

Time delay valve, normally open 539759 1

Equipment set – Advanced Level (TP102)

Equipment set – Advanced

Level (TP102

Order No.: 540711)



Desccription Symbol

3/2-way valve with pushbutton,

normally closed

2

31

3/2-way valve with mushroom

actuator,

normally open (EMERGENCY-STOP)

2

31

3/2-way roller lever valve with idle

return

2

31

Back pressure valve

31

2

3/2-way pneumatic valve,

normally closed

2

31

12

5/2-way double pilot valve 24

35 1

14 12

Predetermining counter, pneumatic 2

1

12 10

Time delay valve,

normally open 10

2

31

One-way flow control valve 21

Equipment set symbols



Description Symbol

Shuttle valve, 3-fold 2 2 2

1 1/31/31/3 1 1

Shuttle valve 2

1/31

Dual pressure valve, 3-fold 2 2 2

1 1/31/31/3 1 1

Double-acting cylinder

Non-return valve, piloted 2

1 21

Description Symbol

Stepper module

L L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

A1

X1

YnY Yn+1 Yn+1Yn

Zn Zn Zn+1Z Z

L LLL

P PP P PP

Y

TABTAATAATAA

Zn+1


Exercise 1 2 3 4 5 6 7 8 9 10

Equipment

Cylinder, double-acting 1 2 2 2 2 2 2 1 1 2

One-way flow control valve 2 2 2 2 2 2 2 2 2 2

Non-return valve, piloted 2

3/2-way pneumatic valve, convertible 2 1 1 3 3 4 3 1

5/2-way double pilot valve 2 2 2 2 2 2 2 2 2

3/2-way roller lever valve with idle return, normally closed 1 1 1

Back pressure valve 1 1 1

3/2-way valve with push button, normally closed 1 1 2 2 2 2 1 1

3/2-way valve with mushroom actuator, normally open

(EMERGENCY-STOP)

1 1

Stepper module 1 1 1 1 1 1

Time delay valve, normallyopen 1 1

Predetermining counter, pneumatic 1 1

Shuttle valve 1 1 1

Shuttle valve, 3-fold 3 3 3 3 2

Dual pressure valve, 3-fold 1 2 3 3 1 1 2

Allocation of equipment and exercises

Equipment set TP102

Allocation of equipment and exercises


Exercise 1 2 3 4 5 6 7 8 9 10

Equipment

Cylinder, double-acting 1

Cylinder, single-acting 1

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

3/2-way pneumatic valve 1

5/2-way pneumatic valve 1*

5/2-way double pilot valve 1 3 2*

3/2-way roller lever valve with idle return 1 2 2 2 2 2 2 2

Pneumatic proximity sensor 2 1 2 2 2 2 1 1 2

3/2-way valve with pushbutton, normally closed 2 2 1 1

3/2-way valve with selector switch, normally closed 1 1

5/2-way valve with selector switch 1 1 1 1 1

Time delay valve, normally closed 1 1

Shuttle valve 1 1

Dual pressure valve 1

Manifold 1 1 1 1 1 1 1 1 1 1

ON/off valve with filter regulating valve 1 1 1 1 1 1 1 1 1 1

* Convert the available valve into the required valve.

Equipment set TP101


• Training

The training aim of this collection of exercises is the systematic design of circuit

diagrams and the practical assembly of control systems on a profile plate. This

direct interaction of theory and practice ensures quick progress with learning.

Naturally questions and problems arise, which will vary from training group to

training group and these provide a very useful platform for you to discuss the

training aims addressed at the time.

• Variations in training aims

The above training aim can be varied in various different ways. For many

vocational groups, the designing of a control system is only of secondary

importance.

For instance, if the circuit diagram is added to the exercise definition, the

vocational or further training focus can then be shifted to the assembly and

commissioning of the control system.

Other possible main areas of focus in vocational and further training are for

instance fault finding on assembled control systems or the modification of circuit

diagrams, such as circuit documentation due to an altered exercise definition.

Parts of the documentation of a control system can be prepared during the

theoretical part of training.

The preparation of complete solution descriptions or sections thereof based on

the circuit documentation or the assembled control system also facilitates

interdisciplinary tuition.

• Time required

The time required to work through the 10 exercises depends on the prior

knowledge of the trainees:

– Trainees who have undergone vocational training in the engineering and

electrical field:

Just under 160 hours,

– Trainees with technician’s or engineering training:

up to 80 hours.

Whereby the second group is to be involved more in the designing of circuit

diagrams or sections of circuit diagrams.

Methodological help for the trainer

Methodological help for the trainer


• Components of the equipment set

The collection of exercises in TP102 is didactically and methodologically

harmonised with the training hardware (equipment set of Basic Level TP101 and

Advanced Level TP102).

These two equipment sets are all you require for all the exercises.

• Representation

Abbreviated notation, possibly divided into groups, as well as motion diagrams

are used for the representation of motion sequences and switching statuses.


All 10 exercises in Part A are of the same methodological structure.

The exercises are divided into:

• Title

• Training aims

• Problem definition

• Parameters

as well as

• Project task

• Positional sketch

• Worksheets

The proposed solutions in Part C are divided into:

• Circuit diagram

• Solution description

as well as

• Circuit design

• Equipment list

Enlarged circuit diagrams on DIN-A3 sheets are enclosed for exercises 4 to 10.

Methodological structure of exercises


The designation of components in a circuit diagram is effected in accordance with

the DIN-ISO 1219-2 standard. All components of a circuit have the same main code

number. Letters are assigned depending on component. Several components within

a circuit are number consecutively. The designation of multiple pressure ports is P

and these are consecutively numbered separately.

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

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

Sensors: 1B1, 1B2, ...

Signal input: 1S1, 1S2, ...

Accessories: 0Z1, 0Z2, 1Z1, ...

Designation of equipment


This equipment set has been compiled for basic training in pneumatic control

technology. It comprises all the components required for the training aims specified

and can be expanded in any way using other equipment sets. In addition you will

also need a profile plate and compressed air supply to assemble a fully functional

control system.

Description Order No. Quantity

3/2-way pneumatic valve, convertible 539768 1

3/2-way roller lever valve with idle return, normally closed 152866 2

3/2-way valve with pushbutton, normally open 152861 1

3/2-way valve with pushbutton, normally closed 152860 2

3/2-way valve with selector switch, normally closed 152863 1

5/2-way double solenoid valve 539769 3

5/2-way pneumatic valve 538694 1

5/2-way valve with selector switch 152862 1

Double-acting cylinder 152888 1

Dual pressure valve 539770 2

Manifold 152896 1

One-way flow control valve 539773 2

On-off valve with filter regulating valve 540691 1

Plastic tubing 4 x 0.75, 10 m 151496 2

Pneumatic proximity sensor 539775 2

Pressure gauge 152865 2

Pressure regulating valve with pressure gauge 539756 1

Pressure sequence valve 152884 1

Push-in sleeve 153251 10

Push-in T-connector 153128 10

Quick exhaust valve 539772 1

Shuttle valve 539771 1

Single-acting cylinder 152887 1

Time delay valve, normally closed 540694 1

Equipment set – Basic Level (TP101)

Equipment set – Basic Level

(TP101

Order No.: 540710)


• To familiarise yourself with the design and function of a single-acting cylinder.

• To familiarise yourself with the design and mode of operation of a 3/2-way valve.

• To be able to identify and draw types of directional control valve actuation.

• To able to explain and design an example of direct actuation.

• To be able to analyse and evaluate circuits.

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

cylinder.

• To familiarise yourself with the design and mode of operation of a 5/2-way valve.

• To be able to explain and design an example of indirect actuation.

• To familiarise yourself with the mode of operation of a 5/2-way valve with

pneumatic actuation.

• To familiarise yourself with the difference between a signalling element and a

control element.

• To be able to measure pressure in pneumatic control circuits.

• To be able to differentiate between and utilise types of flow control according to

specifications.

• To be able to set cylinder advancing and retracting speeds.

• To familiarise yourself with one type of signal storage in pneumatic circuits.

• To be able to explain and realise logic AND/OR/NOT operations.

• To be able to explain and configure latching circuits.

• To familiarise yourself with one option of cylinder end position sensing.

• To be able to combine logic operations.

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

proximity sensors.

• To be able to differentiate between and select and use 5/2-way valves according

to specifications.

• To be able to further develop existing circuits.

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

regulating valve.

• To be able to analyse circuits and optimise these according to specifications.

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

regulating valve.

• To be able to analyse circuits and optimise these according to specifications.

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

valve.

• To be able to design circuits with oscillating movements.

• To be able to use time delay valves dependent on parameters.

• To be able to analyse and design circuits using two cylinders.

Training aims – Basic Level (TP101)

© Festo Didactic GmbH & Co. KG • 541089 A-1

Part A – Exercises

Exercise 1: Opening and closing of an oven door ___________________________A-3

Exercise 2: Separating of drinks bottles __________________________________A-9

Exercise 3: Drilling of valve manifold blocks ______________________________A-17

Exercise 4: Filling of drinks bottles______________________________________A-25

Exercise 5: Cleaning of workpieces _____________________________________A-35

Exercise 6: Printing of mobile phone housings ____________________________A-43

Exercise 7: Packaging spark plugs ______________________________________A-49

Exercise 8: Sealing of guide bushes_____________________________________A-55

Exercise 9: Hardening of material test specimens__________________________A-63

Exercise 10: Bending of sheet metal strips _______________________________A-69

Contents

Contents

A-2 © Festo Didactic GmbH & Co. KG • 541089


• To familiarise yourself with different types of end position sensing.

• To familiarise yourself with the options of designing control systems with a

memory function.

• To be able to convert 3/2- and/or 5/2-way valves (normally closed/normally

open).

The hardening system is designed for the continual hardening of mass produced

metal parts. The workpieces are hardened and subsequently quenched in an oil-

quenching bath. The flaps at the entry and exit of the hardening system are to be

closed and opened using double-acting cylinders.

• Due to the heat build-up, no limit switches are to be used. The pressure is to be

sensed when the cylinder moves into one of the two end positions.

1. Complete the pneumatic circuit diagram.

2. Convert the directional control valves contained in the equipment set.

3. Carry out the assembly.

4. Check the assembled circuit.

5. Describe the mode of operation of the circuit.

6. Compile the equipment list.

Exercise 1: Opening and closing of an oven door

Training aims

Problem definition

Parameters

Project task



Hardening oven

1. The opening and closing function is to be started using a pushbutton 1S1.

2. A 5/2-way double pilot valve controls the double-acting cylinder. The control

pulse for this is to be the pressure that builds up when the cylinder moves into

one of the two end positions.

A pulse occurs either via valves 1V1, 1V3 to1V4: "Retract";

or a pulse occurs via valves 1V2, 1V3 to 1V4: "Advance"

3. The cylinder movement in abbreviated annotation is

1A1+ 1A1–

• What faults may occur when tubing up the circuit?

What are the effects of such faults? Describe these.

• The convertible 3/2-way pneumatic valves are intended for the required

3/2 way valves 1V1 and 1V2. These valves are supplied in normally closed

position. How do they need to be converted in order to fulfil the necessary

function?

• As an alternative, use the 5/2-way pneumatic valves. How do these need to be

converted?

• How does the circuit react after a pressure loss?

• What is a binary reducing stage?

Positional sketch

Additional exercises




Name: Date:

Completing the pneumatic circuit diagram Sheet 1 of 1

– Complete the pneumatic circuit diagram and enter the port designations.

1V4

1V3

2

1 1

2 2

2

4

4

3

3

5

5

1

1

1V5

14

14

12

12

1V6

1A1

2

31

1S1

10

10

2

2

3

3

1

1

1V2

1V1

Pneumatic circuit diagram




Name: Date:

Compiling the equipment list Sheet 1 of 1

Apart from the circuit diagram, comprehensive project documentation also requires

an equipment list.

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

below.

Quantity Description

Equipment list




Name: Date:

Carrying out additional exercises Sheet 1 of 2

– What faults can occur when tubing up the circuit?

What are the effects of such faults? Describe these.

– The convertible 3/2-way pneumatic valves are intended for the required

3/2-way valves 1V1 and 1V2. These valves are supplied in the normally closed

position. How do they need to be converted in order to fulfill the necessary

function?

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Exercise 1: Opening and closing of an over door

Name: Date:


– As an alternative, use the 5/2-way pneumatic valves for this. How do these need

to be converted?

– How does the circuit react after a loss of pressure?

– What is a binary reducing stage?

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________


• To familiarise yourself with displacement-step diagrams and to be able to design

these for a specified circuit.

• To be able to realise circuits with parallel movements in push-pull mode.

• To be able to use pneumatic decrementing counters.

In a bottling plant, bottles are to be filled with drinks. The bottles are to be

separated immediately after the filling station. Three bottles at a time are to be

pushed on to a conveyor via an ejecting cylinder. In a subsequent station, these

bottles are to be placed into a drinks crate/box?.

• It is essential to ensure that only one single start signal is emitted even if the

start button is actuated for a longer period.






Exercise 2: Separating of drinks bottles

Training aims

Problem definition

Parameters

Project task



Filling system

1. If the 5/2-way pneumatic valve with selector switch 0S1 is actuated, cylinder 1A1

is to advance and cylinder 2A1 to retract.

2. The output signal of the pneumatic proximity sensor 2B1 is to decrement the

numeric value by one at the predetermining counter 0Z1 with each actuation.

3. If the numeric value of the pneumatic predetermining counter 0Z1 is 0, the

compressed air supply of pilot port 14 of the 5/2-way double pilot valve 0V2 is to

be switched off via the 3/2-way pneumatic valve 0V1.

4. Resetting of the 5/2-way pneumatic valve with selector switch 0S1 is to reset the

pneumatic predetermining counter.

5. The cylinder movement in abbreviated notation is

1A+ 1A–

2A– 2A+

3 double strokes

Positional sketch



• What happens if both limit switches on the cylinder are moved?

Notes

• You will need to mount one of the two magnetic limit switches of the double-

acting cylinder from TP101 on the double-acting cylinder from TP102.

• The pneumatic predetermining counter 0Z1 is set by pressing the wide key

adjacent to the counter and entering the units (one, ten, .. ) (see data sheet).

Additional exercise




Name: Date:

Designing the displacement-step diagram Sheet 1 of 1

– Design the displacement-step diagram for the process described.

1A1

0

1

2A1

0

1

1 2 3=1

Displacement-step diagram




Name: Date:


– Complete the pneumatic circuit diagram.

1V1

0V2 0Z1

2V1

2

224

4

4

3

3

35

5

51

1

1

14

14

1412 12

12

31

2B1 2

1V2 2V21V3 2V3

1A1 2A1

1B1 2B1

2

1

12 10

1 11 1

2 22 2

2

31

1B1 2

10

2

31

0V1

0S1 24

35

1





Name: Date:



an equipment list.


below.


Equipment list




Name: Date:


– What happens if both limit switches on the cylinder are moved?

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________


• To be able to design indirect circuit actuation.

• To be able to compare different sensors and select appropriate sensors for an

application.

Valve manifold blocks are to be drilled horizontally and vertically by two

pneumatically actuated feed units. The two drilling axes are to intersect.

The start is to be effected via a valve with pushbutton.

• Since the drilling axes are intersecting, you need to ensure that the first drilling

operation is completed before the second one starts.






Exercise 3: Drilling of valve manifold blocks

Training aims

Problem definition

Parameters

Project task



Automatic drilling machine

1. The double-acting cylinders 1A1 and 2A1 are to be monitored in the end position

by a roller lever valve with idle return 1B1, a back pressure valve 1B2, pneumatic

proximity sensor 2B1 and a roller lever valve 2B2.

2. The start is to be effected via a 3/2-way valve with pushbutton 1S1.

3. Cylinder1A1 is to advance and simulate the first drilling operation. In the

forward end position, the cylinder is to actuate a back pressure valve 1B2, which

is to switch the final control element 1V1. Cylinder 1A1 is to retract.

4. If cylinder 1A1 is back in the retracted end position, the roller lever valve with

idle return 1B1 is to switch in the direction of flow and actuate the final control

element 2V1.

