Learning System for Automation and Communications

Hydraulics
Workbook Basic Level

094468
Authorised applications and liability
The Learning System for Automation and Communication has been de-
veloped and prepared exclusively for training in the field of automation
and communication. The training organization and / or trainee shall en-
sure that the safety precautions described in the accompanying Techni-
cal documentation are fully observed.
Festo Didactic hereby excludes any liability for injury to trainees, to the
training organization and / or to third parties occurring as a result of the
use or application of the station outside of a pure training situation, un-
less caused by premeditation or gross negligence on the part of Festo
Didactic.

Order no.: 094468

Description: TEACHW. HYDRAUL.
Designation: D.S501-C-SIBU-GB
Edition: 11/1998
Layout: 03.11.1998, OCKER Ingenieurbüro
Graphics: OCKER Ingenieurbüro
Author: D. Waller, H. Werner

© Copyright by Festo Didactic GmbH & Co., D-73770 Denkendorf 1998

The copying, distribution and utilization of this document as well as the
communication of its contents to others without expressed authorization
is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved, in particular the right to carry out patent, utility model
or ornamental design registrations.
Parts of this training documentation may be duplicated, solely for train-
ing purposes, by persons authorised in this sense.

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Preface
Festo Didactic’s Learning System for Automation and Communications
is designed to meet a number of different training and vocational re-
quirements. The Festo Training Packages are structured accordingly:
„ Basic Packages provide fundamental knowledge on a wide range of
technologies.
„ Technology Packages deal with important areas of open-loop and
closed-loop control technology.
„ Function Packages explain the basic functions of automation sys-
tems.
„ Application Packages provide basic and further training closely ori-
ented to everyday industrial practice.
Technology Packages deal with the technologies of pneumatics, elec-
tropneumatics, programmable logic controllers, automation with PCs,
hydraulics, electrohydraulics, proportional hydraulics and application
technology (handling).

Mounting frame Fig. 1:

Hydraulics 2000 –
i.e. mobile workstation

U = 230V~
Profile plate

p = 6 MPa

Storage tray

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The modular structure of the Learning System permits applications to be

assembled which go beyond the scope of the individual packages. It is
possible, for example, to use PLCs to control pneumatic, hydraulic and
electrical actuators.
All training packages have an identical structure:
„ Hardware
„ Courseware
„ Software
„ Courses

The hardware consists of industrial components and installations,

adapted for didactic purposes.
The courseware is matched methodologically and didactically to the
training hardware. The courseware comprises:
„ Textbooks (with exercises and examples)
„ Workbooks (with practical exercises, explanatory notes, solutions and
data sheets)
„ OHP transparencies and videos (to bring teaching to life)
Teaching and learning media are available in several languages. They
have been designed for use in classroom teaching but can also be used
for self-study purposes.
In the software field, computer-based training programs and program-
ming software for programmable logic controllers are available.
Festo Didactic’s range of products for basic and further training is com-
pleted by a comprehensive selection of courses matched to the contents
of the technology packages.

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Latest information about the technology package TP501.

New in Hydraulic 2000:

„ Industrial components on the profile plate.
„ Exercises with exercise sheets and solutions, leading questions.
„ Fostering of key qualifications:
Technical competence, personal competence and social competence
form professional competence.
„ Training of team skills, willingness to co-operate, willingness to learn,
independence and organisational skills.
Aim – Professional competence

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

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TP501 • Festo Didactic

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Table of contents
Introduction 11
Notes on safety 13
Notes on operation 13
Technical notes 14
Training contents 17
Equipment set for “Hydraulics Basic Level” 19
Component / exercise table for TP 501 24

