245

Solutions

Section C Solutions to the exercises in chapter 5

246
Solutions

Exercise 1: Direct control of a double-acting cylinder Problem definition A double-acting cylinder is to extend when a push button is operated. Upon release of the push button the cylinder is to retract. The cylinder is of small bore (25 mm diameter) requiring a small flow rate to operate at the correct speed.

Fig. 1 Circuit diagram with 5/2-way valve

247
Solutions

The following manually operated directional control valves can be used as control elements: 5/2-way valve. 4/2-way valve

Solution

In the initial position, the valve is unactuated, pressure is applied at the piston rod side and the piston rod of the cylinder is retracted. On operating the push button, the air passes through the valve from 1 to the 4 port and advances the piston rod. The displaced air flows to atmosphere via the ports 2 and 3. On release of the push button, the valve spring returns the control valve to its initial position and the cylinder retracts. Air returns from the cylinder via the exhaust port 5. The push button is released, the direction of movement is immediately reversed and the piston rod retracts. It is therefore possible to change the direction of movement without the piston rod reaching its initial or end position.
Fig. 2 Circuit diagram with 4/2-way valve

248
Solutions

Exercise 2: Indirect control of a double-acting cylinder Problem definition A double-acting cylinder is to advance when a push button is operated. Upon release of the push button the cylinder is to retract. The cylinder is 250 mm in diameter and consumes a large volume of air.

Fig. 3 Circuit diagram with 4/2-way valve

249
Solutions

For controlling cylinders at high speed or of large diameter, the air flow required determines that a large size control valve should be used. The operating force to actuate the valve may be relatively large and in this case indirect control is preferable. The valve 1S when operated by a push button supplies a pilot signal to the 14 port of the control valve 1V. The valve 1V reverses, the piston rod of the cylinder is pressurised and the piston rod of cylinder 1A advances. If the push button is released, the control port of valve 1V exhausts to atmosphere. The valve 1V then reverses and the cylinder retracts. If the push button is released, the direction of movement is immediately reversed and the piston rod retracts. A change in the direction of movement is therefore possible without the piston rod reaching its initial or end position. Since the valve 1V is without memory function, it changes its switching position immediately after the push button of valve 1S has been pressed.

Solution

Fig. 4 Circuit diagram with 5/2-way valve

250
Solutions

Exercise 3: The logic AND function Problem definition The piston rod of cylinder 1A is to advance only if a workpiece is inserted in the workpiece retainer, a guard has been lowered and the operator presses the push button valve. Upon the release of the push button or if the guard is no longer in the lower position, the cylinder 1A is to retract to the initial position.

Fig. 5 Circuit diagram

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Solutions

The logic AND operation of the output signals of valves 1S1, 1S2 and 1S3 is checked by the dual-pressure valves 1V1 and 1V2. If the valves are actuated, i.e. 1S2 (via the workpiece), 1S3 (via the guard) and 1S1 (via the operator), a signal is applied at output A of the dual-pressure valve 1V2. This signal is passed on to the control port 14 of the control element 1V3. The valve 1V3 reverses, pressure is applied at the piston side of the cylinder 1A and the piston rod advances. If the push button is released or the guard opened, this means that the AND conditions are no longer met. The control port 14 of the valve 1V3 is unpressurised. The valve 1V3 switches and the piston rod retracts.

Solution

252
Solutions

Exercise 4: The logic OR function Problem definition A double-acting cylinder is used to transfer parts from a magazine. If either a push button or a footpedal is operated, then the cylinder is to advance. Once the cylinder is fully advanced, it is to retract to the initial position. A 3/2-way roller lever valve is to be used to detect the full extension of the cylinder.