5. Cylinder 2A1 is to advance and simulate the second drilling operation. Once it

reaches the forward end position, it is to actuate the roller lever valve 2B2. The

final control element 2V1 is to reverse and cylinder 2A1 is to return into the

retracted end position where it is to actuate the pneumatic proximity sensor 2B1.


1A1+ 1A1– 2A1+ 2A1–

Positional sketch



If the cylinder impacts on the back pressure valve, this may be damaged.

• How does the circuit react if a limit switch is moved?

• What must be observed when mounting the back pressure end stop?

• Compare the function and response of the various sensors.





Name: Date:


– Design the displacement-step diagram.

1A1

0

1

2A1

0

1

1 2 3 4 5=1





Name: Date:



2

2

3

3

1

1

1S1

1B1

3 3 31 1 1

2B1 1B2 2B22 2 2

1B1 1B2 2B21A1

2A1

2B1





Name: Date:



an equipment list.


below.


Equipment list




Name: Date:


– How does the circuit react if a limit switch is moved?

– What needs to be observed when mounting the back pressure end stop?

– Compare the function and response of the various sensors.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________


• To be able to design indirect cylinder actuation.

• To familiarise yourself with the design and function of stepper modules.

• To be able to design the basic „continuous cycle“ stepper control system.

• To be able to install one-way flow control valves dependent on given parameters.

A drinks producer requires bottles to be filled automatically. During the filling

operation, the bottles are to be pressed against the extended piston rod of the

separating cylinder by a continuously running conveyor. The storage container is

located above this and is to be opened and closed by a cylinder. The cylinder is to

close the container opening in the retracted state.

• The flow control of the separating cylinder is to be set such that only the filled

bottle is released and a new, empty drinks bottle is positioned underneath the

filling valve.

1. First of all, process the introductory exercises for the stepper module.






Exercise 4: Filling of drinks bottles

Training aims

Problem definition

Parameters

Project task



Filling device

1. If a valve is actuated using selector switch 0S1, the closing cylinder 1A1 is to

advance and retract again with restricted exhaust air. Both cylinder end positions

are to be monitored via the roller lever valves 1B1 and 1B2.

2. The separating cylinder 2A1 is then to retract with restricted exhaust air and

immediately advance again with restricted exhaust air. The cylinder end

positions are to be monitored via the pneumatic proximity sensors 2B1 and 2B2.

3. Both proximity sensors and the roller lever valves are to signal the cylinder

positions to the sequencer.

4. The motion sequence is to end if the valve is reset via selector switch 0S1.


1A+ 1A– 2A– 2A+

• How does the circuit react if the roller lever valve 1B2 or the proximity sensor

2B2 are moved?

• Design the displacement-step diagram for this circuit.

Positional sketch





Name: Date:

Stepper module Sheet 1 of 3

Introductory exercise using a stepper module

(without drives and sensors)

Connect the correct connections of the stepper so that it runs automatically.

– Which connections do you need to connect together?

Connection Connection

Yn Yn+1

P P

Zn Zn+1

L L

X1 A1

X2 A2

X3 A3

X4 A4

– What are the effects of the interruption in the tubing connections?

Draw up an evaluation table.

Connection Effect

A1 – X1

A2 – X2

A3 – X3

A4 – X4

Zn – Zn+1

Yn – Yn+1




Name: Date:


Mode of operation of a stepper sequencer

A signal is input into the stepper module 1 via input, thereby triggering the output

command, e.g. 1A1+. Step 2 is prepared simultaneously and the last step in the

chain (in this case step 4) is cancelled via the output connection Z.

Step 2 is reset and an output signal, e.g. 2A1, is triggered if step 1 receives the

acknowledgement „step executed" via the limit switch 1B2. Step 3 is prepared

simultaneously and step 1 is cancelled.

The next steps are executed correspondingly.

L L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

A1

X1

YnY Yn+1 Yn+1Yn

Zn Zn Zn+1Z Z

L LLL

P PP P PP

Y

TABTAATAATAA

Zn+1

Resetting a sequencer

If the sequencer stops in any step, the currently activated step can be cancelled via a

central reset signal at connection "L". The central reset signal is transmitted to one

of the two OR inputs.




Name: Date:


– What are the advantages of the stepper module compared to reversing valve

technology?

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_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

– Which exercises can the individual stepper module undertake?

_____________________________________________________________________

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_____________________________________________________________________




Name: Date:


– Design the displacement-step diagram.

1A1

0

1

2A1

0

1

1 2 3 4 5=1





Name: Date:



Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

1V1 2V1 2 24 4

3 35 51 1

1V2 2V2

14 1412 12

1V3 2V3

1B1 1B21A1

s1

s2

s3

s4

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

1B2 2B1 2B22 2 2

3 3 31 1 1

1B1 2

31

2B1

2A1

2B2

Y

TABTAATAATAA

0S1 2

31

1 11 1

2 22 2





Name: Date:



an equipment list.


below.


Equipment list




Name: Date:


– How does the circuit react if the roller lever valve 1B2 or the proximity sensor

2B2 are moved?

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________


• To be able to design a stepper sequencer control with the input commands

AUTOMATIC/MANUAL, START and RESET.

• To be able to realise an OR function of the feedback signals.

• To be able to set time delays according to specifications.

• To familiarise yourself with circuits in order to cancel time delays via signal input.

A cleaning bath is to be fed automatically. A wire cage with material is to be moved

above the bath via a double-acting cylinder. A second double-acting cylinder is to

lower the wire cage into the cleaning bath, where it is to remain for an adjustable

time period, until it is raised again for draining. The draining time must also be

adjustable, after which the first cylinder is to return into the initial position.

• It must be possible for the drives and sequencer to be reset via a pushbutton

0S3, if a valve with selector switch 0S1 is reset from AUTOMATIC to MANUAL.

• The bath dwell time t1 is to be cancelled if pushbutton 0S4 is pressed and the

dipping cylinder 2A1 is to move into the retracted end position.

• Actuation of a valve with pushbutton 0S5 is to terminate the draining time t2 and

the horizontal cylinder 1A1 is to return into the initial position.

1. First of all, design a simplified ciruit diagram without taking into account the

parameters and time delay.

2. Assemble this circuit and check its functioning.

3. Expand the pneumatic circuit diagram in accordance with the parameters.

4. Carry out the circuit assembly.



7. Complete the equipment list.

Exercise 5: Cleaning of workpieces

Training aims

Problem definition

Parameters

Project task



Cleaning bath

1. A horizontally built-in double-acting cylinder 1A1 is to move the wire cage to the

right underneath the extractor hood, i.e. the cleaning bath, if a valve is actuated

using pushbutton 0S2.

2. The cage is to remain in the bath for t1 = 3 seconds after the double-acting

cylinder 2A1 has advanced.

3. Once the cage is raised again, it is to pause for t2 = 2 seconds to drain before the

horizontal cylinder 1A1 moves into the retracted end position again.

4. The cylinder movements are to be with exhaust air restriction at both ends.

5. The cylinder movements in abbreviated notation are

1A+ 2A+ 2A– 1A–

• Design the displacement-step diagram with signal lines.

Positional sketch





Name: Date:


– Design the displacement-step diagram with signal lines.

1A1

0

1

2A1

0

1

1 2 3 4 5=1





Name: Date:


– Complete the pneumatic circuit diagram without realising the parameters.

s1

s2

s3

s4

Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

1V1 2V1 2

1 11 1

2 22 2

24 4

3 35 51 1

1V2 2V21V3 2V3

14 1412 12

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

Y

TABTAATAATAA

1A1

1B1 1B2

2 2

3 31 1

0S2 0S3

0S1 24

351

2B1 2B22A1





Name: Date:


– Complete the pneumatic circuit diagram including the parameters.

s1

s2

s3

s4

Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

1V1 2V1 2

1 11 1

2 22 2

24 4

3 35 51 1

1V2 2V21V3 2V3

14 1412 12

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

2B2

2B1

2

2

3

3

1

1

Y

TABTAATAATAA

0V7 0V8 2 2

1/3 1/31 1

1A1

1B1 1B2

2 2 2 2

3 3 3 31 1 1 1

0S2 0S3

0S1

0S4 0S5

24

351

2B1 2B22A1

1B2 1B12 2

3 31 1

0V4 0V52 2

1/3 1/31 1

0V1 2

31

31

0V32

10

10

2

31

0V2





Name: Date:


– Modify the circuit diagram such that, during the reset function, cylinder 2A1

advances first and then cylinder 1A1.

s1

s2

s3

s4

Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

1V1 2V1 2

1 11 1

2 22 2

24 4

3 35 51 1

1V2 2V21V3 2V3

14 1412 12

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

2B1 2

31

Y

TABTAATAATAA

0V7

0V8

2 2

1/3

1/3

1

1

1A1

1B1 1B2

2 2 2

3 3 31 1 1

0S2 0S3

0S1

0S5

24

351

2B1 2B22A1

1B2 1B12 2

3 31 1

0V5 2

1/3

2

31

0S4

0V4 2

1/31 1

0V1 2

31

31

0V32

10

10

2

31

0V22B2 2

31





Name: Date:

Completing the equipment list Sheet 1 of 1


an equipment list.

– Complete the equipment list by entering the required equipment in the table

below.


2 Cylinder, double-acting

4 One-way flow control valve

2 5/2-way pneumatic double pilot valve

5/2-way valve with selector switch

3/2-way valve with pushbutton, normally closed

3/2-way pneumatic valve, normally open

3/2-way roller lever valve, normally closed

Proximity sensor, pneumatic

Shuttle valve (OR)

Dual pressure valve (AND)

Time delay valve, normally closed

Time delay valve, normally open

1 Stepper module Type 3TAA/1TAB

1 Manifold

1 On/off valve with filter regulating valve

1 Compressed air supply

Equipment list


• To be able to realise the following input commands:

EMERGENCY-STOP, acknowledge EMERGENCY-STOP, START, RESET, STOP at

CYCLE END and AUTOMATIC/MANUAL.

Mobile phone faceplates are to be printed using a tampon-printing machine. The

faceplates are to be fed in pairs via a conveyor.

The tampon printing machine sequence is to be realised via a feed unit.

• Pre-selection between MANUAL and AUTOMATIC mode is to be facilitated via a

valve with selector switch.

• In AUTOMATIC mode, two valves with pushbuttons (START, STOP at CYCLE END),

that influence a memory, are to be pressurised.

• Two further valves with mushroom actuator or pushbutton (EMERGENCY-STOP,

acknowledge EMERGENCY-STOP) also influence a memory.

• In MANUAL mode, the sequencer and the drives must be resettable via a fifth

valve with pushbutton.

1. Extend the pneumatic circuit diagram in accordance with the parameters.





Exercise 6: Printing of mobile phone housings

Training aims

Problem definition

Parameters

Project task



Tampon printing machine

1. Continuous operation is to be started by pressing the START button 0S6. The

sequence is to stop at the end of a cycle by pressing the STOP at CYCLE END

button 0S5.

2. In MANUAL mode, the cylinders and sequencer are to be resettable by pressing

the RESET button 0S4.

3. The retracting movements of the cylinders are to be exhaust air restricted.

4. The cylinder movements in abbreviated annotation are:

1A+ 3A+ 1A– 3A–

2A– 2A+

Positional sketch



Exercise 6: Printing of mobile phone casings

Name: Date:



1A1

0

1

2A1

0

1

3A1

0

1

1 2 3 4 5=1





Name: Date:



2B1

31

1B2 2 2

31

Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

1V1 3V1 2V1 2 224 4 4

3 335 551 11

1V2 2V2 3V2

14 1414

14

12 1212

12

1B1 3B11B2 3 B21A1 3A1

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

2B2

31

3B1

1B1

2

2 2

3

3

1

1

Y

TABTAATAATAA

2

31

3B2

0V9 0V10

0V12

2 2

2

1/3 1/3

1/3

1 0V8 2

1/31

1

1

2A12B1 2B2

10

10

2

23

3

1

1

0V13

0V11

0V6 24

351

14 12

0V5 2

1/31

2

2

2

2

3

3

3

3

1

1

1

1

0S6

Start

0S4

0S3

Reset

0S2

0S5

Stop at cycle end

AcknowledgeEMERGENCY-STOP

Manual/Automatic

0V2

2

2

4

4

3

3

5

5

1

1

2

31

0S1

EMERGENCY-STOP

1 1 1

2 2 2

0V1 2

31

10

s1

s2

s3

s4





Name: Date:



an equipment list.

– Complete the equipment list by entering the required equipment in the table

below.




5/2-way pneumatic double pilot valve



3/2-way valve with mushroom actuator, normally open (EMERGENCY-STOP)


3/2-way toggle lever valve with idle return, normally closed

3/2-way back pressure valve, normally closed



Shuttle valve (OR)



1 Manifold



Equipment list


• To be able to design a stepper sequencer control with idle step.

• To familiarise yourself with the option of facilitating variable step repetitions

within a motion sequence and to assemble this circuit.

• To be able to develop an input circuit with self-latching loop, that enables the

following inputs: AUTOMATIC/MANUAL, START, STOP at CYCLE END AND RESET.

• To be able to select suitable sensors for an application and adjust these sensors

(use of a sensor to detect cardboard boxes in a magazine).

Two double-acting cylinders 1A1 and 2A1 are to operate two magazines. One flat

magazine is to contain the spark plugs and the other the cardboard boxes for the

packaging. Four spark plugs each are to be fed from the flat magazine to a

cardboard box. The number of spark plugs to be packed is to be adjustable.

A cardboard box is to be pushed out of the gravity feed magazine with the advancing

of cylinder 1A1, to be ready for filling. Then, cylinder 2A1 is to execute four double

strokes, thereby separating the spark plugs from the flat magazine. The cycle is to

be completed with the retraction of cylinder 1A1 (gravity feed magazine).

• Switching between MANUAL and AUTOMATIC mode is to be possible by actuating

the valve with selector switch 0S1.

• Actuation of the STOP at CYCLE END pushbutton 0S4 is to start the cycle through

to the end and stop the control system.

• In AUTOMATIC mode, the control system is to operate in continuous cycle.

• When switching to MANUAL, both cylinders are to retract if the RESET

pushbutton 0S2 is actuated and the sequencer is to be returned into the initial

position.

• It must not be possible to start unless cardboard boxes are present. A 3/2-way

valve with selector switch 0S5 is to simulate the conditions „magazine empty“

and „magazine loaded“.

1. Complete the pneumatic circuit diagram and enter the port designations.


3. Check the circuit assembly.



Exercise 7: Packaging of spark plugs

Training aims

Problem definition

Parameters

Project task



2A1

1A1

0S5

Packaging device

1. Actuation of the START button 0S3 is to set up a self-holding circuit with the

control system operating in a continuous cycle. Actuation of the STOP at CYCLE

END button 0S4 is to interrupt the self-latching loop and cancel the stored START

signal. The self-latching loop is to be interrupted also, i.e. it cannot be set up, if

the selector switch 0S5 simulates the condition „magazine empty“, i.e. in the

absence of any packaging material in the stacking magazine.

2. In AUTOMATIC mode, the self-holding circuit and sequencer are to be supplied

with compressed air. If operation is switched to MANUAL via a 5/2-way valve

with selector switch 0S1, the RESET button 0S2 is to be supplied with

compressed air. Its actuation is to cause the two cylinders to retract and the

sequencer to assume the initial position.

3. A pneumatic predetermining counter is to count the advance movements of

cylinder 2A1 and emit a signal to the stepper sequencer when reaching a preset

value.

4. The end positions of cylinder 1A1 are to be monitored using pneumatic proximity

sensors. Two roller lever valves are to monitor the end positions of cylinder 2A1.

5. The cylinder movement in abbreviated notation is:

1A1+ 2A1+ 2A1– 1A1–

4x

• Design the displacement-step diagram for this circuit.

Positional sketch




Notes

• In practice, a roller lever valve is used to monitor whether the stacking magazine

is full. This is not suitable in this case, since continuous actuation of the valve is

not intended. The use of a 3/2-way valve with selector switch 0S5 is suggested

instead.

• According to the circuit diagram, the stepper sequencer 0Z1 consists of three

modules. The Festo Didactic stepper module is equipped with four modules. You

should therefore bridge the second step by tubing up output A2 and input X2.