Section A – Course
Exercise 1: Automatic lathe
Pump characteristic A-3
Exercise 2: Package lifting device
Pressure relief valve characteristic A-7
Exercise 3: Drawing press
Hydraulic resistances A-11
Exercise 4: Calender feeding device
Single-acting cylinder (basic circuit) A-15
Exercise 5: Hardening furnace
Single-acting cylinder
(measurement and calculation) A-19
Exercise 6: Furnace door control
Double-acting cylinder A-23
Exercise 7: Conveyor tensioning device
4/3-way valve with bypass to pump A-29
Exercise 8: Cold-store door
Accumulator A-33
Exercise 9: Rotary machining station
Flow control valve and counter-holding A-37
Exercise 10: Painting booth
Flow control valve characteristic A-41

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Exercise 11: Embossing machine

One-way flow control valve and counter-holding A-45
Exercise 12: Surface grinding machine
Differential circuit A-49
Exercise 13: Drilling machine
Pressure regulator A-55
Exercise 14: Bulkhead door
Hydraulic clamping of a cylinder A-59
Exercise 15: Ferry loading ramp
Flow control valve in inlet and outlet lines A-63
Exercise 16: Skip handling
Varying load A-69
Exercise 17: Bonding press
Comparison of pressure regulator and –
pressure relief valve A-73
Exercise 18: Assembly device
Pressure sequence circuit,
displacement-step diagram A-77
Exercise 19: Assembly device
Calculation of pressure and time A-81
Exercise 20: Tipping container
Electrohydraulics A-85

Section B - Fundamentals

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Section C – Solutions
Solution 1: Automatic lathe C-3
Solution 2: Package lifting device C-7
Solution 3: Drawing press C-11
Solution 4: Calender feeding device C-15
Solution 5: Hardening furnace C-19
Solution 6: Furnace door control C-23
Solution 7: Conveyor tensioning device C-27
Solution 8: Cold-store door C-33
Solution 9: Rotary machining station C-37
Solution 10: Painting booth C-41
Solution 11: Embossing machine C-45
Solution 12: Surface grinding machine C-49
Solution 13: Drilling machine C-59
Solution 14: Bulkhead door C-65
Solution 15: Ferry loading ramp C-69
Solution 16: Skip handling C-73
Solution 17: Bonding press C-77
Solution 18: Assembly device C-79
Solution 19: Calculation for an assembly device C-83
Solution 20: Tipping container C-85

Section D – Appendix
Storage tray D-3
Mounting systems D-4
Sub-base D-6
Coupling system D-7
Data sheets ...

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TP501 • Festo Didactic

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Introduction
This workbook forms part of Festo Didactic’s Learning System for
Automation and Communications. The Technology Package “Hydrau-
lics”, TP500, is designed to provide an introduction to the fundamentals
of hydraulic control technology. This package comprises a basic level
and an advanced level. The basic level package TP501 teaches basic
knowledge of hydraulic control technology, while the advance level
package TP502 builds on this.
The basic level hydraulic exercises are designed to be carried out with
manual actuation. It is, however, also possible to use electrical actua-
tion. The hydraulic components have been designed to provide the fol-
lowing:
„ Easy handling
„ Secure mounting
„ Environmentally-friendly coupling system
„ Compact component dimensions
„ Authentic measuring methods

We recommend the following for the practical execution of the exer-

cises:
„ Hydraulic components: Equipment set TP501
„ One hydraulic power pack
„ A number of hose lines
„ A profile plate or a suitable laboratory trolley
„ A measuring set with the appropriate sensors

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This workbook provides knowledge of the physical interrelationships and

the most important basic circuits in hydraulics. The exercises deal with
the following:
„ Plotting of characteristics for individual components
„ Comparison of the use of different components
„ Assembly of various basic circuits
„ Use of basic hydraulics equations

The following technical equipment is required for safe operation of the

components:
„ A hydraulic power pack providing an operating pressure of 60 bar
and a flow rate of 2 l/min
„ An electrical power supply of 230V AC for the hydraulic power pack
„ A power supply unit with an output of 24V DC for solenoid-actuated
valves
„ A Festo Didactic profile plate for mounting the components

