Electro pneumatics

Exercise

Advanced Level
FESTECH Education

Table of Contents

Introduction .......................................................................................................... 4
Notes on safety and operation ............................................................................. 5
Symbols for components ...................................................................................... 9

Chapter 1. Installation and setting

1.1 General information and specification ............................................................ 12
1.2 Initial setting procedure .................................................................................. 13

Chapter 2. Applications
Exercise 1: Bench drill ......................................................................................... 16
Exercise 2: Feed unit for sheet metal trip ............................................................. 18
Exercise 3: Filling device ..................................................................................... 20
Exercise 4: Stamping device ................................................................................ 22
Exercise 5: Drilling jig........................................................................................... 24
Exercise 6: Clamping unit for grinding.................................................................. 26
Exercise 7: Forming press ................................................................................... 28
Exercise 8: Embossing device ............................................................................. 30
Exercise 9: Handling device ................................................................................. 32
Exercise 10: Drilling and reaming machine .......................................................... 34
Exercise 11: Loading station ................................................................................ 36
Exercise 12: Internal grinding machine ................................................................ 38
Exercise 13: Assembly unit .................................................................................. 40
Exercise 14: Molding press .................................................................................. 42
Exercise 15: Pick-and-place unit .......................................................................... 44
Exercise 16: Galvanising process ........................................................................ 46
Exercise 17: Loading station ................................................................................ 48
Exercise 18: Rotary indexing station .................................................................... 52

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Chapter 3. Solution
Solution 1: Bench drill.......................................................................................... 58
Solution 2: Feed unit for sheet metal trip ............................................................. 64
Solution 3: Filling device...................................................................................... 72
Solution 4: Stamping device ................................................................................ 76
Solution 5: Drilling jig ........................................................................................... 82
Solution 6: Clamping unit for grinding .................................................................. 90
Solution 7: Forming press ................................................................................... 96
Solution 8: Embossing device ........................................................................... 102
Solution 9: Handling device ............................................................................... 106
Solution 10: Drilling and reaming machine ......................................................... 112
Solution 11: Loading station ............................................................................... 116
Solution 12: Internal grinding machine .............................................................. 120
Solution 13: Assembly unit ................................................................................ 126
Solution 14: Molding press ................................................................................ 134
Solution 15: Pick-and-place unit ........................................................................ 140
Solution 16: Galvanising process ...................................................................... 148
Solution 17: Loading station .............................................................................. 156
Solution 18: Rotary indexing station .................................................................. 164

Appendix. Datasheets

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Introduction

This workbook forms part of the Training System for Automation by FESTECH. Co. Ltd.
The system provides a solid framework for practically orientated vocational and further
training.
Technology package FP200 deals exclusively with electro pneumatic controls.

Basic level FP201 provides initial training in electro pneumatic control technology.
Knowledge on the physical fundamentals of electro pneumatics
as well as of the function and application of electro pneumatic components is conveyed.
The set of equipment enables the construction of simple electro pneumatic control circuits.

Advanced level FP202 aims to provide further training in electro pneumatic control
technology.
The set of equipment can be used to build up extensive combination circuits with logic
linking of the input and output signals, as well as programmed control systems.
Precondition for assembling control circuits is a fixed workstation equipped with a
FESTECH. profile plate.
The profile plate has 29 parallel T-grooves at intervals of 25 mm each.
A short-circuit-proof power supply unit (input: 220V, 60 Hz; output: 24V, maximum 5 A) is
used for DC. supply.
For compressed air supply, a mobile silenced compressor (220V, maximum 8 bar = 800
kPa) is recommended.

Working pressure should be a maximum of p = 6 bar (= 600 kPa)

You will achieve maximum reliability of operation if the control system is run at a working
pressure of p = 5 bar (= 500 kPa), with unduplicated air.

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Notes on safety and operation

In the interest of your own safety you should observe the following:

* Pressurized air lines that become detached can cause accidents.

Switch off pressure immediately!
First connect all tubing and secure before switching on the compressed air.

* Warning!
Cylinders may advance or retract as soon as the compressed air is switched on.

* Do not operate the electrical limit switch manually during fault finding (use a tool).

* Observe general safety regulations!

* There are two different designs with electrical limit switches:

– Actuation only from the left
– Actuation only from the right

*Limit switches should be fixed in such a way that they contact the trip cam of the cylinder
only in the determined direction.
Do not use them being in the mid-position. Do not actuate limit switches from the front.