Fig. 6 Circuit diagram

253
Solutions

The logic OR operation of the ourtput signals of valves 1S1 and 1S2 is checked by the shuttle valve 1V1. Upon operation of either the push button of valve 1S1 or the pedal of valve 1S2, a signal is generated at the 1 or 1(3) side of the shuttle valve. The OR condition is met and the signal is passed to the control port 14 of the valve 1V2. The valve 1V2 switches, pressure is applied to the piston side of the cylinder 1A, and the cylinder advances. If the actuation (push button or pedal) of the valve is released, the signal at the control port of valve 1V2 is reset. Since valve 1V2 is a double pilot valve (with memory function), its switching position does not change. The limit swith 1S3 is actuated, when the piston rod reaches its end position. A signal is then applied at the control port 12 of the valve 1V2. The valve 1V2 reverses and the piston rod retracts. If the limit switch 1S3 is released during retracting, the direction of movement can be changed by actuating the push button or the pedal, even if the piston rod has not yet reached its initial position.

Solution

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Solutions

Exercise 5: Memory circuit and speed control of a cylinder Problem definition A double-acting cylinder is to be used to transfer parts from a magazine. The cylinder is to fully advance when a push button is operated and then retract automatically. Full extension is confirmed by a roller lever valve. The cylinder is to continue forward even if the push button is released before full extension is reached. The speed of the cylinder is to be adjustable in both directions of motion.

Fig. 7 Circuit diagram

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Solutions

The limit switch 1S2 is actuated, when the piston rod reaches its end position. If the push button 1S1 remains pressed in this status, a reversal of the valve 1V1 is not possible, since a signal is applied at both control ports 12 and 14. The first signal applied 14 is dominant. The signal at control port 12 is ineffective. The piston rod remains in the extended status. The piston rod cannot be retracted until the push button 1S1 has been released and the control port 14 becomes unpressurised. If the roller lever valve 1S2 is fitted at the stroke mid-position, then the piston rod retracts again upon reaching this position. However, this is not possible unless the push button 1S1 has already been released again. If the push button 1S1 has not yet been released at this point, the piston rod overtravels the limit switch 1S2 and travels up to the cylinder stop. A return stroke is not possible unless the roller lever valve has been manually actuated or with the help of the manual override of the control element 1V1. Both valves 1S1 and 1S2 are unactuated in the initial position. The switching position of the valve 1V1 is such that connections 1 and 2 and connection 4 and 5 are each interconnected. With this, pressure is applied at the piston rod side of the cylinder 1A and the piston rod remains in the retracted status. If push button 1S1 is actuated, a signal is applied at the input 14 of the valve 1V1. The valve 1V1 switches, pressure is applied at the piston side of the cylinder 1A and the piston rod advances. Upon reaching the end position, the piston rod actuates the limit switch 1S2, and a signal is applied at the control port 12 of the valve 1V1. This reverses and the piston rod retracts. The speed of the piston rod is set via the adjusting screw on the flow control valves 1V2 and 1V3 (exhaust air flow control). After each of the valves 1S1 and 1S2 has been released, the control ports become pressureless. The use of a double pilot valve (valve 1V1 has a memory function) ensures that the switching position does not change.

Answer to question 1

Answer to question 2

Answer to question 3

Answer to question 4

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Solutions

Exercise 6: The quick exhaust valve Problem definition The combined actuation of a manually actuated valve and a roller lever valve advances a forming tool on an edge-folding device. The forming tool is driven by a double-acting cylinder. For rapid forward travel, the circuit utilises a quick exhaust valve. The retracting speed is to be adjustable. If either of the two valves are released, the tool returns to its initial position.

Fig. 8 Circuit diagram

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Solutions

In the initial position, the inserted workpiece actuates the roller lever valve 1S2. The quick exhaust valve 1V4 is closed to atmosphere, pressure is applied at the piston rod side of the cylinder 1A, and the piston rod remains in the retracted status. If the start button 1S1 is actuated, a signal is applied at both inputs 1 and 1(3) of the dual-pressure valve 1V1. The AND condition is met and the signal is passed to the control port 14 of the control element 1V2. The valve 1V2 switches, pressure is applied to the piston side of the cylinder 1A, and the piston rod advances. As a result of the valve 1V2 reversing, input 1 of the quick exhaust valve 1V4 becomes pressureless. The air displaced on the piston rod side of the cylinder during advancing opens the quick exhaust valve and flows directly to atmosphere via the output 3. The flow resistance, created by the valve 1V2 and the lines against the displaced air, no longer applies. The piston rod is able to advance more rapidly. If one of the two valves 1S1 or 1S2 is released, the AND condition at the dual-pressure valve 1V1 is no longer met. The final control element 1V2 switches, the quick exhaust valve 1V4 closes and the piston rod retracts. The retracting speed is set at the restrictor of the one-way flow control valve 1V3.