The theoretical background is described in the “Hydraulics Basic Level”

textbook TP501. Technical descriptions of the components used are
given in the data sheets in Part D of this workbook.
Festo Didactic offers the following further training material for hydraulics:
„ Magnetic symbols
„ Hydraulics slide rule
„ Set of OHP transparencies
„ Transparent models
„ Interactive video
„ Symbol library

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Notes on safety
Observe the following in the interests of your own safety:
„ Exercise care when switching on the hydraulic power pack. Cylinders
may advance unexpectedly!
„ Do not exceed the maximum permissible operating pressure (see
data sheets).
„ Observe all general safety instructions (DIN 58126 and VDE 100).

Notes on operation
Always work in the following sequence when assembling a hydraulic
circuit.

1. The hydraulic power pack and electrical power supply must be

switched off during the assembly of the circuit.

2. All components must be securely fitted to the profile plate, i.e. se-
curely snap-fitted or bolted down.

3. Check that all return lines are connected and all hose lines are se-
curely fitted.

4. Switch on the electrical power supply first and then the hydraulic
power pack.

5. Before dismantling the circuit, ensure that pressure in hydraulic com-

ponents has been released:

Couplings must be connected and disconnected only under

zero pressure!

6. Switch off the hydraulic power pack first and then the electrical
power supply.

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Technical notes
Observe the following in order to ensure safe operation.
„ The hydraulic power pack PN 152962 incorporates an adjustable
pressure relief valve. In the interests of safety, the pressure is limited
to approx. 60 bar (6 MPa).
„ The maximum permissible pressure for all hydraulic components is
120 bar (12 MPa).

The operating pressure should not exceed 60 bar (6 MPa).

„ In the case of double-acting cylinders, the pressure intensification

effect may produce an increased pressure proportional to the area
ratio of the cylinder. With an area ratio of 1:1.7 and an operating
pressure of 60 bar (6 MPa), this increased pressure may be over
100 bar (10 MPa)!
Fig. 2:
Pressure intensification

„ If connections are detached under pressure, the non-return valve in

the coupling may cause pressure to become trapped in the valve or
other component concerned. The pressure relieving device PN
152971 can be used to release this pressure. Exception: This is not
possible in the case of hose lines and non-return valves.
„ All valves, other components and hose lines are fitted with self-
closing quick-release couplings. This prevents the accidental spillage
of hydraulic fluid. In the interests of simplicity, these couplings are not
shown in circuit diagrams.

Fig. 3:
Simplified drawing of
self-closing couplings

Throttle valve Hose Shut-off valve

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„ It is frequently necessary when assembling a control circuit to modify

the given circuit diagram. Within the scope of the equipment set in
this Training Package, the following alternative solutions are possible:
„ Plugs can be used to change the function of directional control valves
(Figs. 4 and 5).
„ Directional control valves with different normal positions can be used
(Fig. 6).
„ Solenoid-actuated valves can be used in place of hand lever valves
(Fig. 7).

2/2-way valve 3/2-way valve Fig. 4:

Circuit diagram

4/2-way valve 4/2-way valve Fig. 5:

Practical assembly

Circuit diagram Practical assembly Fig. 6:

Directional control valves
with various
normal positions

Fig. 7:
Solenoid-actuated
directional control valve

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Flow rate sensor

The flow rate sensor consists of:

„ A hydraulic motor, which converts the flow rate q into a rotary speed
n.
„ A tachogenerator, which produces a voltage V proportional to the
rotary speed n.
„ A universal display unit, which converts the flow rate q into l/min. The
universal display should be set to sensor no. 3 for this purpose.