* Do not exceed the permissible working pressure (see data sheets).

* Use only low voltages of DC 24 V

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* Pneumatic circuit construction:

Use the silver-metallic plastic tubing of 4 mm external diameter to connect the
components.
The plastic tube is to be inserted fully into the CU-connector up to the stop; no tightening
necessary!

* Releasing the CU quick push-pull connector:

The tube can be released by depressing the cullet (black ring) (releasing whilst
pressurized is not possible!)

* Switch off the air and voltage supply before disconnecting the circuit.

* The mounting boards for the equipment are equipped with mounting alternatives A, B, C
or D:

Alternative A, Detent system

Light, non-load bearing components (e.g. directional control valves).
Simply clip the components into the groove on the profile plate; release is affected by
actuating the blue lever.

Alternative B, Rotational system

Medium weight load-bearing components (e.g. actuators).
These components are clamped on to the profile plate by means of T-head bolts.
The components are clamped or released via the blue triple grip nut.

Alternative C, Screw-in system

For heavy load-bearing components or components, which are seldom removed from
the profile plate (e.g. the service unit with on off valve).
These components are attached by means of cheese head screws and T-head nuts.

Alternative D, Plug-in system

For light, non-load bearing components with plug-in bolts (i.e. the indicator plate).

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These components are mounted via plug-in adapters.

* Observe the data given in the data sheets of section D for individual components.

[Electrical Danger]

[Warning]

[Caution]

[Note]

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Training contents of basic level

Basic level (FP202)

The following training contents are worked through

- Function and use of electro-pneumatic components

- Stroke-dependent control systems with sensors
- Stroke-dependent control systems with preselect counter
- Control systems with marginal conditions
(e.g. Single/continuous cycle, EMERGENCY-STOP)
- Position-scheduled control/process orientated sequence controls
- Timing controls/time orientated sequence controls
- Program control systems with latching and resetting sequence
- Fault finding in extensive electro-pneumatic control systems

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Symbols for components

Relay, 3-off Signal input plate, electrical

Indicator and distributor plate, electrical Single-acting cylinder

Double-acting cylinder Service unit with on-off valve

Manifold Proximity switch with cylinder mounting

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Limit switch, electrical, Limit switch, electrical,

actuated from the left actuated from the right

Pneumatic-electrical converter 3/2-way single solenoid valve,

normally closed

5/2-way single solenoid valve 5/2-way double solenoid valve

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Chapter 1. Installation and setting

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1.1 General Information and specification

Electric control box

Air service unit

Profile working panel

Air distributor

Cabinet(drawer)

Castor with a brake

▪ Specification of hydraulics working table

Subject Description

Size 1600 * 750 * 1700 (mm)

Weight 162Kg(2 cabinets)
Frame Aluminum
Cabinet 4 drawers with key lock
Castor 4 castors with push lock
Table board Wooden

Note: Pneumatic working table should be installed on flat ground and lock the brakes on each
castor.
※ Specifications and appearances are subject to change without prior notice.

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1.2 Initial setting procedure

1.2.1 Pneumatic power connection

1. Attach the air service unit and air distributor on the left corner of profile panel.

2. Then connect the air service unit and air distributor with pneumatic hose(6mm).

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3. Connect the pneumatic supply line to input of the air service unit(6mm).

1.2.2 Adjusting pressure

1. Pull up the cover of air service unit and turn to CCW direction to increase pressure.

2. Turn to CW direction to decrease pressure.

3. Normally set the pressure to 6 bar(0.6MPa).

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Chapter 2. Applications

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Exercise 1
Bench drill

Training aim
To teach the student the principle of a latching sequence.

Procedures
Drawing the pneumatic and electrical circuit diagrams
Construction of the pneumatic and electrical circuits
Checking the circuit sequence

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Problem description
Workpieces are inserted into the clamping device by hand. Clamping cylinder A is to
extend when the start button is pressed. When the workpiece is clamped, it is to be drilled
via feed unit B and the drill retracted once again. At the same time, the swarf is to be
blown away by an air jet C. Then, the clamping cylinder A is to release the workpiece.

Positional sketch

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Exercise 2
Feed unit for sheet metal strip

Training aim
To teach the student the principle of a resetting sequence
(with reliable switching reversal).

Problem description
A sheet metal strip is to be fed from a drum towards the cutting tool. The feed unit may
only start when the punch-tool is in the upper position (this signal must be simulated by a
push button S3). Cylinder A holds the sheet metal strip and cylinder B retracts. Cylinder A
releases the strip and cylinder B returns to the forward end position.