The following applies for the bridging of steps:

– The last step must not be an idle step.

– Two idle steps must not be consecutively switched.

• The valves for input are:

STOP at CYCLE END 0S4,

START 0S3,

RESET 0S2,

AUTOMATIC/MANUAL 0S1.

Trial run

Proceed as follows:

1. Reset: "MAN" and "RESET"

2. Start: "AUTO" and "START"

3. Interrupt: "STOP at CYCLE END"




Name: Date:



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

2A1

0

1

1A1

0

1





Name: Date:



s1

s2

s3

s4

Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

1V1 2V1 2

1 11 1

2 22 2

24 4

3 35 51 1

1V2 2V21V3 2V3

14 1412 12

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

Y

TABTAATAATAA

0V1

2

1/3

1

1A1

1B1 1B2

2

2

22

2

2

2B1 2B22A1

1B2 1B12 2

3 31 1

0Z3 2

1

12 10

2B2 2

31

2B1 2

31

10

10

12

3

3

3

33

3

3

1

1

1

11

1

1

0V7

0V4

0V2

0S50S4

0S3

0S2

0S1 24

351





Name: Date:



an equipment list.

– Complete the equipment list by entering the number of required components in

the table below.






3/2-way valve with selector switch, normally closed


3/2-way pneumatic valve, normally closed




Pneumatic predetermining counter

Shuttle valve (OR)



1 Manifold



Equipment list


• To familiarise yourself with the option of realising the double stroke of a cylinder

and to be able to assemble this circuit.

• To familiarise yourself with circuits in order to realise the reversal of a cylinder

movement in the partial stroke range.

• To be able to develop an input circuit for a stepper control with protected pilot air

with the inputs START, AUTOMATIC/MANUAL and RESET.

Guide bushes with lapped through holes are to be sealed on both sides using a

plastic plug. The guide bushes are to be manually inserted into the device and the

plugs are to be fed via a gravity magazine.

The START signal 0S4 is to first of all trigger the advancing of the piston rod of the

exhaust air restricted double-acting cylinder 1A1. A plug is to be pressed through

the hole and close the rear righthand opening of the bush. Once the piston rod has

retracted a second plug is to follow and the piston then is to advance halfway and

immediately retract again thereby sealing the front lefthand side of the bush. The

bush can then be removed and a new sequence started.

• Actuation of the EMERGENCY-STOP mushroom actuator 0S1 is to switch off the

compressed air supply. If cylinder 1A1 is in motion, it is to return into the

retracted end position. If cylinder 1A1 is in the forward end position, it is to

remain there.

• If the RESET button 0S5 is actuated, both the cylinder and the stepper sequencer

are to move into the initial position.

1. Complete the circuit diagram.





Exercise 8: Sealing of guide bushes

Training aims

Problem definition

Parameters

Project task



1B1 1B3 1B2

1A1

Sealing device

1. A single cycle is to be introduced by pressing the START button 0S4. The

AUTOMATIC/MANUAL switch 0S3 is switched to AUTOMATIC for this. The pilot air

supply of the stepper sequencer is to be protected by means of a self-latching

loop via valves 0V3, 0V4 and 0V5.

2. The retracted end position of the cylinder is to be monitored via roller lever valve

1B1 and the forward end position via roller lever valve 1B2. The reversal in the

partial stroke range is to be triggered by the pneumatic proximity sensor 1B3.

3. Roller lever valve 1B1 is to transmit its signal to inputs X2 and X4 of the stepper

sequencer, since a second start takes place within a cycle.

Positional sketch



Note

• This is a case where a signalling element actuates two stepper modules

simultaneously.

The magnetic limit switch (1S4) simultaneously operates inputs X2 and X4. If the

second step is reset, then this transmits the pulse. If the fourth step is reset, then

the signal is sent to the cylinder via A4 and resets the stepper module. Both step

outputs are connected via the shuttle valve (0V6), i.e. both the second step and

fourth step emit the pulse to the final control element (1V1) via valves (0V7),

(0V10) and (0V11).


• Convert an available 5/2-way pneumatic valve into the required 3/2-way

pneumatic valve. Check the functioning of the valve prior to installation.





Name: Date:



1 2 3 4 5=1

0

1A m

1





Name: Date:



0V6

2

1/31

1B3

31

2

Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

1V1 24

35 1

1V2 1V3

14 12

1B1 1B2

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

1B1 2

31

Y

TABTAATAATAA

2

31

1B2

0V7

0V3

0V12

0V13

2

2

2

2

1/3

1/3

1/3

1/3

1

1

1

1

0V8 2

1/31

1B3

10

10

12

10

102

2

2

2

2

3

3

3

3

3

1

1

1

1

1

0V9

0V5

0V4

0V11

0V10

22

33 11

0S50S4

1 1

2 2

s1s2s3s4

1A1

14 12

0S3 Manual/Automatic

0V2

2

2

4

4

3

3

5

5

1

1

2

31

0S1

EMERGENCY-

STOP

0V1 2

31

10

2

31

0S2


Start Reset





Name: Date:



an equipment list.


the table below.






3/2-way valve with mushroom actuator, normally open (EMERGENCY-STOP)





Shuttle valve (OR)


1 Stepper module Type 3TAA/1 TAB

1 Manifold



Equipment list




Name: Date:

Carrying out additional exercises. Sheet 1 of 1

– Convert an available 5/2-way pneumatic valve into the required 3/2-way

pneumatic valve. Check the functioning of the valve prior to installation.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________


• To be able to stop a double-acting cylinder in the partial stroke range.

• To understand how valve output signals can be inverted.

• To be able to select appropriate sensors for an application and adjust these.

Steel tool specimens from various smelters are to undergo reproducible heat

treatment. The alloyed steel tool specimens are to be annealed, quenched and

tempered.

A test specimen is to be placed into a wire cage and the START button actuated.

Cylinder 1A1 is to move from the retracted end position into the mid-position. After

an annealing time of t1 = 3 seconds, the forward end position is to be approached

and the test specimen quenched by a jet of tempered oil or water. Before the

cylinder assumes the initial position again, it is to remain in the mid-position for

tempering for t2 = 2 seconds.





5. Check the equipment list.

Exercise 9: Hardening of material test specimens

Training aims

Problem definition

Project task



t = 3 s1

t = 2 s2

1B1 1B3 1B2

Hardening device

1. If the START button 0S1 is pressed, cylinder 1A1 is to move from the retracted

end position into the mid-position. The retracted end position is to be monitored

via the roller lever valve 1B1 and the mid-position via the pneumatic proximity

sensor 1B3.

2. The cylinder is to remain in the mid-position for a preset time of t1 = 3 seconds

for the annealing of the test specimen. After this, the righthand end position is to

be approached and the roller lever valve 1B2 actuated.

3. The cylinder is to retract into the mid-position again. A further time delay valve

now starts and the cylinder returns into the retracted end position after a time

period of t2 = 2 seconds.


Positional sketch

Additional exercise




Name: Date:



0

1A1 m

1

1 2 3 4 5=1





Name: Date:



s1

s2

s3

s4

Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

Y

TABTAATAATAA

2

31

0S1 1B3 2

31

1B2 1B12 2

3 31 1

10

0V60V5 22

1/31/3 11

2

31

1V3 1V4

1V61V5

1A1

1B3

12 12

10

2 2

2

3 3

3

1 1

1

1V1 1V2

0V30V2

0V4

1

2 2

1

2

1 121 21

2

1B1 1B2

2

31





Name: Date:

Checking the equipment list Sheet 1 of 1


an equipment list.

– Check the equipment list by comparing the number of components listed in the

table below with your circuit design.



Non-return valve, piloted

One-way flow control valve






Time delay valve, normally closed


Shuttle valve (OR)



1 Manifold



Equipment list


• To be able to realise a control system with control behaviour in combination with

a sequence control in stepper design.

• To be able to select appropriate sensors for an application and to adjust these.

Sheet metal strips are to be bent using a bending tool. A sheet metal strip is to be

manually inserted into the bending device. Once the START button is actuated, a

cylinder is to clamp the workpiece. The first bending cylinder is to pre-bend the

metal strip and immediately retract again. The second bending cylinder is to

complete the bending of the metal strip. Following this, the second bending cylinder

and the clamping cylinder are to retract simultaneously and the newly formed

bracket is to be removed manually.

• The clamping cylinder is to exhibit monitored behaviour when advancing, i.e. the

sequence control is to be started when the forward end position is reached. If the

START button is released before the cylinder reaches the forward end position, it

is to return into the initial position again.

1. Complete the circuit diagram.




5. Check the equipment list.

Exercise 10: Bending of sheet metal strips

Training aims

Problem definition

Parameters

Project task



1A1

2A1

3A1

Bending device

1. The single-acting clamping cylinder 1A1 operates with throttled supply air and is

to be actuated via a spring-returned 3/2-way pneumatic valve. The bending

cylinders 2A1 and 3A1 are to be actuated via 5/2-way double pilot valves and a

stepper module.

2. The end positions of the double-acting bending cylinder 2A1 are to be sensed via

a roller lever valve 2B1 and a roller lever valve with idle return 2B2, and those of

the double-acting bending cylinder 3A1 via a pneumatic proximity sensor 3B1

and 3B2. A back pressure valve 1B2 is to monitor the forward end position of the

single-acting clamping cylinder 1A1 and the retracted end position is to be

monitored via the roller lever valve 1B1.

3. The START button 0S1 must be held down until the clamping cylinder 1A1 is

advanced and the back pressure valve has responded, whereby the stepper

sequencer receives the signal for starting.

Positional sketch



4. The bending cylinder 2A1 is to advance and actuate the roller lever valve with

idle return 2B2 in its forward end position. This is to reset the first module and

switch the second step. The bending cylinder 2A1 is to retract immediately again

and actuate the roller lever valve 2B1 in the retracted end position. This is to

reset the second module and switch the third step. Bending cylinder 3A1 is to

advance and actuate pneumatic proximity sensor 3B2 in the forward end

position. This is to reset the third module and switch the fourth step. Clamping

cylinder 1A1 is to be exhausted and return into the retracted end position. At the

same time, the bending cylinder 3A1 is to retract and actuate pneumatic

proximity sensor 3B1 in the retracted end position. This is to reset the fourth

module and consequently the stepper sequencer.


1A1+ 2A1+ 2A1– 3A1+ 3A1–

1A1–

Notes

• The safety guards required in practice are not taken into consideration.

• Reliable clamping is to be ensured before the bending process is started. The

back pressure valve 1B2 ensures that the metal strip is reliably clamped by the

clamping cylinder. The manually operated valve 0S1 must be actuated until the

back pressure valve 1B2 reacts. This latching safeguards the subsequent

bending operations.

• As the circuit requires 3 roller lever valves, but only two are contained in the

TP101 and TP102 construction kits, valve 2B2 has been replaced by a roller lever

valve with idle return.


• Convert the available 5/2-way double pilot valves into the required 3/2-way

double pilot valves. Check the functioning of the valves prior to installation.

Additional exercise




Name: Date:



1 2 3 4 5 6=1

1A1

0

1

2A1

0

1

3A1

0

1





Name: Date:



s1

s2

s3

s4

Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

2V1 2

1 1

2 2

24 4

3 35 51 1

2V2 3V2

1412 1412 12

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

Y

TABTAATAATAA

3A1

3B1 3B2

2 2

3 31 1

0S1 1B2

2B1 2B21B22A1

3B2 2

31

3

3

1

1

0V3

0V2

12

12

10

10

3B1 2

31

2

31

2B2 2B1

1B1

2

2

3

3

1

1

0V4 2

1/31

2

2

1V2

1A1

1V1 2

31

1B1

2

1





Name: Date:



an equipment list.





1 Cylinder, single-acting






3/2-way toggle lever valve with idle return, normally closed

3/2-way back pressure valve, normally closed



Shuttle valve (OR)



1 Manifold



Equipment list




Name: Date:

Carrying out additional exercises. Sheet 1 of 1

– Convert the available 5/2-way double pilot valves into the required 3/2-way

double pilot valves. Check the functioning of the valves prior to installation.

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

© Festo Didactic GmbH & Co. KG • 541089 B-1

The theoretical fundamentals for the pneumatics training package are summarised

in the textbook:

Pneumatics, Basic Level

This book is intended for basic training in pneumatic control technology and teaches

the physical fundamentals of pneumatic control technology as well as the function

and use of pneumatic components. Numerous illustrations and diagrams aid

comprehension. Pneumatic circuits are explained with the help of examples and

sample solutions and detailed explanations improve the students’ knowledge of

circuit design and sequences.

P. Croser, F. Ebel, 2002 edition,

274 pages, bound

Order No.: 093131

Part B – Fundamentals

B-2 © Festo Didactic GmbH & Co. KG • 541089

© Festo Didactic GmbH & Co. KG • 541089 C-1

Part C – Solutions

Exercise 1: Opening and closing of an oven door ___________________________C-3

Exercise 2: Separating of drinks bottles __________________________________C-7

Exercise 3: Drilling of valve manifold blocks ______________________________C-11

Exercise 4: Filling of drinks bottles______________________________________C-17

Exercise 5: Cleaning of workpieces _____________________________________C-27

Exercise 6: Printing of mobile phone housings ____________________________C-35

Exercise 7: Packaging of spark plugs ____________________________________C-41

Exercise 8: Sealing of guide bushes_____________________________________C-47

Exercise 9: Hardening of material test specimens__________________________C-53

Exercise 10: Bending of sheet metal strips _______________________________C-59

Contents

Contents

C-2 © Festo Didactic GmbH & Co. KG • 541089



Name: Date:


1V4

1V3

2

1 1

2 2

2

4

4

3

3

5

5

1

1

1V5

14

14

12

12

1V6

1A1

2

31

1S1

10

10

2

2

3

3

1

1

1V2

1V1



Solutions

Exercise 1: Opening and closing of an oven door Solutions



Name: Date:

Process description Sheet 1 of 1

Initial position

The oven door is closed. The piston rod of cylinder 1A1 is advanced. The 5/2-way

double pilot valve 1V4 (final control element) pressurises the piston chamber and

exhausts the piston rod chamber. The 5/2-way double pilot valve 1V3 (reversing

valve) is switched to flow from 1 to 4.

Steps 1-2 – opening the oven door

The 3/2-way pneumatic valves 1V1 and 1V2 are actuated simultaneously if the

pushbutton on the 3/2-way valve 1S1 is pressed. Pilot ports 12 and 14 of the

reversing valve 1V3 are exhausted. The compressed air then pressurises the pilot

port 12 of the 5/2-way double pilot valve 1V4 via ports 1 and 4 of the 5/2-way

double pilot valve 1V3. Valve 1V4 switches. The piston rod end of cylinder 1A1 is

pressurised and the piston returns into the retracted end position.

At the same time, the pilot port 12 of the reversing valve 1V3 is pressurised via the

3/2-way pneumatic valve 1V2. The reversing valve 1V3 is connected such as to

enable the reversing of the final control element 1V4 via a new start signal.

Steps 2-3 – closing the oven door

The 3/2-way pneumatic valves 1V1 and 1V2 are simultaneously actuated if the

pushbutton at the 3/2-way valve 1S1 is pressed again. The pilot ports 12 and 14 of

the reversing valve 1V3 are exhausted. The compressed air then pressurises pilot

port 14 of the final control element 1V4 via ports 1 and 1 of the reversing valve 1V3.

Cylinder 1A1 is pressurised at the piston end. The piston rod advances.

At the same time pilot port 14 of the reversing valve 1V3 is pressurised again as a

result of the air via the 3/2-way pneumatic valve 1V1. The control system is in the

initial position again and the oven door can be opened again via a new start signal.




Name: Date:


Apart from a circuit diagram, comprehensive project documentation also requires an

equipment list.


below.





1 3/2-way valve with pushbutton, normally closed

2 3/2-way pneumatic valve, normally open

1 Manifold



Equipment list




Name: Date:


What faults can occur during the tubing up of circuits?

What is the effect of such faults? Describe these.

The 3/2-way valves have not been correctly converted. � Circuit does not function.

Port 2 has been mixed up with port 4 on valve 1V4. � Cylinder does not advance.

How do the 3/2-way valves need to be converted in order to fulfil the necessary

function?