Fig. 8: q Hydraulic n Tacho- V Universal q

Block circuit diagram motor generator display

Fig. 9:
Circuit diagrams,
hydraulic and electrical

Fig. 10:
Connecting up the
universal display

Battery operation

External power supply

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Training contents
„ Characteristics of valves and other components.
„ Uses of individual valves and other components.
„ Comparison of uses and functions of different valves and other com-
ponents.
„ Measurement of variables such as pressure, flow rate and time.
„ Control of pressure and speed.
„ Calculations of area ratios, forces, power and speed.
„ Basic physical principles of hydraulics.
„ Use of basic hydraulics equations.
„ Understanding and drafting of circuit diagrams.
„ Drafting of displacement/step diagrams.
„ Use of symbols in accordance with DIN/ISO 1219.
„ Assembly and commissioning of control circuits, including fault-
finding.
„ Assessment of energy consumption.
„ Basic hydraulic circuits such as a pressure sequence circuit, a by-
pass circuit to the pump, a differential circuit, circuits with flow control
valves in the inlet, outlet and bypass, circuits with counter-holding
and bypass circuits with a non-return valve.

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List of training aims Exercise Training aims

1 Drawing a pump characteristic.

2 Drawing a characteristic for a pressure relief valve.
3 Measuring flow resistances.
4 Application of a non-return valve.
Use of a 2/2-way valve to control a single-acting cylinder.
5 Application of a 3/2-way valve.
Determination of times
6 Application of a 4/2-way valve.
Determination of times
7 Application of a 4/3-way valve.
Use of a pilot-operated non-return valve.
8 Use of a hydraulic accumulator as a power source.
Use of accumulator to power advance and return strokes of cylinder after
pump is switched off.
9 Application of a 2-way flow control valve.
Assembly of a counter-pressure circuit.
10 Plotting of characteristic for a 2-way flow control valve.
Comparison between this valve and a throttle valve.
11 Application of a one-way flow control valve.
Difference between flow control valve and throttle valve on the basis of a
concrete application.
12 Design and mode of operation of a differential circuit.
Influence of piston areas on pressures
13 Design of a control circuit with reduced output pressure.
Explanation of mode of operation of a 3-way pressure regulator.
14 Hydraulic clamping with a double-acting cylinder.
Comparison of circuits with and without counter-holding.
15 Speed control circuit with tractive load.
Comparison of circuits with flow control valves in the inlet line and outlet
line respectively.
16 Circuit for a double-acting cylinder with a varying load.
17 Specification of pressure for a double-acting cylinder.
Choice of either a pressure relief valve or a pressure regulator
18 Pressure sequence circuit.
Drawing of a displacement/step diagram
19 Calculation of forces associated with a double-acting cylinder
Calculation of advance-stroke time of a cylinder piston.
20 Electrohydraulic control circuit.

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Equipment set for “Hydraulics Basic Level”

Description Order No. Qty. TP501, PN 080246
Pressure gauge 152841 3
Throttle valve 152842 1
One-way flow control valve 152843 1
Shut-off valve 152844 1
Non-return valve, opening pressure 1 bar 152845 1
Non-return valve, opening pressure 5 bar 152846 1
Branch tee 152847 7
Pressure relief valve 152848 1
Pressure relief valve, piloted 152849 1
Pressure regulator 152850 1
Flow control valve 152851 1
Non-return valve, hydraulically piloted 152852 1
Double-acting cylinder 152857 1
Hydraulic motor 152858 1
Diaphragm accumulator 152859 1
Loading weight, 9 kg 152972 1
4/2-way hand lever valve 152974 1
4/3-way hand lever valve, recirculation mid-position 152977 1

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Additional equipment Description Order No. Qty.

Stop-watch 151504 1
4/3-way hand lever valve, closed in mid-position 152975 1
4/3-way hand lever valve, relieving mid-position 152976 1
Relay, 3-fold 162241 1
Signal input unit, electrical 162242 1
Flow-rate sensor 183736 1
4/2-way solenoid valve 167082 1
4/3-way solenoid valve, closed in mid-position 167083 1
4/3-way solenoid valve, relieving mid-position 167084 1
4/3-way solenoid valve, recirculating mid-position 167085 1
Universal display 183737 1
Pressure sensor 184133 1

Accessories Description Order No. Qty.