Operating condition
The sheet metal strip feed unit must be provided with a main switch S. When cylinder B
has retracted and cylinder A has released the strip, a signal (optical indicator) is to be
passed on to the press for the next part to be punched out.

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Positional sketch

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Exercise 3
Filling device

Training aim
To familiarise the student with the procedure for skipping program steps and the use of a
timer with switch-on delay.

Problem description
Bottles are transported along a conveyor belt to a rotary table. Cylinder A is to retract only
when a bottle has arrived on the conveyor belt (position 1) and the START signal
(continuous/single cycle) has been given. The table is then to continue indexing (B+),
when the signal "bottle on indexing table" (position 2) has been sent. When a bottle has
reached the filling station (position 3), cylinder C is to open the filling valve, remain it open
for approx. 2 seconds and then reclose it.

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Positional sketch

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Exercise 4
Stamping device

Training aim
To teach the student how to realise a stroke-dependent sequence control with a resetting
sequence.

Problem description
Cylinder A is to push parts out of the gravity feed magazine and clamp them. Only then
can cylinder B stamp the part and retract once again. Next, clamping cylinder A is to
unclamp. The part is to be ejected by cylinder C, which then returns to the retracted end
position.

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Positional sketch

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Exercise 5
Drilling jig

Training aim
To teach the student how to realise multiple movements of a cylinder and the use of an
incrementing preselect counter.

Problem description
Rectangular castings are to be drilled in 4 positions. Castings are inserted by hand and
clamped by an eccentric cam.
Feed unit C with hydraulic cushioning cylinder is aligned vertically (Zaxis). Positioning
cylinders A and B move the table in X- and Y-direction so that drilling positions (1), (2), (3)
and (4) can be approached consecutively.
The first hole is drilled by means of feed unit C after the START button has been pressed.
Next, double-acting cylinder A retracts and the second drilling process takes place. After
double-acting cylinder B has retracted, feed unit C carries out the third double stroke.
When cylinder A has once again reached its forward end position, the fourth hole is drilled.
In the 12th step, cylinder B extends once again and the initial position is obtained.

Operating condition
To ensure that the service life of the drill is not exceeded, it is to be monitored via a
counter. This is to emit a signal and interrupt the cycle once a predetermined number of
drilling operations has taken place. Once the drill has been replaced and the counter has
been reset by hand, the cycle is to continue again.

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Positional sketch

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Exercise 6
Clamping unit for grinding

Training aim
To familiarise the student with the use of a pneumatic/electric converter.
To teach the student how to construct a control system using single and double solenoid
valves (Resetting sequence with extension).

Problem description
Semi-finished flanges of workpieces are to be placed manually in a clamping and grinding
unit, pneumatically clamped and ground on the right and lefthand flanges.
Once single-acting clamping cylinder A has reached its forward end position and the
clamping pressure has built up in the piston chamber, feed unit B performs a double stroke.
The righthand flange is ground. Double-acting cross-feed cylinder C extends prior to feed
unit B carrying out the second double stroke and grinding the lefthand flange. Clamping
cylinder A releases the workpiece when cylinder C has reached its retracted end position.

Operating condition
Clamping cylinder A, single-acting, controlled via a solenoid valve.
Feed cylinders B and cross feed cylinder C are both double-acting and each controlled via
a double solenoid valve.
Monitoring of clamping pressure.

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Positional sketch

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Exercise 7
Forming press

Training aim
To teach the student how to realise a control system with specified EMERGENCY-STOP
conditions.
To teach the student how to realise a two-hand safety control via a timer with switch-on
delay.

Problem description
A metal plate is inserted by hand into the forming press. A profile is to be stamped into the
metal plate by means of a two-handed operation.
When the operation is complete, the formed metal part is to be ejected by means of
ejecting cylinder B.

Operating condition
The START signal is obtained through a two-hand safety control with delayed switch-on
timer. When the EMERGENCY-STOP button is pressed, the two cylinders must return
immediately to their initial positions.

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Positional sketch

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Exercise 8
Embossing device

Training aim
To teach the student how to incorporate step repetitions and manual step mode into a
sequence.

Problem description
Workpieces to be embossed are inserted manually into a retainer and pushed under the
embossing stamp by cylinder A. Cylinder B extends and embosses the workpiece. Then,
cylinder B retracts again followed by cylinder A.