The valves have to be converted to normally open by swapping the blanking plug

and working port.

How do the 5/2-way pneumatic valves need to be converted?

Working port 4 needs to be closed.

Possible solution if a blanking plug is not available: Plug a T-piece (push-in T-

connector) with short tubing onto the valve and connect the remaining two outputs

of the T-piece with a short piece of tubing.

What is the behaviour of the circuit after pressure loss?

The activating circuit stores its status. The result: If the door is moved during

pressure loss, it will return to its previous position if pressure is renewed.

What is a binary reducing stage?

Binary reducing stages are also known as toggle flip flops.

Flip-flops, also referred to as bistable elements, are circuits, that realise basic status

memories.

They assume two statuses: Set and reset. In order to set the flip-flop, a signal needs

to be applied at the input, in this case a pressure signal. The flip-flop then remains in

the set status until a further signal is applied at the input. A binary digit (0 or 1) can

be represented via these statuses.

A binary reducing state changes its status with every active pulse edge, i.e. it acts as

a frequency divider/reducer.



Name: Date:


1V1

0V2 0Z1

2V1

2

224

4

4

3

3

35

5

51

1

1

14

14

1412 12

12

31

2B1 2

1V2 2V21V3 2V3

1A1 2A1

1B1 2B1

2

1

12 10

1 11 1

2 22 2

2

31

1B1 2

10

2

31

0V1

0S1 24

35

1



Solutions

Exercise 2: Separating of drinks bottles Solutions



Name: Date:


Initial position

Cylinder 1A1 is in the retracted end position. Cylinder 2A1 assumes the forward end

position. The pneumatic proximity sensor 1B1 is actuated. The 5/2-way valve 0S1 is

detented to flow from 1 to 2. The pneumatic predetermining counter 0Z1 is reset and

set to preset value 3.

Separating of drinks bottles

Actuation of the start pushbutton 0S1 causes the pneumatic signal to be switched to

pilot port 14 of the 5/2-way double pilot valve via the 3/2-way valve 0V1 and the

pneumatic proximity sensor 1B1.

Both of the two 5/2-way double pilot valves1V1 and 2V1 are reversed via output 4 of

the 5/2-way double pilot valve 0V2. The piston rod of cylinder 1A1 advances and the

piston rod of cylinder 2A1 retracts.

If cylinder 1A1 moves out of the retracted end position, the pneumatic proximity

sensor 1B1 is no longer actuated and pilot port 14 of the 5/2-way double pilot valve

0V2 is exhausted.

The pneumatic proximity sensor 2B1 is actuated if cylinder 2A1 reaches the

retracted end position. The output signal of the pneumatic proximity sensor 2B1

reverses the 5/2-way double pilot valve 0V2. At the same time, this output signal is

applied to pilot port 12 of the pneumatic predetermining counter and the preset

value is reduced by 1.

Cylinder 1A1 retracts again and cylinder 2A1 advances. This process is repeated

until the pneumatic predetermining counter 0Z1 has counted to 0. Once the value is

0, a pneumatic signal is applied at pilot port 10 of the 3/2-way valve 0V1 by output 2

of the predetermining counter. This causes the air supply to pilot port 14 of the

5/2-way double pilot valve 0V2 to be interrupted.

Cylinder 1A1 is in the retracted end position again and cylinder 2A1 in the forward

end position.



Exercise 2:Separating of drinks bottles

Name: Date:



equipment list.


below.





1 5/2-way valve with selector switch


2 Proximity sensor, pneumatic

1 Pneumatic predetermining counter

1 Manifold



Equipment list




Name: Date:


– Draw the displacement-step diagram with signal lines.

2B1

1B1

0S2

1A1

0

1

2A1

0

1

1 2 3=1

What happens if both proximity sensors are moved on the cylinder?

If the cylinders move into the end position, the pneumatic proximity sensors are not

actuated and the circuit no longer starts.



Name: Date:


2

2

3

3

1

1

1S1

1B1

1V1 2V1 2

1 11 1

2 22 2

24 4

3 35 5

1 1

1V2 2V2

14 1412 12

3 3 31 1 1

2B1 1B2 2B2

1V3 2V3

2 2 2

1B1 1B2 2B21A1

2A1

2B1



Solutions

Exercise 3: Drilling of valve manifold blocks Solutions



Name: Date:


In this exercise, the end position of the double-acting cylinder is monitored via four

different sensors.

Double-acting cylinder 1A1

Retracted end position: 3/2-way toggle lever valve with idle return 1B1

Forward end position: Back pressure valve 1B2

Double-acting cylinder 2A1

Retracted end position: Pneumatic proximity sensor 2B1

Forward end position: Roller lever valve 2B2

Initial position

The double-acting cylinders 1A1 and 2A1 are in the retracted end position. The

pneumatic proximity sensor 2B1 is actuated. The roller lever valve with idle return

1B1 is overtravelled by the trip cam of cylinder 1A1 and therefore not actuated. The

final control elements 1V1 and 2V1 each assume the switching position with flow

from 1 to 2.

Drilling using a vertical feed unit

Actuation of the START button 1S1 causes the final control element 1V1 to switch via

the switched-through pneumatic proximity sensor 2B1. The piston rod of cylinder

1A1 advances and back pressure valve 1B2 is actuated in the forward end position.

The final control element 1V1 is reversed again and cylinder 1A1 retracts.

Drilling using a horizontal feed unit

Just before reaching the retracted end position, the trip cam of cylinder 1A1

overtravels the roller lever valve with idle return 1B1. The final control element 2V1

is switched from 1 to 4 via the output signal of valve 1B1. The piston rod of cylinder

2A1 advances. Upon reaching the forward end position, cylinder 2A1 actuates the

roller lever valve 2B2. The output signal of valve 2B2 reverses the final control

element 2V1. The piston rod of cylinder 2A1 retracts and actuates the pneumatic

proximity sensor 2B1.

The interlock of the START button 1S1 is cancelled. A new cycle can be triggered via

a renewed manual start signal. This ensures that the feed units cannot collide.




Name: Date:



equipment list.


below.






1 3/2-way toggle lever valve with idle return, normally closed

1 3/2-way back pressure valve, normally closed

1 3/2-way roller lever valve, normally closed


1 Manifold



Equipment list




Name: Date:


– Draw the displacement-step diagram with signal lines.

2B1

1B1

1S1

1A1

0

1

2A1

0

1

1 2 3 4 5=1

2B2

1B2





Name: Date:


How does the circuit react if the roller lever valve is moved?

The cylinder does not fully advance, but only up to the position of the roller lever

valve.

What needs to be considered when mounting the back pressure valve?

It is important to adjust the back pressure valve correctly. On a permanently

installed valve this is facilitated by releasing the lock nut or by twisting the trip cam

on the piston rod. In the test set-up, the back pressure valve is moved along the

profile slot.

If the cylinder impacts on the valve, this can be damaged.

Use and comparison of different sensors

Sensor Type of actuation Use Observe

Roller lever valve

with idle return

Mechanical Signal overlap Actuation direction, when

the sensor actuated

Back pressure end

stop

Compressed air Monitoring of cylinder

end position

Correct adjustment

Pneumatic limit

switch

Magnetic START interlock Position on cylinder

Roller lever valve Mechanical Monitoring of cylinder

end position

Response point



Name: Date:


Introductory exercise with the stepper module

(without drive or sensors)

Connect the correct step connections so that it runs through automatically.

– Which connections need to be interconnected?

Connection Connection

Yn –––––––––––––––––––––––––––––––––––––––––––– Yn+1

P Compressed air Blanking plug P

Zn –––––––––––––––––––––––––––––––––––––––––––– Zn+1

L Not connected, open L

X1 –––––––––––––––––––––––––––––––––––––––––––– A1

X2 –––––––––––––––––––––––––––––––––––––––––––– A2

X3 –––––––––––––––––––––––––––––––––––––––––––– A3

X4 –––––––––––––––––––––––––––––––––––––––––––– A4

– What are the consequences of the interruption in the tubing connections?

Create an evaluation table.

Connection Effect

A1 – X1 Not running. Stepper module stops.




Zn – Zn+1 Not running. Stepper module stops.

Yn – Yn+1 Not running. Stepper module stops.


Solutions

Exercise 4: Filling of drinks bottles Solutions



Name: Date:


Mode of operation of a stepper sequencer

A start signal is input at stepper module 1 via input Yn. This triggers the output

command, e.g. 1A1+. At the same time, step 2 is prepared and the last step in the

sequence (in this case step 4) is cancelled via the output connection Z.

If step 1 receives the "command executed" acknowledgement via limit switch 1B2,

step 2 is set and an output signal, e.g. 2A1+ is triggered. At the same time, step 3 is

prepared and step 1 cancelled.

The next steps are run in parallel.

L L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

A1

X1

YnY Yn+1 Yn+1Yn

Zn Zn Zn+1Z Z

L LLL

P PP P PP

Y

TABTAATAATAA

Zn+1

Resetting a stepper sequencer

If the sequencer stops at any step, the currently activated step can be cancelled via a

central reset signal at connection "L". The central reset signal is transmitted to one

of the two OR inputs.




Name: Date:


What are the advantages of a stepper module compared to reversing valve

technology?

Stepper technology has indisputable advantages compared to reversing valve

technology (cascaded control systems) or the use of roller lever valves with idle

return:

• Minimal design complexity (circuit diagram)

• Simplified reading and understanding of circuit diagram (black box principle)

• Less tubing required (assembly time)

• Parameters can be more easily realised

• Less work required when modifying a control system

• Greater operational reliability

• Simplified monitoring via visual indicator and manual override.

What tasks can the individual stepper module assume?

The individual stepper module completes three tasks:

• Switching through (transmission) of signals from input X to output A

• Preparation of the following step

• Cancelling the previous step




Name: Date:


Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

1V1 2V1 2 24 4

3 35 51 1

1V2 2V2

14 1412 12

1V3 2V3

1B1 1B21A1

s1

s2

s3

s4

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

1B2 2B1 2B22 2 2

3 3 31 1 1

1B1 2

31

2B1

2A1

2B2

Y

TABTAATAATAA

0S1 2

31

1 11 1

2 22 2





Name: Date:


Initial position

Cylinder 1A1 assumes the retracted end position, the piston rod of cylinder 2A1 is

advanced and roller lever valve 1B1 is actuated. The pneumatic proximity sensor

2B2 is switched through via the permanent magnet on the piston and a signal is

therefore applied at input X4 of the stepper sequencer. Output A4 is active. A signal

is applied at the dual pressure valve 0V1 via Yn+1.

Filling bottles, cylinder 1A1

Actuation of the START button 0S1 causes the memory of the first module (Type A)

to be reset via the dual pressure valve 0V1. The output signal A1 reverses the final

control element 1V1 and the cylinder 1A1 advances. Upon reaching the forward end

position, the cylinder actuates the roller lever valve 1B2. This causes the first

module at input X1 to be pressurised. The spring returned 3/2-way valve of the first

module is reversed and the memory is reset at the subsequent second module (Type

A). The output signal A2 of the second module reverses the final control element

1V1. Cylinder 1A1 returns into the retracted end position. Signal A2 also cancels the

memory valve of the first module. It can only be switched via a new start signal and

the output signal Yn+1.

Bottle release, cylinder 2A1

Cylinder 1A1 in the retracted end position actuates the roller lever valve 1B1. Its

signal acknowledges the output signal A2 at X2 and switches through to the third

module (type A). The output signal A3 reverses the final control element 2V1 and

cylinder 2A1 retracts. The pneumatic proximity sensor 2B1 acknowledges the

movement and switches through to the fourth module (type B) via X3. Its signal

reverses the final control element and cylinder 2A1 advances. The pneumatic

proximity sensor 2B2 acknowledges the end position of the cylinder via X4. The

spring returned 3/2-way valve of the fourth module (type B) is switched. The signal

Yn+1 is applied at the dual pressure valve 0V1 again.




Name: Date:


Single cycle

If the START button 1S1 is only briefly pressed, i.e. not detented for continuous

cycle, only signal Yn+1 is applied at the dual pressure valve 0V1 at the end of a

cycle. A new cycle cannot be started until the START button is actuated again.

Continuous cycle

If the START button 1S1 is detented, a continuous signal is applied at input 1 of the

dual pressure valve 0V1. A new cycle starts automatically if the initial position of the

cylinder is signalled via connection Yn+1 of the fourth stepper module (type B).

Cycle end

Disengaging the START button 1S1.

Filling of bottles, cylinder 1A1

Actuation of the START button 1S1 triggers the output signal A1 via 0V1, which

switches 1V1 via connection 14. Cylinder 1A1 advances and actuates 1B2. 1B2

triggers the output signal A2 via input X1. 1V1 reverses; cylinder 1A1 retracts and

actuates 1B1. Signal is applied at input X2.

Releasing of bottles, cylinder 2A1

Signal at X2 pressurises output A3. 2V1 reverses; cylinder 2A1 retracts and actuates

2B1. 2B1 effects connection X3 and thus pressurises A4. 2V1 reverses; cylinder 2A1

advances and actuates 2B2. 2B2 produces X4 and Yn+1. Dual pressure valve 0V1 is

pressurised on one side.

Simplified description




Name: Date:



equipment list.


below.





1 3/2-way valve with selector switch, normally closed



1 Dual pressure valve (AND)

1 Stepper module Type 3TAA/1TAA

1 Manifold



Equipment list




Name: Date:


– Design the displacement-step diagram with the signal lines.

2B2

1B1

0S1

1A1

0

1

2A1

0

1

1 2 3 4 5=1

2B1

1B2





Name: Date:


How does the circuit react, if sensors 1B2 and 2B2 are displaced?

If the pneumatic proximity sensor 2B2 is displaced when the cylinder is advanced,

the proximity sensor is not attenuated and a start condition is not available. The

system will not start up.

If the roller lever valve 1B2 is displaced such that it is not actuated in the cylinder

end position, the cylinder no longer retracts.



Name: Date:


s1

s2

s3

s4

Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

1V1 2V1 2

1 11 1

2 22 2

24 4

3 35 51 1

1V2 2V21V3 2V3

14 1412 12

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

Y

TABTAATAATAA

0V7 0V8 2 2

1/3 1/31 1

1A1

1B1 1B2

2 2

3 31 1

0S2 0S3

0S1 24

351

2B1 2B22A1

1B2 2

31

2B1 2

31

2B2 2

31

1B1 2

31

Pneumatic circuit diagram without parameter conditions


Solutions

Exercise 5: Cleaning of workpieces Solutions



Name: Date:


s1

s2

s3

s4

Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

1V1 2V1 2

1 11 1

2 22 2

24 4

3 35 51 1

1V2 2V21V3 2V3

14 1412 12

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

2B2

2B1

2

2

3

3

1

1

Y

TABTAATAATAA

0V7 0V8 2 2

1/3 1/31 1

1A1

1B1 1B2

2 2 2 2

3 3 3 31 1 1 1

0S2 0S3

0S1

0S4 0S5

24

351

2B1 2B22A1

1B2 1B12 2

3 31 1

0V4 0V52 2

1/3 1/31 1

0V1 2

31

31

0V32

10

10

2

31

0V2

Pneumatic circuit diagram with parameter conditions




Name: Date:


s1

s2

s3

s4

Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

1V1 2V1 2

1 11 1

2 22 2

24 4

3 35 51 1

1V2 2V21V3 2V3

14 1412 12

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

2B1 2

31

Y

TABTAATAATAA

0V7

0V8

2 2

1/3

1/3

1

1

1A1

1B1 1B2

2 2 2

3 3 31 1 1

0S2 0S3

0S1

0S5

24

351

2B1 2B22A1

1B2 1B12 2

3 31 1

0V5 2

1/3

2

31

0S4

0V4 2

1/31 1

0V1 2

31

31

0V32

10

10

2

31

0V22B2 2

31

Pneumatic circuit diagram with latching of the reset function




Name: Date:


Components used:

Delays (t1 = 3 sec; t

2 = 2 sec) are designated. Component 0V1 is the already familiar

time delay valve with normally closed position. Component 0V2 is a time delay valve

with interchanged positions, i.e. normally open. The output signal of this time delay

valve needs to be inverted. A 3/2-way pneumatic valve with normally open position

0V3 assumes this function.