Profile plate, large 159411 1

Schlauchleitung, 600 mm 152960 12
Hydraulik-Aggregat 152962 1
Hose line, 1000 mm 152970 4
Pressure relieving device 152971 1
Protective cover (for weight, 9kg) 152973 1
Power supply unit, 24 V, 4.5 A 162417 1
Cable set with safety plugs 167091 1

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Description Symbol Symbols for

Pressure gauge
equipment set TP501

Throttle valve

One-way flow control valve

Shut-off valve

Non-return valve

Branch tee

Pressure relief valve

Pilot-operated pressure relief valve

Pressure regulator

Flow control valve

Piloted non-return valve

Double-acting cylinder

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Symbols for Description Symbol

equipment set TP501 Hydraulic motor

Diaphragm accumulator, detailed

Diaphragm accumulator, simplified

Weight

4/2-way hand lever valve

4/2-way solenoid valve

4/3-way hand lever valve, closed in mid-position

4/3-way hand lever valve, relieving mid-position

4/3-Wege-Handhebelventil mit Umlaufstellung

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Description Symbol Symbols for

4/3-way solenoid valve, closed in mid-position
equipment set TP501

4/3-way solenoid valve, relieving mid position

4/3-way solenoid valve, recirculating mid-position

Hose line

Hydraulic-power pack, detailed

Hydraulic power pack, simplified

Pressure sensor

Flow rate sensor

Hydraulic motor with tachogenerator

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Component / exercise table for TP 501

Exercises
Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Pressure gauge 1 1 3 1 3 1 1 2 5 3 5 3 4 3 3 3 3 2
Throttle valve 1 1
One-way flow control valve 1 1 1 1
Shut-off valve 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Non-return valve, 1 bar 1 1 1 1 1 1 1 1
Non-return valve, 5 bar 1 1 1 1 1 1
Branch tee 2 3 4 3 2 3 3 6 2 4 4 5 4 4 4 5 7 2
Pressure relief valve *) 1 2 1 1 1 1 1 2 2 2 1 1 2 2 3 2 3 1
Pressure relief valve, piloted (1) (1) (1) (1) (1) (1) (1) (1) (1) (1)
Pressure regulator 1 1
Flow control valve 1 1 1 1 1 1
Piloted non-return valve 1 1
Cylinder, double-acting 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Hydraulic motor 1
Diaphragm accumulator 1
Weight 1 1 1 1
4/2-way hand lever valve 1 1 1 1 1 1 1
4/3-way hand lever valve
recirculating mid-position 1 1 1 1 1 1 1 1

Hydraulic power pack 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Hose line, 600 mm 3 5 5 6 5 4 7 5 9 4 12 5 12 10 11 8 5 12 4
Hose line, 1000 mm 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4 2
Stop-watch 1 1 1 1 1 1 1 1
Pressure sensor (2) 2 2
Flow-rate sensor 1 1 1 1 1
Universal display 1 1 1 1 1
Power supply unit 1 1 1 1 1 1

*) If a sufficient number of directly-controlled pressure relief valves is not available,

the pilot-operated pressure relief valve can also be used.

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Electrical equipment for exercise 20

Description Order No. Qty.

4/3-way solenoid valve, relieving mid-position 167084 1

Signal input unit, electrical 162242 1
Relay, 3-fold 162241 1
Cable set 167091 1

The exercises appear in Section A of the workbook, with solutions to Methodological

these in Section C. The methodological structure is the same for all ex- structure of exercises
ercises.
The exercises in Section A are structured as follows:
„ Subject
„ Title
„ Training aim(s)
„ Problem definition
„ Exercise
„ Positional sketch

A worksheet then follows for use in carrying out the exercise.

The solutions in Section C contain the following:

„ Hydraulic circuit diagram
„ Practical assembly
„ Component list
„ Solution description
„ Evaluation
„ Conclusions

TP501 • Festo Didactic