Operating condition
It must be possible to carry out the individual movements step by step via a push button
(manual step mode). In addition, steps B+/Bmust be repeatable to enable adjustment of
the embossing cylinder.
Cylinder B+ is to be moved in manual step mode, meaning that the B- movement must be
effected via an additional push button. Step repetition and manual step mode should only
be possible when no START signal is present.

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Positional sketch

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Exercise 9
Handling device

Training aim
To teach the student how to incorporate EMERGENCY-STOP and marginal conditions in a
latching sequence.

Problem description
Round parts are to be fed by a handling device from the outlet channel of processing
station I to the inlet channel of processing station II.
As an additional start condition, the outlet channel is to be interrogated for round parts.

Operating condition
Separate push buttons for SINGLE/CONTINUOUS CYCLE. EMERGENCY-STOP: Linear
drive B must be unpressurised. Gripper A must remain closed or open according to status.
When EMERGENCYSTOP is no longer being actuated, pressing a push button is to bring
the linear drive back into the initial position. A second push button is then to release the
gripper (if this was closed in the EMERGENCYSTOP status). This push button must also
simultaneously latch the start button (after the EMERGENCY-STOP), so that it is only
possible to restart via the START button after this button has been pressed.

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Positional sketch

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Exercise 10
Drilling and reaming machine

Training aim
To teach the student how to realise a control system with an alternative program by means
of program switching step jump.

Problem description
Program 1: Drilling
Parts, which only need to be drilled, are clamped by hand. The part is drilled when the
START button is actuated.
(Cylinder A).

Program 2: Drilling and reaming

Parts, which also need to be reamed, are also clamped by hand.
Then, upon actuation of a PROGRAM SELECTOR button and the START button, cylinder
A starts the drilling process. When the drilling process is completed, positioning cylinder B
extends and transfers the drilled part to the reaming station (cylinder C). When reaming of
the part has taken place, positioning cylinder B retracts and the part can be removed. The
PROGRAM SELECTOR button must be actuated before the START button in order to
start up program 2. If these buttons remain unactuated, then program 1 is to automatically
run.

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Positional sketch

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Exercise 11
Loading station

Training aim
To teach the student to program repetition using an additional movement.

Problem description
A plate on a conveyor belt is fitted with two steel parts.
The parts advanced via a rail are centred by a spigot and held by an electromagnet whilst
being transferred.
The motion sequence towards position 1 is to be executed via cylinders A and B.
Position 2 is to be reached by means of the same sequence as that employed for position
1, with the addition of cylinder C (see displacement-step diagram).

Operating condition
Sensing of steel parts is to be realised via a push button S2.
When the conveyor belt has passed on the next plate for loading and transmitted a signal
to the loading unit (simulated by push button S1), the machine is to proceed automatically.
The functioning of the electromagnet is to be simulated by means of a lamp H1.

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Positional sketch

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Exercise 12
Internal grinding machine

Training aim
To familiarise the student with step repetition using the preselect counter.

Problem description
Workpieces are fed along a conveyor belt. The forwardmost workpiece is pushed against
the stop by the following one. When a workpiece is present, it is signalled by a sensor
(switch) and the clamping stop is raised (cylinder A).
Next, cylinder B is to clamp the part and signal when the clamping pressure has been
reached so that the grinding process can commence.
Cylinder C is to advance and the grinding wheel switched on simultaneously (simulation by
means of visual indicator). Then cylinder C is to travel up and down ten times (half strokes)
and then return to the initial start position. Next, cylinders A and B are to retract
simultaneously.
Cylinder B now is to extend once again and push the part onto the conveyor belt which is
to carry it away (only a minimal section of the stroke was required for the clamping
operation). When cylinder B has returned once again and another workpiece has reached
the stop, the cycle is to be repeated.

Operating condition
START and STOP at the end of each cycle are each controlled by one push button.

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Positional sketch

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Exercise 13
Assembly unit

Training aim
To teach the student how to set up manual activation of a cylinder including precautions
with protection against collision.
To familiarise the student with automatic setting conditions.

Problem description
Bushes which are placed ready for assembly in a gravity feed magazine are pressed into
metal blocks which are also introduced in a similar manner.
Cylinder A pushes a metal block from the magazine to a stop and clamps it. Then, cylinder
B extends and presses the first bush into place. Next, cylinder C is activated, pressing the
second bush into place. Then cylinders A and C retract simultaneously, followed by
cylinder B retracting. The assembled metal block drops onto a conveyor belt.