Solution

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Solutions

Exercise 7: Pressure dependent control; embossing of plastic components Problem definition A plastic component is embossed using a die powered by a doubleacting cylinder. The return of the die is to be effected when the cylinder rod has fully extended to the embossing position and the preset pressure is reached. A roller lever valve is to be used to confirm full extension. The signal for retracting must only be generated when the piston rod has reached the embossing position. The pressure in the piston chamber is indicated by a pressure gauge.

Fig. 9 Circuit diagram

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Solutions

In the initial position, valves 1S1 and 1S2 are unactuated, pressure is applied at the piston rod side of the cylinder 1A and the piston rod remains in the retracted state. If necessary, the circuit needs to be put into its initial position with the help of the manual override on the control element 1V2. A signal is applied at the control port 14 of the control element 1V2, if the push button 1S1 is actuated. The valve 1V2 switches, pressure is applied at the piston side of the cylinder 1A, and the piston rod advances. If the push button 1S1 is released, the switching position of the double pilot valve 1V2 does not change due to its memory function. Just before reaching the forward end position (embossing position), the limit switch 1S2 is actuated. The actuated roller lever valve 1S2 releases the pressure line 1 to the pressure sequence valve 1V1. During the embossing process, the pressure on the piston side starts to increase. The indicator of the pressure gauge turns to the right. When this pressure reaches the value set at the control port 12 of the pressure sequence valve, the 3/2-way valve of the pressure sequence valve switches. The control element 1V2 reverses and the piston rod retracts. During the retracting movement, the limit switch 1S2 is released and the signal at the control port 12 of the valve 1V2 is reset and the pressure sequence valve is also reset.

Solution

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Solutions

Exercise 8: The time delay valve Problem definition A double-acting cylinder is used to press together glued components. Upon operation of a push button, the clamping cylinder slowly advances. Once the fully extended position is reached, the cylinder is to remain for a time of t1 = 6 seconds and then immediately retract to the initial position. A new start cycle is only possible after the cylinder has fully retracted and after a delay of t2 = 5 seconds. During this delay the finished part is manually removed and replaced with new parts for gluing. The retracting speed is to be rapid, but adjustable.

Fig. 10 Circuit diagram

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Solutions

In the initial position, the roller lever valve 1S2 is actuated by the piston rod and the time delay valve 1V1 is switched through, i.e. the working port 2 supplies a signal. The piston rod side of the cylinder 1A is pressurised and the piston rod remains in the retracted state. The following start condition must apply: Roller lever valve 1S2 is actuated Time delay valve 1V1 is switched through Start button is actuated

Solution

If the roller lever valve 1S2 is actuated for a sufficiently long time period (t1 = 5 seconds), then the air reservoir of the time delay valve 1V1 is filled and the corresponding 3/2-way valve is switched, following which a signal is applied at input 1(3) of the dual-pressure valve 1V2. If the push button 1S1 is actuated, the AND condition at the dualpressure valve is met. A signal is applied at the control port 14 of the control element 1V4. The valve 1V4 switches, pressure is applied to the piston side of the cylinder 1A and the piston rod advances. After a short advancing distance, the limit switch 1S2 is released, pressure is reduced in the air reservoir of the time delay valve 1V1 via the roller lever valve 1S2, and the integrated 3/2-way valve switches back to its initial position. The AND condition at the dual-pressure valve is now no longer met. Actuation of the push button 1S1 becomes ineffective. Upon reaching the advancing position, the piston rod actuates the roller lever valve 1S3. The pressure line to the time delay valve 1V3 is now released and pressure in the air reservoir is increased. The rate of pressure increase is adjustable via the integrated flow control valve. When the switching pressure has been reached, the integrated 3/2-way valve switches and a signal is applied at the control port 12 of the final control element 1V4. The valve 1V4 reverses and the piston rod retracts. Upon release of the limit switch 1S3, the time delay valve 1V3 switches to its initial position again. The limit switch 1S2 is actuated, when the piston rod reaches its initial position. The pressure in the air reservoir of the time delay valve 1V1 starts to increase until the switching pressure has been reached after t2 = 5 seconds. The integrated 3/2-way valve switches. The initial status of the system is now reached again and a new cycle can be started. The piston rod speed is set at the restrictors of the one-way flow control valves 1V5 and 1V6 (exhaust air flow control).