The 5/2-way pneumatic valve with selector switch 0S1 facilitates the switching of

AUTOMATIC/MANUAL. "MAN" in combination with the actuation of pushbutton 0S2

causes the sequencer and cylinder to be reset, i.e. all valves and cylinders assume

the initial position. "AUTO" in combination with the actuation of the START

button 0S2 initiates the automatic execution of a cycle (single cycle).

The delays can be shortened or cancelled via the pushbuttons 0S4 (immersion time)

and 0S5 (draining time).

Initial position

Cylinder 1A1 is in the retracted end position. The pneumatic proximity sensor 1B1 is

attenuated and switched to flow from 1 to 2. Cylinder 2A1 is in the retracted end

position. The roller lever valve 2B1 is actuated. The 5/2-way pneumatic valve with

selector switch 0S1 is switched to AUTOMATIC, flow from 1 to 2.

Steps 1-2

Cylinder 1A1 moves to the right above the electroplating bath (movement 1A1+).

The START signal is input to the first module of the stepper sequencer, connection

Yn, via the 3/2-way valve 0S2 and via the dual pressure valve 0V6, (module 4 is

deactivated via line Z). The final control element 1V1 is reversed via output A1 and

cylinder 1A1 advances.

Steps 2-3

Cylinder 2A1 immerses the wire cage into the electroplating bath (movement

2A1+).

Cylinder 1A1 switches through the pneumatic proximity sensor 1B2. Its signal is

applied at input X1 of the stepper module 0Z1. The sequencer switches through to

the second module. The final control element is reversed via output A2. Cylinder 2A1

advances and actuates the roller lever valve 2B2 in the forward end position.




Name: Date:


Steps 3-4

Cylinder 2A1 raises the wire cage (movement 2A1-).

After the set time t1 = 3 sec, the time delay valve 0V1 switches to flow. Its signal

pressurises input X2 of the second module of the stepper sequencer. The third

module is reset. The final control element 2V1 is reversed via output A3 and the

shuttle valve 0V8. Cylinder 2A1 retracts and actuates the roller lever valve 2B1 in the

retracted end position.

Steps 4-5

Cylinder 1A moves to the left (movement 1A-).

After the set time t2 = 2 sec, the time delay valve 0V2 exhausts the pilot line of the

3/2-way pneumatic valve 0V3. This switches to normally open. Connection X3 of the

stepper sequencer is pressurised via the shuttle valve 0V5 (the signal switch-off of

the time delay valve 0V2 has been inverted). Signal X3 switches through to the

fourth module. The dual pressure valve 0V7 is supplied with compressed air via

output A4. The final control element 1V1 is reversed via the simultaneously applied

output signal of the roller lever valve 2B1. Cylinder 1A1 retracts and actuates the

pneumatic proximity sensor 1B1. Its signal switches through the fourth module of

the stepper sequencer. The signal Yn+1 is applied at the dual pressure valve 0V6. A

new cycle can now commence via a start signal.




Name: Date:



equipment list.


the table below.










4 Shuttle valve (OR)


1 Time delay valve, normally closed

1 Time delay valve, normally open


1 Manifold



Equipment list




Name: Date:



0V1

1B2

1B1

2B2

2B1

0V2

1A1

0

1

2A1

0

1

0S2 0S5

0S4

t1

1 2 3 4 5=1

t2




Name: Date:


2B1

31

1B2 2 2

31

Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

1V1 3V1 2V1 2 224 4 4

3 335 551 11

1V2 2V2 3V2

14 1414

14

12 1212

12

1B1 3B11B2 3 B21A1 3A1

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

2B2

31

3B1

1B1

2

2 2

3

3

1

1

Y

TABTAATAATAA

2

31

3B2

0V9 0V10

0V12

2 2

2

1/3 1/3

1/3

1 0V8 2

1/31

1

1

2A12B1 2B2

10

10

2

23

3

1

1

0V13

0V11

0V6 24

351

14 12

0V5 2

1/31

2

2

2

2

3

3

3

3

1

1

1

1

0S6Start

0S4

0S3

Reset

0S2

0S5Stop at cycle end


Manual/Automatic

0V2

2

2

4

4

3

3

5

5

1

1

2

31

0S1

EMERGENCY-STOP

1 1 1

2 2 2

0V1 2

31

10

s1

s2

s3

s4



Solutions

Exercise 6: Printing of mobile phone housings Solutions



Name: Date:


Initial position

The double-acting cylinder 1A1 is in the retracted end position and actuates the

roller lever valve 1B1. The double-acting cylinder 2A1 is advanced and actuates the

pneumatic proximity sensor 2B2. The double-acting cylinder 3A1 is in the retracted

end position and actuates the roller lever valve 3B1. The 5/2-way pneumatic valve

with selector switch 0S3 is detented to flow from 1-2. The 3/2-way pneumatic valve

with the „EMERGENCY-STOP“ mushroom actuator 0S1 is unlatched. The memory

valve 0V2 has flow from 1 to 2. The stepper sequencer is reset.

Continuous cycle

Steps 1-2

Cylinder 1A1 advances, cylinder 2A1 retracts.

The START signal 0S6 switches the memory valve 0V6 from 1 to 4. A continuous

signal is applied at the dual pressure valve 0V7. Combined with signal Yn+1 of the

last module of the sequencer, the dual pressure valve 0V7 is able to input the start

pulse into the stepper sequencer. The output signal A1 simultaneously reverses the

final control elements 1V1 and 2V1 via string s1. Cylinder 1A1 advances and cylinder

2A1 retracts throttled.

Steps 2-3

Feed cylinder 3A1 advances, whereby cylinder 1A1 remains advanced.

As soon as cylinder 1A1 reaches the forward end position and cylinder 2A1 reaches

the retracted end position, the sequencer is advanced via the acknowledgement

signal X1. The dual pressure valve 0V3 ensures that only one signal arrives at X1, if

both the back pressure valve 1B2 and the pneumatic proximity sensor 2B1 are

actuated. Signal A2 reverses the final control element 3V1 via string s2. The double-

acting cylinder 3A1 advances and actuates the roller lever valve with idle return 3B2

in the end position.




Name: Date:


Steps 3-4

Cylinder 1A1 retracts, cylinder 2A1 advances.

The acknowledgement signal of the roller lever valve with idle return 3B2 advances

the stepper sequencer by one step via connection X2. The actuating signal A3

reverses the final control elements 1V1 and 2V1 via the pilot line s3. Cylinder 1A1

moves into the retracted end position and actuates the roller lever valve 1B1,

cylinder 2A1 moves into the forward end position and actuates the pneumatic


Steps 4-5

Feed cylinder 3A1 retracts, whereby cylinder 2A1 remains advanced.

Once cylinders 1A1 and 2A1 have acknowledged their end positions (initial position)

(1B1 and 2B2 actuated), the signal of the dual pressure valve 0V4 at input X3

advances the stepper sequencer by one step. The actuating signal reverses the final

control element 3V1 via string s4. Cylinder 3A1 retracts and one cycle is completed.

Two signals are now applied again at the dual pressure valve 0V7, i.e. the

continuous signal from the memory valve 0V6 and the signal Yn+1 from the stepper

sequencer. Consequently all further cycles are executed without a renewed START

signal.




Name: Date:


Parameters

• STOP at CYCLE END

The memory valve 0V6, realised via a 5/2-way double solenoid valve in the

exercise, can be converted via the 3/2-way valve with pushbutton 0S5. The line

at the dual pressure valve 0V7 is exhausted. The start signal Yn+1 for the next

cycle is thus blocked via the dual pressure valve 0V7.

• EMERGENCY-STOP

Actuation of the EMERGENCY-STOP valve 0S1 causes the 3/2-way pneumatic

valve 0V1 to be reversed. The memory valve 0V1 is reversed, with flow from

1 to 4. The start processors are exhausted. The final control element 2V1) is

reversed via connection 14. Cylinder 2A1 advances. Port 12 of the final control

element 2V1 is exhausted via the 3/2-way pneumatic valve 0V13. This ensures

that the final control element is able to switch to flow from 1 to 4. The air supply

line to control element 3V1 is exhausted via the 3/2-way pneumatic valve 0V11

and consequently cylinder 3A1 is stationary.

• EMERGENCY-STOP release and RESET

After an EMERGENCY-STOP, the cylinders must be returned to their initial

position. RESET is achieved by actuating the 3/2-way valve via pushbutton 0S4.

The following sequence is to be observed:

1. EMERGENCY-STOP (0S1)

2. Switch from AUTOMATIC to MANUAL (0S3)

3. Release EMERGENCY-STOP (0S2)

4. RESET (0S4)




Name: Date:



equipment list.


the table below.







1 3/2-way valve with mushroom actuator, normally open (EMERGENCY-STOP)









1 Manifold



Equipment list




Name: Date:



1B2

1B1

2B2

2B1

3B2

3B1

1A1

0

1

2A1

0

1

3A1

0

1

0S6

1 2 3 4 5=1




Name: Date:


s1

s2

s3

s4

Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

1V1 2V1 2

1 11 1

2 22 2

24 4

3 35 51 1

1V2 2V21V3 2V3

14 1412 12

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

Y

TABTAATAATAA

0V9 0V10

0V1

2 2

2

1/3 1/3

1/3

1

1 1

1A1

1B1 1B2

2

2

22

2

2

2B1 2B22A1

1B2 1B12 2

3 31 1

0Z3 2

1

12 10

2B2 2

31

2B1 2

31

10

10

12

3

3

3

33

3

3

1

1

1

11

1

1

0V7

0V4

0V2

0S50S4

0S3

0S2

0S1 24

351



Solutions

Exercise 7: Packaging of spark plugs Solutions



Name: Date:


Initial position

The double-acting cylinder 1A1 at the gravity feed magazine is in the retracted end

position and actuates the pneumatic proximity sensor 1B1. The double-acting

cylinder 2A1 at the flat magazine is also in the retracted end position and actuates

the roller lever valve 2B1. The 5/2-way valve with selector switch 0S1 is detented for

flow from 1 to 2 (AUTOMATIC). The 3/2-way valve with selector switch 0S5 is

actuated (a roller lever valve is simulated, which indicates a full cardboard box

magazine).

Continuous cycle

Steps 1-2

Cylinder 1A1 at the gravity feed magazine advances.

The START signal of the 3/2-way valve 0S2 causes the pneumatic valve 0V2 to be

switched to flow from 1 to 2 via the shuttle valve 0V1. The pneumatic valve 0V2

moves into a self-latching loop via valves 0S5, 0V4 (normally open position) and the

shuttle valve (0V1). As a result of this self-latching loop, a continuous signal is

applied at the dual pressure valve 0V5. Combined with the signal Yn+1 of the last

module of the sequencer, the cylinders are actuated. The output signal A1 of the

sequencer switches the final control element 1V1 to flow from 1 to 4. Cylinder 1A1

advances unthrottled and actuates the pneumatic proximity sensor 1B2 in the

forward end position.




Name: Date:


Steps 2-3 to 9-10

Cylinder 2A1 at the flat magazine executes four double strokes.

The stepper sequencer receives the acknowledgement signal X1 from the pneumatic

proximity sensor and steps up. The output signal A2 of the sequencer, together with

the signal of the actuated roller lever valve 2B1, is applied at the dual pressure valve

0V8 and switches the final control element to flow from 1 to 4. Cylinder 2A1

advances unthrottled and in the forward end position actuates the roller lever valve

2B2. Its signal is applied at the dual pressure valve 0V6 together with signal A2 and

reverses the final control element 2V1. Cylinder 2A1 retracts again. The roller lever

valve 2B2 also transmits a pulse to the counter of the pneumatic predetermining

counter 0Z3. After the set 4 strokes, the output signal of the counter is applied at the

dual pressure valve 0V3. Together with the signal of the roller lever valve 2B1, the

4 strokes are acknowledged at X2 and the sequencer steps up. The pneumatic valve

0V7 is exhausted via the same output signal of the counter. Only one signal is still

applied at the dual pressure valve 0V8 and cylinder 2A1 is therefore no longer able

to advance.

Steps 10-11

Cylinder 1A1 at the gravity feed magazine retracts.

The output signal A3 reverses the final control element 1V1. Cylinder 1A1 retracts

and actuates the pneumatic proximity sensor 1B1. The 3rd module switches through

and its signal Yn+1 initiates a new cycle.

Please note: This module must be the last module of the stepper sequencer. One

module must be bridged.

STOP at CYCLE END

Actuation of the 3/2-way valve 0S4 causes the pneumatic valve 0V4 to exhaust the

self-latching loop. The pneumatic valve 0V2 switches into the normally closed

position and no signal is therefore applied at the dual pressure valve 0V5. The

sequencer can only be activated again via a renewed start signal.

RESET

If the 5/2-way valve with selector switch 0S1 is detented to MANUAL, the cylinders

and sequencer can be moved into the initial position via the actuation of the

3/2-way valve 0S2.




Name: Date:



equipment list.


the table below.






1 3/2-way valve with selector switch, normally closed


1 3/2-way pneumatic valve, normally closed




1 Pneumatic predetermining counter




1 Manifold



Equipment list




Name: Date:



0S3

1B1

1B2

2B1

2B2 2B2 2B22B1

2B2

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

2A1

0

1

1A1

0

1

2B1 2B1




Name: Date:


0V6

2

1/31

1B3

31

2

Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

1V1 24

35 1

1V2 1V3

14 12

1B1 1B2

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

1B1 2

31

Y

TABTAATAATAA

2

31

1B2

0V7

0V3

0V12

0V13

2

2

2

2

1/3

1/3

1/3

1/3

1

1

1

1

0V8 2

1/31

1B3

10

10

12

10

102

2

2

2

2

3

3

3

3

3

1

1

1

1

1

0V9

0V5

0V4

0V11

0V10

22

33 11

0S50S4

1 1

2 2

s1s2s3s4

1A1

14 12

0S3 Manual/Automatic

0V2

2

2

4

4

3

3

5

5

1

1

2

31

0S1

EMERGENCY-

STOP

0V1 2

31

10

2

31

0S2


Start Reset



Solutions

Exercise 8: Sealing of guide bushes Solutions



Name: Date:


Initial position

The piston rod of the double-acting cylinder 1A1 is in the retracted end position and

actuates the roller lever valve 1B1.

The 3/2-way pneumatic valves 0V5, 0V9, 0V10 and 0V11 assume the normally open

position. The 3/2-way pneumatic valve 0V4, required for the latching circuit,

assumes the normally closed position.

The mode selector switch 0S3 is set to AUTOMATIC (flow from 1 to 2)

Steps 1-2

The piston rod moves into the forward end position.

The START signal of the 3/2-way valve 0S4 causes the pneumatic valve 0V4 to be

switched to flow via the shuttle valve 0V3. The pilot air can now flow to the

sequencer, port P, via valve 0V5. Via the shuttle valve 0V3, this pilot air

simultaneously transmits a continuous signal to the 3/2-way pneumatic valve 0V4.

This valve switches into a self-latching loop and the compressed air supply for the

sequencer is protected. Pressure is applied at both sides of the dual pressure valve

0V6 via the start signal and signal Yn+1 and this switches through. The sequencer is

able to actuate the final control element. The output signal A1 of the sequencer

reverses the pneumatic valve 0V10 and the final control element 1V1 via the shuttle

valve 0V7. The piston rod advances and actuates the roller lever valve 1B2 in the

forward end position. The over-travelling of the proximity sensor 1B3 does not have

any effect.




Name: Date:


Steps 2-3

Piston rod moves into the retracted end position.

The signal of the roller lever valve 1B2 is applied at intput X1 and steps up the

sequencer. The output signal A2 flows via the shuttle valve 0V8, the pneumatic valve

0V9) and shuttle valves 0V12 and 0V13 and resets the final control element 1V1. The

piston rod retracts and actuates the roller lever valve 1B1.

Steps 3-4

Piston rod advances halfway.

