Pneumatics

Advanced Level

Workbook TP 102

CD-ROM included

Festo Didactic
541089 en
Intended use

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.: 541089

Status: 04/2005
Authors: W. Haring, M. Metzger, R.-C. Weber
Editor: Frank Ebel
Graphics: Doris Schwarzenberger
Layout: 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.

2 © Festo Didactic GmbH & Co. KG • 541089

Contents

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

© Festo Didactic GmbH & Co. KG • 541089 3

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

4 © Festo Didactic GmbH & Co. KG • 541089

Preface

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.

© Festo Didactic GmbH & Co. KG • 541089 5

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.

6 © Festo Didactic GmbH & Co. KG • 541089

Introduction

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.).

© Festo Didactic GmbH & Co. KG • 541089 7

Introduction

8 © Festo Didactic GmbH & Co. KG • 541089

Notes on safety and operation

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.

© Festo Didactic GmbH & Co. KG • 541089 9

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.

10 © Festo Didactic GmbH & Co. KG • 541089

Technology package for pneumatics (TP100)

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.

Important elements of • Fixed workstation with Festo Didactic profile plate

TP100 • 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

© Festo Didactic GmbH & Co. KG • 541089 11

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.

12 © Festo Didactic GmbH & Co. KG • 541089

Training aims of Advanced Level (TP102)

• 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.

© Festo Didactic GmbH & Co. KG • 541089 13

Training aims of Advanced Level (TP102)

14 © Festo Didactic GmbH & Co. KG • 541089

Allocation of training aims and exercises

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.

© Festo Didactic GmbH & Co. KG • 541089 15

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.

16 © Festo Didactic GmbH & Co. KG • 541089

Equipment set – Advanced Level (TP102)

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.

Equipment set – Advanced Description Order No. Quantity

Level (TP102
3/2-way roller lever valve with idle return, normally closed 152867 1
Order No.: 540711)
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 152864 1

(EMERGENCY-STOP)

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

© Festo Didactic GmbH & Co. KG • 541089 17

Equipment set – Advanced Level (TP102)

Equipment set symbols Desccription Symbol

3/2-way valve with pushbutton, 2

normally closed

1 3

3/2-way valve with mushroom 2

actuator,
normally open (EMERGENCY-STOP)
1 3

3/2-way roller lever valve with idle 2

return

1 3

Back pressure valve 2

1 3

3/2-way pneumatic valve, 2

normally closed
12

1 3

5/2-way double pilot valve 4 2

14 12

5 1 3

Predetermining counter, pneumatic 2

12 10

Time delay valve, 2

normally open
10

1 3
One-way flow control valve 1 2

18 © Festo Didactic GmbH & Co. KG • 541089

Equipment set – Advanced Level (TP102)

Description Symbol

Shuttle valve, 3-fold 2 2 2

1 1/3 1 1/3 1 1/3

Shuttle valve
2

1 1/3

Dual pressure valve, 3-fold 2 2 2

1 1/3 1 1/3 1 1/3

Double-acting cylinder

Non-return valve, piloted 2

1 21

Description Symbol
A1 A2 A3 A4
Stepper module TAA TAA TAA TAB

Yn Y Yn Yn+1 Yn Yn+1 Yn Yn+1 Yn Yn+1 Y Yn+1

P P P P P P P P P P P P
Zn Z Zn Zn+1 Zn Zn+1 Zn Zn+1 Zn Zn+1 Z Zn+1
L L L L L L L L L L L L

X1 X2 X3 X4

© Festo Didactic GmbH & Co. KG • 541089 19

Allocation of equipment and exercises

Equipment set TP102

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 1 1

(EMERGENCY-STOP)

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

20 © Festo Didactic GmbH & Co. KG • 541089

Allocation of equipment and exercises

Equipment set TP101

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.

© Festo Didactic GmbH & Co. KG • 541089 21

Methodological help for the trainer

• 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.

22 © Festo Didactic GmbH & Co. KG • 541089

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.

© Festo Didactic GmbH & Co. KG • 541089 23

Methodological structure of exercises

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.

24 © Festo Didactic GmbH & Co. KG • 541089

Designation of equipment

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, ...

© Festo Didactic GmbH & Co. KG • 541089 25

Equipment set – Basic Level (TP101)

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.

Equipment set – Basic Level Description Order No. Quantity

(TP101
3/2-way pneumatic valve, convertible 539768 1
Order No.: 540710)
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

26 © Festo Didactic GmbH & Co. KG • 541089

Training aims – Basic Level (TP101)

• 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.

© Festo Didactic GmbH & Co. KG • 541089 27

28 © Festo Didactic GmbH & Co. KG • 541089
Contents

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

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

Contents

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

Exercise 1: Opening and closing of an oven door

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).

Problem definition 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.

Parameters • 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.

Project task 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.

© Festo Didactic GmbH & Co. KG • 541089 A-3

Exercise 1: Opening and closing of an oven door

Positional sketch

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–

Additional exercises • 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?

A-4 © Festo Didactic GmbH & Co. KG • 541089

Exercise 1: Opening and closing of an oven door

Exercise 1: Opening and closing of an oven door

Name: Date:

Completing the pneumatic circuit diagram Sheet 1 of 1

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

1A1

1V5 1 1 1V6

2 2

1V4 4 2

14 12

5 3
1

1V3 4 2

14 12

5 3
1 1V2 2

10

1 3

1V1 2 1S1 2

10

1 3 1 3

Pneumatic circuit diagram

© Festo Didactic GmbH & Co. KG • 541089 A-5

Exercise 1: Opening and closing of an oven door

Exercise 1: Opening and closing of an oven door

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

A-6 © Festo Didactic GmbH & Co. KG • 541089

Exercise 1: Opening and closing of an oven door

Exercise 1: Opening and closing of an oven door

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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© Festo Didactic GmbH & Co. KG • 541089 A-7

Exercise 1: Opening and closing of an oven door

Exercise 1: Opening and closing of an over door

Name: Date:

Carrying out additional exercises Sheet 2 of 2

– 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?

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A-8 © Festo Didactic GmbH & Co. KG • 541089