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Solutions

List of standards and references

List of Standards

DIN/EN 292-1

Safety of machinery Basic concepts, general principles of design Part 1: Basic terminology, methodology Safety of machinery Basic concepts, general principles of design Part 2: Technical principles and specifications Safety of machinery Emergency stop equipment, functional aspects Principles for design Safety of machinery Safety requirements for fluid power systems and their components Pneumatics Fluid power systems and components Graphic symbols and circuit diagrams Part 1 and Part 2 Pneumatic fluid power Identification of ports and control mechanisms of control valves and other components (port designations for pneumatic equipment) Reference conditions, standard conditions, standard volumes, concepts and values Pneumatic systems, design principles Circuit documents (IEC 848 modified); Part 6: Rules for function charts Coding of indicating devices and actuators (VDE 0199) by colours and supplementary means Graphical symbols for diagrams (IEC 617-8) Part 8: Measuring instruments, lamps and signalling devices

DIN/EN 292-2

DIN/EN 418

DIN/EN 983

DIN/ISO 1219-1 ISO/DIS 11727

DIN 1343 DIN 24558 DIN 40719 DIN/EN 60073 DIN/EN 60617-8

Eberhardt, H.-J., Scholz, D. Servo-pneumatic positioning, Workbook Festo Didactic, Esslingen 2000 Gerhartz, J., Scholz, D. Gevatter, H.-J. Prede, G., Scholz, D. Stoll, K.: Stoll, K.: Closed-loop control pneumatics, Workbook Festo Didactic, Esslingen 2001 Automatisierungstechnik 2, Gerte Springer Verlag, Berlin Heidelberg 2000 Elektropneumatics, Basic level, Textbook Festo Didactic, Esslingen 2001 Pneumatische Steuerungen Vogel Verlag, Wrzburg 1999 Pneumatik Anwendungen Vogel Verlag, Wrzburg 1999

List of References

10

11

Index

12

Subject 2/2-way valve 3/2-way valve 4/2-way valve 4/3-way valve 5/2-way valve 5/3-way valve

Page 181 181 193 195 197 200 139 138 34 15 131 24, 141 136 26, 144 26, 149 176 134 144 24, 129 229 65 11 230 229 170 240 126 204 56, 116, 238

Absorption drying Adsorption dryers Actuators Advantageous characteristics of compressed air Air compressor Air distribution Air dryers Air filter Air lubricator Air motor Air reservoir Air preparation equipment Air supply Analogue control Analysis of problem Applications Asynchronous control Binary control Cylinder performance characteristics Chain sequence control Characteristics of air Check valves Circuit diagram

B C

13

Subject Clamping devices Combinational valves Comparison of media Components Compressor Compressed air regulators Condensate Control chart Control circuits - Systems Control medium criteria Control system development Control theory Coordinated motion Derived elements Derived units Design process Designating the elements Designations Dew point Diagnostics Diaphragm Diaphragm compressor Diaphragm cylinder Diaphragm valve Digital control DIN ISO5599-3 Direct control of a pneumatic cylinder Directional control valves Disc seat Displacement-step diagram Distinguishing features Documentation Double-acting cylinder Double piston rod Dry compressed air Dryers Dual pressure valve: AND function