The sequencer is stepped up via the acknowledgement signal X2 of the roller lever

valve 1B1. (The AND gate of the 4th module is not yet prepared and the signal at X4

therefore cannot step up the sequencer. Also, the traversing of proximity sensor 1B3

has no effect, since the 3rd module has not yet been prepared). The output signal A3

flows via the shuttle valve 0V7 and the pneumatic valve 0V10 to the pilot port 14 of

the final control element 1V1 and reverses this. The piston rod advances and

actuates the pneumatic proximity sensor 1B3.

Steps 4-5

Piston rod moves into the retracted end position.

The acknowledgement signal of the pneumatic proximity sensor 1B3 can now step

up the sequencer via connection X3. The output signal A4 flows via the shuttle valve

0V8, the pneumatic valve 0V9 and shuttle valves 0V12 and 0V13 to pilot port 12 of

the final control element 1V1 and reverses this. The piston rod retracts. The roller

lever valve 1B1 acknowledges the end position of the piston rod at connection X4.

The signal Yn+1 is applied at the dual pressure valve 0V6 again and the next cycle

can commence via a new start signal.




Name: Date:


Behaviour during EMERGENCY-STOP

EMERGENCY-STOP, piston rod in "forward movement"

If the EMERGENCY-STOP mushroom actuator 0S1 is actuated, the self-latching loop

of the compressed air supply for the sequencer is first of all interrupted via valve

0V5. This means that the sequencer cannot emit any output signals. The signal

blocks valves 0V9 and 0V10 and reverses the final control element 1V1 via valves

0V11, 0V12 and 0V13). The piston rod moves into the retracted end position.

EMERGENCY-STOP, piston rod in "retract movement"

The final control element 1V1 is already switched to flow from 1 to 2. The piston rod

consequently moves into the retracted end position.

EMERGENCY-STOP, piston rod in forward end position

The final control element 1V1 is switched to flow from 1 to 4. The roller lever valve

1B2 is actuated and blocks the valve 0V11. Consequently, the line for the signal to

the final control element is interrupted and the piston rod remains in the forward

end position.

EMERGENCY-STOP release and RESET

After an EMERGENCY-STOP, the cylinders must be returned to their initial position.

RESET is achieved by actuating the 3/2-way valve using pushbutton 0S5.

The following sequence is to be observed:

1. EMERGENCY-STOP (0S1)

2. Switch from AUTOMATIC to MANUAL (0S3)

3. Release EMERGENCY-STOP (0S2)

4. RESET (0S5)




Name: Date:



equipment list.


the table below.






1 3/2-way valve with mushroom actuator, normally open (EMERGENCY-STOP)








1 Manifold



Equipment list




Name: Date:



1B2

1B3

1B11B1

1 2 3 4 5=1

0

1A m

1

0S1




Name: Date:


s1

s2

s3

s4

Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

Y

TABTAATAATAA

2

31

0S1 1B3 2

31

1B2 1B12 2

3 31 1

10

0V60V5 22

1/31/3 11

2

31

1V5

1V3 1V4

1V6

1A1

1B3

12 12

10

2 2

2

3 3

3

1 1

1

1V1 1V2

0V30V2

0V4

1

2 2

1

2

1 112 12

2

1B1 1B2

2

31



Solutions

Exercise 9: Hardening of material test specimens Solutions



Name: Date:


Initial position

The piston of cylinder 1A1 is in the retracted end position and actuates the roller

lever valve 1B1; the continuous signal Yn+1 is therefore applied at the dual pressure

valve 0V1. The 4th module (type B) of the stepper sequencer is reset and its signal

A4 blocks the time delay valve 0V3. The pneumatic valve 0V4 is not actuated and is

in the normally open position. Consequently, the pilot port 12 of the final control

element 1V2 is pressurised. The piston rod chamber of the cylinder is pressurised at

a pressure of p = 6 bar (600 kPa).

Steps 1-2

Cylinder 1A1 moves into mid position for annealing.

The first module (type A) of the sequencer is reset via the START signal of the

3/2-way valve 0S1. Its signal A1 actuates the final control element 1V1, i.e. a spring

returned 3/2-way pneumatic valve. The time delay valve 0V3 moves into the normal

position (flow). The pneumatic valve 1V2 moves into the normal position. Cylinder

1A1 advances and in the mid-position actuates the pneumatic proximity sensor 1B3.

Steps 2-3

Awaiting the annealing time, cylinder moves into righthand end position for

quenching.

The acknowledgement signal of the pneumatic proximity sensor 1B3 is applied at

connections X1 and X3 of the stepper sequencer, but can only be switched through

via the reset 1st module. Signal A2 actuates the time delay valve 0V2. The cylinder

remains in the mid-position during the set annealing time of t1 = 3 seconds. Valves

1V1 and 1V2 are exhausted. After 3 seconds, the final control element 1V1 is

switched via the time delay valve 0V2. The cylinder moves into the forward end

position and actuates the roller lever valve 1B2.




Name: Date:


Steps 3-4

Cylinder moves into mid-position for start-up.

The acknowledgement signal of the roller lever valve 1B2 switches through to the

3rd stepper module. Its signal A3 switches the final control element 1V2 to flow.

Cylinder 1A1 moves to the left into mid-position and re-activates the pneumatic


Steps 4-5

Awaiting the tempering time, cylinder moves into lefthand end.

The acknowledgement signal of the pneumatic proximity sensor 1B3 switches to the

4th module (type B) of the sequencer via connection X3. The signal at X1 has no

effect, since module 1 is not reset. Signal A4 actuates the time delay valve 0V3. After

the tempering time of t2 = 2 seconds, the final control element is switched to flow via

the time delay valve 0V3. The cylinder moves into the initial position.

A new cycle can be started via a renewed START signal.




Name: Date:



equipment list.





2 Non-return valve, piloted







1 Time delay valve, normally closed

1 Time delay valve, normally open




1 Manifold



Equipment list




Name: Date:



1B3 1B3

1B1

1B2

0

1A1 m

1

t2t1

0V2 0V3

0S1

1 2 3 4 5=1




Name: Date:


s1

s2

s3

s4

Zn+1

L

L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

2V1 2

1 1

2 2

24 4

3 35 51 1

2V2 3V2

1412 1412 12

A1

X1

YnY Yn+1

Yn+1Yn

Zn Zn+1

Zn

Z Z

L LL

L

P PP P PP

Y

TABTAATAATAA

3A1

3B1 3B2

2 2

3 31 1

0S1 1B2

2B1 2B21B22A1

3B2

3B1

22

33

11

3

3

1

1

0V3

0V2

12

12

10

10

2

31

2B2 2B1

1B1

2

2

3

3

1

1

0V4 2

1/31

2

2

1V2

1A1

1V1 2

31

1B1

2

1



Solutions

Exercise 10: Bending of sheet metal strips Solutions



Name: Date:


Initial position

The three drives are in the retracted end position. Sensors 1B1, 2B1 and 3B1 are

actuated. The memory valve 0V3 is switched to flow from 1 to 2. Memory valve 0V2

is closed.

Steps 1-2

Clamping cylinder 1A1 advances (1A1+).

The final control element 1V1 switches to flow if the START button 0S1 is actuated.

The single-acting clamping cylinder 1A1 advances with throttled supply air and in

the forward end position actuates the back pressure valve 1B2. Two signals (start

signal and acknowledgement signal of movement 1A1+) are applied at the dual

pressure valve 0V1). The final control element 1V1 remains actuated via the memory

valve 0V2 and the shuttle valve 0V4. The clamping cylinder remains in the forward

end position.

Steps 2-3

The first bending cylinder 2A1 advances (2A1+).

A signal is also applied at the dual pressure valve 0V5 via the memory valve 0V2.

Together with signal Yn+1, the first module (type A) of the stepper sequencer is reset

and its signal A1 reverses the final control element 2V1. The bending cylinder 2A1

advances and actuates the roller lever valve with idle return 2B2.

Steps 3-4

The first bending cylinder 2A1 retracts (2A1-).

The second module (type A) is reset via the acknowledgement signal of the roller

lever valve with idle return 2B2 and its signal A2 reverses the final control element

2V1. The bending cylinder 2A1 moves into the retracted end position and actuates

the roller lever valve 2B1.

Steps 4-5

The second bending cylinder 3A1 advances (3A1+).

The acknowledgement signal of the roller lever valve 2B1 causes the third module

(type A) to be reset; its signal A3 reverses the final control element 3V1. The bending

cylinder 3A1 moves into the forward end position and actuates the pneumatic





Name: Date:


Steps 5-6

The second bending cylinder 3A1 and the clamping cylinder 1A1 retract

(3A1-), (1A1-).

First of all, the acknowledgement signal of the pneumatic proximity sensor 3B2

switches through to the fourth module (type B), and its signal A4 reverses the final

control element 3V1. Cylinder 3A1 retracts and actuates the pneumatic proximity

sensor 3B1. Secondly, the memory valve 0V2 is reversed, as a result of which there

is no continuous signal at the final control element 1V1. The clamping cylinder 1A1

also retracts and actuates the roller lever valve 1B1, whereby the initial position is

obtained again. The fourth module of the sequencer is switched through and its

signal Yn+1 is applied at the dual pressure valve 0V5. The memory valve 0V3 is back

in the righthand switching position (flow from1 to 2).

A new cycle can be started via a START signal.




Name: Date:



equipment list.





1 Cylinder, single-acting













1 Manifold



Equipment list



Exercise 10: Bending of strip metal sheets

Name: Date:



1B2

2B2

3B2

3B1

1B1

2B1

1 2 3 4 5 6=1

1A1

0

1

2A1

0

1

3A1

0

1

0S1


© Festo Didactic GmbH & Co. KG • 541089 D-1

Organiser __________________________________________________________ D-2

Assembly technology ________________________________________________ D-3

Plastic tubing_______________________________________________________ D-4

3/2-way valve with pushbutton, normally closed _______________________ 152860

3/2-way valve with mushroom actuator, normally open (EMERGENCY-STOP) 152864

3/2-way roller lever valve with idle return, normally closed_______________ 152867

Back pressure valve ______________________________________________ 152868

Pneumatic predetermining counter __________________________________ 152877

Shuttle valve, 3-fold ______________________________________________ 152882

Dual pressure valve, 3-fold_________________________________________ 152883

Stepper module__________________________________________________ 152886

Double-acting cylinder ____________________________________________ 152888

Time delay valve, normally open ____________________________________ 539759

3/2-way pneumatic valve, convertible________________________________ 539768

5/2-way double pilot valve_________________________________________ 539769

Shuttle valve ____________________________________________________ 539771

One-way flow control valve_________________________________________ 539773

Non-return valve, piloted __________________________________________ 540715








Part D – Appendix

Data sheets

Circuit diagrams

D-2 © Festo Didactic GmbH & Co. KG • 541089

Equipment set in the organiser

All components of the equipment set for the technology package TP102 are stored in

an organiser within a Systainer. The organiser also serves as a drawer insert for use

in conjunction with our laboratory furniture.

Organiser

© Festo Didactic GmbH & Co. KG • 541089 D-3

The components of the equipment set are intended for assembly on the Festo

Didactic profile plate, which consists of 14 parallel T-slots, set at 50 mm intervals.

Three variants are available for the assembly of equipment on the profile plate:

Variant A

A latching system, without auxiliary means, clamping mechanism with lever and

spring, adjustable in slot direction, for lightweight non-loadable components.

Variant B

A rotary system, without auxiliary means, knurled nut with locking disc and T-head

bolts, vertical or horizontal alignment, for medium weight loadable components

Variant C

A screwed system, with auxiliary means, socket head screw with T-head bolt, vertical

or horizontal alignment, for heavy loadable components and equipment that is

rarely released from the profile plate.

The proven ER units on a plug-in board can be attached to the profile plate using

adapters.

In the case of variant A, a slide is engaged in the T-slot of the profile plate. The slide

is pre-tensioned by means of a spring and, by pressing the blue lever, is pulled back

whereby the component can be removed from or attached to the profile plate.

Components are aligned along the slot and can be moved in the direction of the slot.

With variant B, components are attached to the profile plate by means of a T-head

bolt and blue knurled nut. A locking disc serves to fix the device in position, which

can be secured in all four 90° directions. Components can thus be mounted to the

profile plate either lengthwise or perpendicular to the slot.

Once the desired locking disc position is set, the device is mounted on the profile

plate. By turning the knurled nut in a clockwise direction, the T-head bolt is turned in

the slot by 90° as a result of thread friction. The component is pulled against the

profile plate by further turning the knurled nut.

Assembly technology

D-4 © Festo Didactic GmbH & Co. KG • 541089

Variant C is used for heavy or similar devices, screwed on to the profile plate only

once or removed very seldom. Components are attached by means of socket head

screws with internal hex and T-head bolts.

The time-tested ER units on a plug-in board with locating pins in a 50 mm grid can be

mounted on the profile plate using adapters. A black adapter is required for each

locating pin. The adapters are plugged into the T-slot, positioned at intervals of

50 mm and secured by means of a 90° turn. The locating pins of the ER unit are

plugged into the adapter holes.

The polyurethane tubing is particularly flexible and kink resistant.

Technical data

Pneumatics

Colour Silver metallic

Outer diameter 4 mm

Inner diameter 2.6 mm

Minimum bending radius within

temperature range of -35 to +60°C

17 mm

Maximum operating pressure within

Temperature range of -35 to +30°C

Temperature range of +30 to +40°C

Temperature range of +40 to +60°C

10 bar (1000 kPa)

9 bar (900 kPa)

7 bar (700 kPa)

Subject to change

Plastic tubing

152860

3/2-way valve with pushbutton actuator, normally closed

© Festo Didactic GmbH & Co. KG, 07/2005 Subject to change 1/1

The 3/2-way valve with pushbutton actuator, normally closed is assembled in a

polymer housing. The unit is mounted on the profile plate via a quick release detent

system with blue lever (mounting alternative "A").

The valve is actuated by pressing the pushbutton. Releasing of the pushbutton

returns the valve to the normal position via a return spring.

Pneumatic

Medium Compressed air, filtered (lubricated or unlubricated)

(or vacuum; port 1)

Design Poppet valve, directly actuated on one side, with return spring

Actuation Pushbutton

Pressure range -95 – 800 kPa (-0.95 – 8 bar)

Standard nominal flow rate 1...2 60 l/min

Actuating force at 600 kPa (6 bar) 6 N

Connection QSM-4 fittings for plastic tubing PUN 4 x 0.75

2

31

Design

Function

Technical data

152864

3/2-way valve with mushroom actuator


The 3/2-way valve with plug-in connections is assembled in a yellow polymer

housing. The unit is mounted on the profile plate via a quick release detent system

with blue lever (mounting alternative „A“).

The valve is actuated by pressing the red mushroom actuator. The switching status

is maintained after the actuator has been released. Rotation to the right returns the

mushroom actuator to its normal position and returns the valve to its initial position

via the return spring.

Pneumatic



Actuation Mushroom actuator

Pressure range -90 – 800 kPa (-0.90 – 8 bar)


Actuating force at 600 kPa (6 bar) 6 N

Connection QSM-4 fittings for plastic tubing PUN 4 x 0.75

2

31

Design

Function

Technical data

152867

3/2-way roller lever valve with idle return, normally closed


The 3/2-way roller lever valve with idle return and push-in elbow fittings is screwed

onto a plastic base. The unit is mounted on the profile plate via the rotary detent

system with blue triple grip nut (mounting alternative "B").

The valve is actuated when the trip roller has been traversed by a cylinder trip cam

passing in the positive direction. The valve is returned to the normal position via a

return spring after the trip roller has been released. The trip roller flips down when

traversed in the opposite direction.

Pneumatic



Pressure range 0 – 800 kPa (0 – 8 bar)


Actuating force at 600 kPa (6 bar) 12.5 N

Connection QSML-M5-4 fittings for plastic tubing PUN 4 x 0.75

2

31

Design

Function

Technical data

152868

Back pressure valve


The back pressure valve with poppet action and quick push-pull T-connectors is

screwed on to an assembly base. The unit is mounted on the profile plate via a quick

release detent system with blue triple grip nut (mounting alternative „B“).

The back pressure valve with poppet action is actuated via the end face of the

cylinder cam. If the stem is actuated, compressed air exhausts to atmosphere until

the nozzle outlet is closed. At this point, a signal is generated at output 2 up to the

level of the supply pressure. There is thus only low air consumption within the stem

actuation range of 1 mm.

The connections are identified according to the different tubing lengths:

1 = long tubing

2 = short tubing

The supply pressure can be regulated via a restrictor. Prior to the back pressure

valve being used, a functional check should be carried out. If necessary, the back

pressure valve can be adjusted to the cylinder end position by loosening the lock

nut.

The output signal should be amplified if the supply pressure is very low.

Pneumatic


Supply pressure range 0 – 800 kPa (0 – 8 bar)

Closing force at 600 kPa (6 bar) 12.5 N

Connection QS-4 fittings for plastic tubing PUN 4 x 0.75

31

2

Design

Function

Note

Comment

Technical data

152877

Pneumatic preselect counter


The pneumatic preselect counter with straight push-in fittings is fitted on a polymer

base. The unit is mounted on the profile plate via a quick release detent system with

blue lever (mounting alternative „A“).

The counter counts pneumatic signals downwards from a preselected figure. When

the zero position has been reached, the counter emits a pneumatic output signal.

This output signal is maintained until the counter is reset. The counter is pre-set by

pressing the reset key (alongside the number window) and simultaneously keying-in

(adjustment key on the counter roll) of the preselect value. The figure, once set,

is retained whilst the counter is reset.

The valve ports are identified by numbers:

1 = Supply port

2 = Output signal

10 = Reset signal

12 = Counting signal

2

1

12 10

Design

Function

Note

152877

Pneumatic preselect counter

2/2 Subject to change © Festo Didactic GmbH & Co. KG, 07/2005

Pneumatic

Medium Compressed air

Design Mechanical counter with pneumatic drive

Display 5-digit, height of figures 4.5 mm

Reset Push button or pneumatic signal


Minimum pulse duration Count: 10 ms, Reset: 180 ms

Counting rate continuous operation 2 Hz

Connection QSMS-4, QSML-M5-4 fittings for plastic tubing PUN 4 x 0.75

Technical data

152882

Shuttle (OR) valve, 3-fold


The manifold consisting of three OR gates is screwed on to an assembly base

equipped with the required straight push-in fittings. The unit is mounted on the

profile plate via a quick release detent system with blue lever (mounting

alternative „A“).

Each OR gate has two inlets (1, 1/3) and one output (2). The inlet which is not

pressurised is automatically blocked. If different pressures are applied, then the

higher pressure reaches the outlet (2).


2 = Working or outlet port

1, 1/3 = Supply lines

Pneumatic


Design OR gate (shuttle valve)

Pressure range 160 – 800 kPa (1.6 – 8 bar)

Standard nominal flow rate 1, 1/3...2 100 l/min

Connection QSM-M5-4-I fittings for plastic tubing PUN 4 x 0.75

2

1/3 1/3 1/31

2

1 1

2

Design

Function

Note

Technical data

152883

Dual pressure (AND) valve, 3-fold


A manifold consisting of three AND gates is screwed on to an assembly base

equipped with the required straight push-in fittings. The unit is mounted on the

profile plate via a quick release detent system with blue lever

(mounting alternative „A“).

Each AND gate has two inlets (1, 1/3) and one outlet (2). Outlet (2) is only

pressurised for as long as pressure is applied at both inlets. If different pressures

are applied, then the lower pressure reaches outlet (2).



1, 1/3 = Supply lines

Pneumatic


Design AND gate (dual pressure valve)

Pressure range 160 – 800 kPa (1.6 – 8 bar)



2 2 2

1 1/31/31/3 1 1

Design

Function

Note

Technical data

152886

Stepper module


L L

A3 A4

X3 X4

Yn YnYn+1 Yn+1

Zn ZnZn+1 Zn+1

L LL L

P PP P

A2

X2

Yn Yn+1

Zn Zn+1

L L

P P

A1

X1

YnY Yn+1 Yn+1Yn

Zn Zn Zn+1Z Z

L LLL

P PP P PP

Y

TABTAATAATAA

Zn+1

This unit consists of three TAA and one TAB stepper module which are screwed on to

an assembly base, which is equipped with the required straight push-in fittings. The

unit is mounted on the profile plate via a quick release detent system with blue lever

(mounting alternative „A“).

Design

152886

Stepper module


In the case of module type TAB, an OR gate is positioned upstream of the Yn inlet of

the double pilot valve. If a signal is applied at Yn or L, the valve is reversed and a

signal appears at outlet A. In addition, this signal also resets the preceding stepper

module, the visual indicator and the AND gate is supplied with pressure. When the

acknowledgement signal reaches X, the AND flow is released and the signal Yn+1

appears. This signal is also maintained if the entire sequencer is reset at L and can

thus be used for a renewed start. When the sequencer chain is started, the module

is reset externally at port Z via the reset signal Zn+1

of the first module of the

sequencer. With the TAA modules, an OR gate is connected upstream of port Z in the

double pilot valve. This is why, in this case, the double pilot valve is returned via a

signal at Zn+1

from the following stepper.

The valve ports are identified by letters:

P = Supply port

A1, A

2, A

3, A

4 = Outputs

X1, X

2, X

3, X

4 = Acknowledgements

L = Reset (clear)

Yn+1

= Set: Output

Yn = Set: Input

Zn = Reset: Output

Zn+1

= Reset: Input

Pneumatic


Design Poppet valve with integrated AND and OR gate

Standard nominal flow rate P…A 60 l/min



Function

Note

Technical data

152888

Double-acting cylinder


The double-acting cylinder with trip cam and push-in fittings is mounted on a plastic

retainer. The unit is mounted on the profile plate via a quick release detent system

with two triple grip nuts (mounting alternative "B").

The piston rod of the double-acting cylinder is reversed by means of alternating

supply of compressed air. End position cushioning at both ends prevents a sudden

impact of the piston on the cylinder housing. The end position cushioning can be

adjusted by means of two regulating screws.

The magnetic field of a permanent magnet attached to the cylinder piston actuates

the proximity switches.

Pneumatic


Design Piston cylinder

Operating pressure max. 1000 kPa (10 bar)

Piston diameter 20 mm

Max. stroke length 100 mm

Thrust at 600 kPa (6 bar) 189 N

Return force at 600 kPa (6 bar) 158 N

Connection QS-G1/8-4 fittings for plastic tubing PUN 4 x 0.75

Design

Function

Technical data

539759



The time delay valve is screwed on an assembly base equipped with straight push-in

fittings. The unit is mounted on the profile plate via a quick release detent system

with blue lever (mounting alternative „A“).

After the pilot signal is applied at port 10, a preset time elapses before the time

delay valve is actuated. It returns to its initial position via a return spring once the

signal is removed. The time delay is infinitely adjustable by means of a regulatig

screw.


1 = Supply port


3 = Exhaust

10 = Pilot

10

2

31

Design

Function

Note

539759



Pneumatic


Design Poppet valve with return spring

Pressure range 200 to 600 kPa (2 to 6 bar)

Pilot pressure >160 kPa (1.6 bar)


Time delay 0.2 to 3 s (adjustable)

Setting accuracy ±0.3 ms

Time delay to reset >200 ms


Technical data

539768

3/2-way pneumatic valve, pneumatically actuated, one side


The 5/2-way pneumatic valve with push-in connectors and a single blanking plug is

screwed on to an assembly base, which is equipped with P-connection and silencers.

The unit is mounted on the profile plate via a quick release detent system with blue

lever (mounting alternative „A“).

The pneumatic valve switches at port 14 (Z) (10 (Z)) via a pneumatic signal and is

returned to the initial position via a spring when the signal has been removed.


1 = Supply port

2, 4 = Working or outlet ports

3, 5 = Exhausts (via silencers in function plate)

14, 10 = Pilot port

By blocking a working line (2 or 4), the 5/2-way valve can be converted into a

3/2-way valve:

Blanking plug in outlet 4 = normally open

Blanking plug in outlet 2 = normally closed

2

31

12

or 2

31

10

Symbol used in circuit diagrams.

24

35 1

14

The internal structure of this valve

Design

Function

Note

539768

3/2-way pneumatic valve, pneumatically actuated, one side


Pneumatic

Medium Compressed air, filtered

Design Spool valve, indirectly actuated on one side, with return spring


Operating pressure range -90 to 1000 kPa (-0.9 to 10 bar)

Standard nominal

flow rate 1…2, 1...4

500 l/min

Switching time at 600 kPa (6 bar) On: 8 ms

Off: 18 ms

Connection QS-1/8-4-I, QSM-M5-4-I fittings for plastic tubing PUN 4 x 0.75

Technical Data

539769

5/2-way double pilot valve, pneumatically actuated, both sides


The 5/2-way double pilot valve with push-in fittings is screwed onto the function

plate, which is equipped with P-connection and silencers. The unit is mounted on the

profile plate via a quick release detent system with blue lever (mounting alternative

"A").

The double pilot valve is actuated by applying pneumatic signals alternately to ports

14 and 12. It remains in its last switched position until a counter signal is received.

Pneumatic

Medium Compressed air, filtered (lubricated or unlubricated) or vacuum

Design Spool valve, directly actuated on both sides

Control pressure range 200 to 1000 kPa (2 to 10 bar)

Operating pressure range -90 to 1000 kPa (-0.9 to 10 bar)

Standard nominal

flow rate 1...2, 1...4

500 l/min

Response time at 600 kPa (6 bar) 6 ms

Connection QS-1/8-4-I, QSM-M5-4-I fittings for plastic tubing PUN 4 x 0.75

24

35 1

14 12

Symbol used in circuit diagrams

24

35 1

14 12

The internal structure of this valve allows flowing of compressed air in both dir

Design

Function

Technical Data

539771

Shuttle valve (OR)


The shuttle valve with push-in elbow fittings is mounted on a function plate. The unit

is mounted on the profile plate via a quick release detent system with blue lever

(mounting alternative "A").

The shuttle valve is switched through to output 2 by applying a signal either to input

1 or 1/3 (OR-Function). If both inputs are pressurised simultaneously, then the

higher pressure reaches the output.

Pneumatic


Design OR-Gate (Shuttle valve)



Connection QSL-1/8-4 fittings for plastic tubing PUN 4 x 0.75

2

1/31

Design

Function

Technical Data

539773



The adjustable one-way flow control valve is screwed into the function plate,

incorporating a straight push-in fitting. The unit is slotted into the profile plate via a

quick release detent system with a blue lever (mounting alternative “A”).

The one-way flow control valve consists of a combination of a flow control valve and

a non-return valve.

The non-return valve blocks the flow of air in one direction, whereby the air flows via

the flow control valve. The throttle cross section is adjustable by means of a knurled

screw. The setting can be fixed by means of a knurled nut. Two arrows indicate the

direction of flow control on the housing. In the opposite direction, the air flow is

unrestricted via the non-return valve.

Pneumatic

Medium Compressed air, filtered, (lubricated or unlubricated)

Design One-way flow control valve

Pressure range 20 to 1000 kPa (0.2 to 10 bar)

Standard nominal flow rate in throttled direction: 0 – 110 l/min

free flow direction: 110 l/min (Throttle open)

65 l/min (Throttle closed)

Connection QSM-M5-4 for plastic tubing PUN 4 x 0.75

21

Design

Function

Technical Data

540715

Non-return valve, piloted


Non-return valve directly connected to the cylinder connection via a push-in sleeve.

The non-return valve shuts off flow from port 2 to port 1. The non-return valve can be

released through the application of compressed air at port 21.

Pneumatics

Medium Compressed air, filtered, lubricated or unlubricated

Design Non-return valve, piloted

Operating pressure 0.5 to 10 bar (50 to 1000 kPa)