Page 51 218 16, 224 23 131 147 119, 144 234 35 17 55, 231 227 101, 231 40 124 65 62 40 136 117 147 131 157 212 229 44 68 27, 179 180 103, 232 15 116, 231 158 160 129 136 205

14

Subject

Page 51 159 52 129 52 65 117 144 201 132 180 30, 211 141 242 177 244 242 192 65 178 72 58 205 44 49 155 230 197 149

Emergency stop End position cushioning Environmental pollution Energy Exhaust silencers Evaluation Fault finding Filters Fitting of valves Flow compressors Flow control elements Flow control valves Flow resistances Fluid muscle Gear motors Gripper, pneumatic Handling technology Idle roller lever valve Implementation Indicators Indirect control of a pneumatic cylinder Input element Junction elements Lettering system Linear actuators Linear motion Logic control Longitudinal slide valve Lubrication

H I

J L

15

Subject Maintenance Malfunctions Manifold mounting of valves Memory control system Methods of actuation Modular systems Motors Mounting of roller valves Mounting of cylinders Multiple actuators Multi-position cylinder Noise pollution Non-return elements Non-return valves Oil mist Oil removal Operational safety Optical indicators Optimum pressures Over-lubrication Pilot control system Pipe material Pipe layout Piston force Piston motors Plastic pipes Pneumatics and control system development Pneumatic elements Pneumatics in review Poppet valves Positional sketch Power components Pressure control valves Pressure level Pressure regulator Pressure regulator with/without vent hole Pressure sequence valve Principles of air Processors: Valves and logic elements Product development

Page 120, 147 51, 118 240 227 45 240 176 201 169 102 241 16, 52 47 27, 203 53 151 53 178 130 149 227 142 143 170 176 142 18 23 12 180 231 34, 58 27, 48, 215 24, 131 24, 130 148 31, 217 124 33 18

16

Subject

Page 209 131 201 134 143 237 164 28, 190 50, 163 156 132 51 144, 165 190 17 224 227 217 148 211 207 57 107 34, 156 141 180 177 39 155 19 213 243 230 40 66 35

Q R

Quick exhaust valve Reciprocating compressor Reliable operation of valves Reservoirs Ring main Riveting process Rodless cylinder Roller lever valve Rotary actuators Rotary motion Rotary piston compressor Safety requirements for pneumatic clamping devices Seals Servo-controlled Selection criteria for working media Selection and comparison of media Sequence control Sequence valves Setting pressure regulator Shut-off valves Shuttle OR valve Signal flow Signal overlap Single-acting cylinder Sizing pipe Slide valves Sliding-vane motors Standards Static output devices Structure Supply air throttling Swivel/linear drive Synchronous control Symbols and descriptions of components System upgrade Systems: Control circuits

17

Subject Tandem double-acting cylinder Throttle valve Time delay valve Time-dependent sequence Trouble-shooting in pneumatic systems Turbine motors Utilisation factor Vacuum generator Vent hole

Page 160 211 32, 219 230 115 177 147 244 148

U V

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Physical values and units

l m t T F A V qv p A A' d D Feff FF FR Fth n pabs pamb pe p qB qH qL qn s t VB z Tn pn

Length Mass Time Temperature Force Area Volume Volumetric flow rate Pressure Piston surface Annular surface Piston rod diameter Cylinder diameter Effective piston force Force of retract spring Friction force Theoretical piston force Number of strokes per minute Absolute pressure Ambient pressure Excess or vacuum pressure Differential pressure Air consumption Air consumption per cm of stroke Delivery quantity Nominal flow rate Stroke length Centigrade temperature Reservoir size Switching cycles per hour Standard temperature Standard pressure

m kg s K N m2 m3 m3/s bar (Pa) m2 m2 m m N N N N 1/min bar (Pa) bar (Pa) bar (Pa) bar (Pa) l/min l/cm m3/min l/min cm C m3 1/h Tn = 273.15 K, tn = 0 C pn = 101325 Pa