Standard nominal flow rate 108 l/min

Connection QSM-M5-4 for plastic tubing PUN 4 x 0.75

2

1 21

Design

Function

Technical data

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H &

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54

10

89

Zn

+1

L

L

A3

A4

X3

X4

Yn

Yn

Yn+1

Yn+1

Zn

Zn

Zn+1

Zn+1

LL

LL

PP

PP

A2

X2

Yn

Yn+1

Zn

Zn+1

LL

PP

1V

1

2V

1

22

4

4

33

55

11

1V

22

V2

14

14

12

12

1V

32

V3

1B

11

B2

1A

1

s1

s2

s3

s4

A1

X1

Yn

YYn+1

Yn

+1

Yn

Zn

Zn+1

Zn

ZZ

LL

L

L

PP

PP

PP

1B

22

B1

2B

22

22

33

31

11

1B

12

31

2B

12A

1

2B

2

Y

TAB

TAA

TAA

TAA

0S

1

2

31

11

11

22

22

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H &

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G •

54

10

89

Zn

+1

L

L

A3

A4

X3

X4

Yn

Yn

Yn+1

Yn+1

Zn

Zn

Zn+1

Zn+1

LL

LL

PP

PP

A2

X2

Yn

Yn+1

Zn

Zn+1

LL

PP

1V

1

2V

1

22

4

4

33

55

11

1V

22

V2

14

14

12

12

1V

32

V3

1B

11

B2

1A

1

s1

s2

s3

s4

A1

X1

Yn

YYn+1

Yn

+1

Yn

Zn

Zn+1

Zn

ZZ

LL

L

L

PP

PP

PP

1B

22

B1

2B

22

22

33

31

11

1B

12

31

2B

12A

1

2B

2

Y

TAB

TAA

TAA

TAA

0S

1

2

31

11

11

22

22

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54

10

89

s1

s2

s3

s4

Zn

+1

L

L

A3

A4

X3

X4

Yn

Yn

Yn+1

Yn+1

Zn

Zn

Zn+1

Zn+1

LL

LL

PP

PP

A2

X2

Yn

Yn+1

Zn

Zn+1

LL

PP

1V

1

2V

1

2

11

11

22

22

24

4

33

55

11

1V

22

V2

1V

32

V3

14

14

12

12

A1

X1

Yn

YYn+1

Yn

+1

Yn

Zn

Zn+1

Zn

ZZ

LL

L

L

PP

PP

PP

Y

TAB

TAA

TAA

TAA

1A

1

1B

11

B2

22

33

11

0S

2

0S

3

0S

1

24

35

1

2B

12

B2

2A

1

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H &

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. K

G •

54

10

89

s1

s2

s3

s4

Zn

+1

L

L

A3

A4

X3

X4

Yn

Yn

Yn+1

Yn+1

Zn

Zn

Zn+1

Zn+1

LL

LL

PP

PP

A2

X2

Yn

Yn+1

Zn

Zn+1

LL

PP

1V

1

2V

1

2

11

11

22

22

24

4

33

55

11

1V

22

V2

1V

32

V3

14

14

12

12

A1

X1

Yn

YYn+1

Yn

+1

Yn

Zn

Zn+1

Zn

ZZ

LL

L

L

PP

PP

PP

2B

2

2B

1

2

2

3

3

1

1

Y

TAB

TAA

TAA

TAA

0V

70

V8

2

2

1/3

1/

31

1

1A

1

1B

11

B2

22

22

33

33

11

11

0S

2

0S

3

0S

1

0S

40

S5

24

35

1

2B

12

B2

2A

1

1B

21

B1

22

33

11

0V

40

V5

22

1/3

1/3

11

0V

12

31

31

0V

32

10

10

2

31

0V

2

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H &

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G •

54

10

89

s1

s2

s3

s4

Zn

+1

L

L

A3

A4

X3

X4

Yn

Yn

Yn+1

Yn+1

Zn

Zn

Zn+1

Zn+1

LL

LL

PP

PP

A2

X2

Yn

Yn+1

Zn

Zn+1

LL

PP

1V

1

2V

1

2

11

11

22

22

24

4

33

55

11

1V

22

V2

1V

32

V3

14

14

12

12

A1

X1

Yn

YYn+1

Yn

+1

Yn

Zn

Zn+1

Zn

ZZ

LL

L

L

PP

PP

PP

2B

12

31

Y

TAB

TAA

TAA

TAA

0V

7

0V

8

22

1/

3

1/3

1

1

1A

1

1B

11

B2

22

2

33

31

11

0S

2

0S

3

0S

1

0S

5

24

35

1

2B

12

B2

2A

1

1B

21

B1

22

33

11

0V

52

1/3

2

31

0S

4

0V

42

1/

31

1

0V

12

31

31

0V

32

10

10

2

31

0V

22

B2

2

31

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54

10

89

s1

s2

s3

s4

Zn

+1

L

L

A3

A4

X3

X4

Yn

Yn

Yn+1

Yn+1

Zn

Zn

Zn+1

Zn+1

LL

LL

PP

PP

A2

X2

Yn

Yn+1

Zn

Zn+1

LL

PP

1V

1

2V

1

2

11

11

22

22

24

4

33

55

11

1V

22

V2

1V

32

V3

14

14

12

12

A1

X1

Yn

YYn+1

Yn

+1

Yn

Zn

Zn+1

Zn

ZZ

LL

L

L

PP

PP

PP

Y

TAB

TAA

TAA

TAA

0V

70

V8

2

2

1/

31

/3

11

1A

1

1B

11

B2

22

33

11

0S

2

0S

3

0S

1

24

35

1

2B

12

B2

2A

1

1B

22

31

2B

12

31

2B

22

31

1B

12

31

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54

10

89

s1

s2

s3

s4

Zn

+1

L

L

A3

A4

X3

X4

Yn

Yn

Yn+1

Yn+1

Zn

Zn

Zn+1

Zn+1

LL

LL

PP

PP

A2

X2

Yn

Yn+1

Zn

Zn+1

LL

PP

1V

1

2V

1

2

11

11

22

22

24

4

33

55

11

1V

22

V2

1V

32

V3

14

14

12

12

A1

X1

Yn

YYn+1

Yn

+1

Yn

Zn

Zn+1

Zn

ZZ

LL

L

L

PP

PP

PP

2B

2

2B

1

2

2

3

3

1

1

Y

TAB

TAA

TAA

TAA

0V

70

V8

2

2

1/3

1/

31

1

1A

1

1B

11

B2

22

22

33

33

11

11

0S

2

0S

3

0S

1

0S

40

S5

24

35

1

2B

12

B2

2A

1

1B

21

B1

22

33

11

0V

40

V5

22

1/3

1/3

11

0V

12

31

31

0V

32

10

10

2

31

0V

2

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54

10

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s1

s2

s3

s4

Zn

+1

L

L

A3

A4

X3

X4

Yn

Yn

Yn+1

Yn+1

Zn

Zn

Zn+1

Zn+1

LL

LL

PP

PP

A2

X2

Yn

Yn+1

Zn

Zn+1

LL

PP

1V

1

2V

1

2

11

11

22

22

24

4

33

55

11

1V

22

V2

1V

32

V3

14

14

12

12

A1

X1

Yn

YYn+1

Yn

+1

Yn

Zn

Zn+1

Zn

ZZ

LL

L

L

PP

PP

PP

2B

12

31

Y

TAB

TAA

TAA

TAA

0V

7

0V

8

22

1/

3

1/3

1

1

1A

1

1B

11

B2

22

2

33

31

11

0S

2

0S

3

0S

1

0S

5

24

35

1

2B

12

B2

2A

1

1B

21

B1

22

33

11

0V

52

1/3

2

31

0S

4

0V

42

1/

31

1

0V

12

31

31

0V

32

10

10

2

31

0V

22

B2

2

31

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54

10

89

2B

1

31

1B

22

2

31

Zn

+1

L

L

A3

A4

X3

X4

Yn

Yn

Yn+1

Yn+1

Zn

Zn

Zn+1

Zn+1

LL

LL

PP

PP

A2

X2

Yn

Yn+1

Zn

Zn+1

LL

PP

1V

1

3V

1

2V

1

22

24

4

4

33

35

55

11

1

1V

22

V2

3V

2

14

14

14

14

12

12

12

12

1B

13

B1

1B

23

B2

1A

13

A1

A1

X1

Yn

YYn+1

Yn

+1

Yn

Zn

Zn+1

Zn

ZZ

LL

L

L

PP

PP

PP

2B

2

31

3B

1

1B

1

2

22

3

3

1

1

Y

TAB

TAA

TAA

TAA

2

31

3B

2

0V

90

V1

0

0V

12

22

2

1/3

1/3

1/3

10

V8

2

1/3

1

1

1

2A

12

B1

2B

2 10

10

2

23

3

1

1

0V

13

0V

11

0V

6

24

35

1

14

12

0V

52

1/3

1

2

2

2

2

3

3

3

3

1

1

1

1

0S

6

Sta

rt

0S

4

0S

3

Re

set

0S

2

0S

5

Sto

p a

t cy

cle

en

d

Ack

no

wle

dg

eE

ME

RG

EN

CY-

STO

P

Ma

nu

al/

Au

tom

ati

c

0V

2

2

2

4

4

3

3

5

5

1

1

2

31

0S

1

EM

ER

GE

NC

Y-S

TOP

11

1

22

2

0V

12

31

10

s1 s2 s3 s4

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G •

54

10

89

2B

1

31

1B

22

2

31

Zn

+1

L

L

A3

A4

X3

X4

Yn

Yn

Yn+1

Yn+1

Zn

Zn

Zn+1

Zn+1

LL

LL

PP

PP

A2

X2

Yn

Yn+1

Zn

Zn+1

LL

PP

1V

1

3V

1

2V

1

22

24

4

4

33

35

55

11

1

1V

22

V2

3V

2

14

14

14

14

12

12

12

12

1B

13

B1

1B

23

B2

1A

13

A1

A1

X1

Yn

YYn+1

Yn

+1

Yn

Zn

Zn+1

Zn

ZZ

LL

L

L

PP

PP

PP

2B

2

31

3B

1

1B

1

2

22

3

3

1

1

Y

TAB

TAA

TAA

TAA

2

31

3B

2

0V

90

V1

0

0V

12

22

2

1/3

1/3

1/3

10

V8

2

1/3

1

1

1

2A

12

B1

2B

2 10

10

2

23

3

1

1

0V

13

0V

11

0V

6

24

35

1

14

12

0V

52

1/3

1

2

2

2

2

3

3

3

3

1

1

1

1

0S

6S

tart

0S

4

0S

3

Re

set

0S

2

0S

5S

top

at

cycl

e e

nd

Ack

no

wle

dg

eE

ME

RG

EN

CY-

STO

P

Ma

nu

al/

Au

tom

ati

c

0V

2

2

2

4

4

3

3

5

5

1

1

2

31

0S

1

EM

ER

GE

NC

Y-S

TOP

11

1

22

2

0V

12

31

10

s1 s2 s3 s4

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H &

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. K

G •

54

10

89

s1

s2

s3

s4

Zn

+1

L

L

A3

A4

X3

X4

Yn

Yn

Yn+1

Yn+1

Zn

Zn

Zn+1

Zn+1

LL

LL

PP

PP

A2

X2

Yn

Yn+1

Zn

Zn+1

LL

PP

1V

1

2V

1

2

11

11

22

22

24

4

33

55

11

1V

22

V2

1V

32

V3

14

14

12

12

A1

X1

Yn

YYn+1

Yn

+1

Yn

Zn

Zn+1

Zn

ZZ

LL

L

L

PP

PP

PP

Y

TAB

TAA

TAA

TAA

0V

1

2

1/3

1

1A

11

B1

1B

2

2 222

2

2

2B

12

B2

2A

1

1B

21

B1

22

33

11

0Z

32 1

12

10

2B

22

31

2B

12

31

10

10

12

3

3 333

3

3

1

1 111

1

1

0V

7

0V

4

0V

2

0S

50

S4

0S

3

0S

2

0S

1

24

35

1

Exe

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ag

ing

of

spa

rk p

lug

s

So

luti

on

© F

esto

Did

acti

c G

mb

H &

Co

. K

G •

54

10

89

s1

s2

s3

s4

Zn

+1

L

L

A3

A4

X3

X4

Yn

Yn

Yn+1

Yn+1

Zn

Zn

Zn+1

Zn+1

LL

LL

PP

PP

A2

X2

Yn

Yn+1

Zn

Zn+1

LL

PP

1V

1

2V

1

2

11

11

22

22

24

4

33

55

11

1V

22

V2

1V

32

V3

14

14

12

12

A1

X1

Yn

YYn+1

Yn

+1

Yn

Zn

Zn+1

Zn

ZZ

LL

L

L

PP

PP

PP

Y

TAB

TAA

TAA

TAA

0V

90

V1

0

0V

1

22

2

1/

31

/3

1/3

1

11

1A

11

B1

1B

2

2 222

2

2

2B

12

B2

2A

1

1B

21

B1

22

33

11

0Z

32 1

12

10

2B

22

31

2B

12

31

10

10

12

3

3 333

3

3

1

1 111

1

1

0V

7

0V

4

0V

2

0S

50

S4

0S

3

0S

2

0S

1

24

35

1

Exe

rcis

e 8

: S

ea

lin

g o

f g

uid

e b

ush

es

© F

esto

Did

acti

c G

mb

H &

Co

. K

G •

54

10

89

0V

6

2

1/3

1

1B

3

31

2

Zn

+1

L

L

A3

A4

X3

X4

Yn

Yn

Yn+1

Yn+1

Zn

Zn

Zn+1

Zn+1

LL

LL

PP

PP

A2

X2

Yn

Yn+1

Zn

Zn+1

LL

PP

1V

1

24

35

1

1V

21

V3

14

121

B1

1B

2

A1

X1

Yn

YYn+1

Yn

+1

Yn

Zn

Zn+1

Zn

ZZ

LL

L

L

PP

PP

PP

1B

12

31

Y

TAB

TAA

TAA

TAA

2

31

1B

2

0V

7

0V

3

0V

12

0V

13

2

2

2

2

1/3

1/3

1/3

1/3

1

1

1

1

0V

82

1/3

1

1B

3

10

10

12

10

10

2

2 2

2

2

3

3 3

3

3

1

1 1

1

1

0V

9

0V

5

0V

4

0V

11

0V

10

22

33

11

0S

50

S4

11

22

s1

s2

s3

s4

1A

1

14

12

0S

3

Ma

nu

al/

Au

tom

ati

c

0V

2

2

2

4

4

3

3

5

5

1

1

2

31

0S1

EMERGENCY-

STOP

0V

12

31

10

2

31

0S

2

Ack

no

wle

dg

eE

ME

RG

EN

CY-

STO

P

Start

Reset

Exe

rcis

e 8

: S

ea

lin

g o

f g

uid

e b

ush

es

So

luti

on

© F

esto

Did

acti

c G

mb

H &

Co

. K

G •

54

10

89

0V

6

2

1/3

1

1B

3

31

2

Zn

+1

L

L

A3

A4

X3

X4

Yn

Yn

Yn+1

Yn+1

Zn

Zn

Zn+1

Zn+1

LL

LL

PP

PP

A2

X2

Yn

Yn+1

Zn

Zn+1

LL

PP

1V

1

24

35

1

1V

21

V3

14

121

B1

1B

2

A1

X1

Yn

YYn+1

Yn

+1

Yn

Zn

Zn+1

Zn

ZZ

LL

L

L

PP

PP

PP

1B

12

31

Y

TAB

TAA

TAA

TAA

2

31

1B

2

0V

7

0V

3

0V

12

0V

13

2

2

2

2

1/3

1/3

1/3

1/3

1

1

1

1

0V

82

1/3

1

1B

3

10

10

12

10

10

2

2 2

2

2

3

3 3

3

3

1

1 1

1

1

0V

9

0V

5

0V

4

0V

11

0V

10

22

33

11

0S

50

S4

11

22

s1

s2

s3

s4

1A

1

14

12

0S

3

Ma

nu

al/

Au

tom

ati

c

0V

2

2

2

4

4

3

3

5

5

1

1

2

31

0S1

EMERGENCY-

STOP

0V

12

31

10

2

31

0S

2

Ack

no

wle

dg

eE

ME

RG

EN

CY-

STO

P

Start

Reset

Exe

rcis

e 9

: H

ard

en

ing

of

ma

teri

al

test

sp

eci

me

ns

© F

esto

Did

acti

c G

mb

H &

Co

. K

G •

54

10

89

s1

s2

s3

s4

Zn

+1

L

L

A3

A4

X3

X4

Yn

Yn

Yn+1

Yn+1

Zn

Zn

Zn+1

Zn+1

LL

LL

PP

PP

A2

X2

Yn

Yn+1

Zn

Zn+1

LL

PP

A1

X1

Yn

YYn+1

Yn

+1

Yn

Zn

Zn+1

Zn

ZZ

LL

L

L

PP

PP

PP

Y

TAB

TAA

TAA

TAA

2

31

0S

1

1B

32

31

1B

21

B1

22

33

11

10

0V

60

V5

22

1/3

1/

31

1

2

31

1V

31

V4

1V

61

V5

1A

1

1B

3

12

12

10

22

2

33

3

11

1

1V

11

V2

0V

30

V2

0V

4

122 1

211

21

21

2

1B

11

B2

2

31

Exe

rcis

e 9

: H

ard

en

ing

of

ma

teri

al

test

sp

eci

me

ns

So

luti

on

© F

esto

Did

acti

c G

mb

H &

Co

. K

G •

54

10

89

s1

s2

s3

s4

Zn

+1

L

L

A3

A4

X3

X4

Yn

Yn

Yn+1

Yn+1

Zn

Zn

Zn+1

Zn+1

LL

LL

PP

PP

A2

X2

Yn

Yn+1

Zn

Zn+1

LL

PP

A1

X1

Yn

YYn+1

Yn

+1

Yn

Zn

Zn+1

Zn

ZZ

LL

L

L

PP

PP

PP

Y

TAB

TAA

TAA

TAA

2

31

0S

1

1B

32

31

1B

21

B1

22

33

11

10

0V

60

V5

22

1/3

1/

31

1

2

31

1V

31

V4

1V

61

V5

1A

1

1B

3

12

12

10

22

2

33

3

11

1

1V

11

V2

0V

30

V2

0V

4

122 1

211

21

21

2

1B

11

B2

2

31

Exe

rcis

e 1

0:

Be

nd

ing

of

she

et

me

tal

stri

ps

© F

esto

Did

acti

c G

mb

H &

Co

. K

G •

54

10

89

s1

s2

s3

s4

Zn

+1

L

L

A3

A4

X3

X4

Yn

Yn

Yn+1

Yn+1

Zn

Zn

Zn+1

Zn+1

LL

LL

PP

PP

A2

X2

Yn

Yn+1

Zn

Zn+1

LL

PP

2V

1

2

11

22

24

4

33

55

11

2V

23

V2

14

12

14

12

12

A1

X1

Yn

YYn+1

Yn

+1

Yn

Zn

Zn+1

Zn

ZZ

LL

L

L

PP

PP

PP

Y

TAB

TAA

TAA

TAA

3A1

3B

13

B2

22

33

11

0S

1

1B

2

2B

12

B2

1B

22

A1

3B

22

31

3

3

1

1

0V

3

0V

2

12

12

10

10

3B

12

31

2

31

2B

22

B1

1B

1

2

2

3

3

1

1

0V

42

1/

31

2

2

1V

2

1A

1

1V

12

31

1B

1

2 1

Exe

rcis

e 1

0:

Be

nd

ing

of

she

et

me

tal

stri

ps

So

luti

on

© F

esto

Did

acti

c G

mb

H &

Co

. K

G •

54

10

89

s1

s2

s3

s4

Zn

+1

L

L

A3

A4

X3

X4

Yn

Yn

Yn+1

Yn+1

Zn

Zn

Zn+1

Zn+1

LL

LL

PP

PP

A2

X2

Yn

Yn+1

Zn

Zn+1

LL

PP

2V

1

2

11

22

24

4

33

55

11

2V

23

V2

14

12

14

12

12

A1

X1

Yn

YYn+1

Yn

+1

Yn

Zn

Zn+1

Zn

ZZ

LL

L

L

PP

PP

PP

Y

TAB

TAA

TAA

TAA

3A1

3B

13

B2

22

33

11

0S

1

1B

2

2B

12

B2

1B

22

A1

3B

22

31

3

3

1

1

0V

3

0V

2

12

12

10

10

3B

12

31

2

31

2B

22

B1

1B

1

2

2

3

3

1

1

0V

42

1/

31

2

2

1V

2

1A

1

1V

12

31

1B

1

2 1

Neumatica avanzada

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