Operating conditions
The installation is to operate in a continuous cycle.
It must be possible to select between manual and automatic operating mode.
Manual operation is to be indicated by a lamp H1.
Separate push buttons are to actuate each of the cylinders. This installation may only be
run in manual mode; only one cylinder is to extend at a time.

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Positional sketch

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Exercise 14
Molding press

Training aim
To teach the student how to construct a two-handed safety start-up control with relay.
To familiarise the student with restart before the end of the cycle.

Problem description
Plastic plates are to be formed from duroplastic pellets. The pellets are inserted manually
into the lower part of the mould.
When the START button is pressed (two-handed safety control), the upper part of the
mould is guided into the lower part of the mould.
When the forward end position is reached, pressure must be sustained for approximately
ten seconds to guarantee hardening of the formed part. Then, the plates are removed from
the mould tool by the extractor unit and stacked next to the press.

Operating conditions
The START signal must continue until cylinder A has assumed its forward end position.
The press cylinder may extend immediately the extractor unit has been removed from the
working area (half return stroke of cylinder B).
The two-handed safety control using a relay.
The function of the vacuum generator V is to be represented by a lamp.

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Positional sketch

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Exercise 15
Pick-and-place unit

Training aim
To teach the student how to develop a latching sequence with marginal conditions.

Problem description
A triple-axis unit is used for insertion of parts from position 2 into positions 3 and 4 of a
gear housing. The vacuum gripper V is to be simulated by a lamp (gripper suction = lamp
on, no gripper suction =lamp off). The start position is to be position 1, where the gripper is
raised (Z-axis) and there is no suction. When the START button is pressed, position 2 is to
be approached and a part picked up from the feed hopper and then deposited in position 3.
Another part is then picked up from position 2 and deposited in position 4. The gripper
then returns to initial position 1.

Operating conditions
Sensing of the magazine (simulated by a switch and indicated via a lamp):
When the magazine is empty, the control system is to remain in position 1 or position 2
and must only proceed or restart when the magazine has been filled and the start button
pressed.
Sensing of the gear housing:
This is to guarantee that a gear housing which is inserted into a device is removed after
processing (switch and lamp off). The initial start positions of the double-acting cylinders
are: A+, B+, C-.

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Positional sketch

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Exercise 16
Galvanizing process

Training aim
To teach the student how to realise program branchings
To teach the student how to make multiple use of time relays
To familiarise the student with program section repetitions using the preselect counter
To teach the student how to realise a pressure-dependent control system

Problem description
An overhead trolley beam transports the parts to be galvanised from a work surface across
the three baths and back again. A doubleacting cylinder positions the basket on the work
surface or else lowers it into the baths. It remains in the forward end position (bath 2) or
swings the basket up and down in the bath (baths 1 and 3). Partial strokes are sensed by
three limit switches.
If the trolley has approached a horizontal position, a control lamp is illuminated (bath 1
lamp H1, bath 2 lamp H2, bath 3 lamp H3 and work surface lamp H4).
In the initial position, the basket hangs above the work surface. When the up/down switch
S2 is actuated, the cylinder extends and the basket is deposited on the work surface for
loading. When the initial start position has once more been reached, the cylinder can be
actuated via start button S. The movements of the trolley (from work surface to bath 1,
from bath 1 to bath 2, from bath 2 to bath 3 and from bath 3 back to the work surface) are
simulated by four identical time periods t1 = 2 seconds. Once the basket has been dipped
into bath 1 (and bath 3), the piston extends four half strokes in the forward stroke area.
The basket remains in bath 2 in the forward stroke area t2 = 3 seconds.

Operating conditions
When the main power supply has been switched on, the control is to be activated via the
SET button S1 and the time interval t1 started simultaneously.
During this time period, the cylinder is to be brought into the initial position (as it would

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have moved into the forward end position by leakage losses when the installation was
stopped.)
When the time t1 has expired, the positioning lamp H4 is illuminated.
The installation can only be started once an pneumatic-electrical converter has signalled
the supply of compressed air.

Positional sketch

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Exercise 17
Loading station

Training aim
Consolidating the student’s knowledge
Program section repetition

Problem description
A loading station is used for loading boxes. Empty boxes which are supplied via a
conveyor belt must be placed onto the transfer unit by hand. Transfer unit A moves
underneath the swivel device D, which then fills the box with containers row by row. The
motion sequence can be seen in displacement-step diagram 1. Indicate on the diagram
the step which has been reached by the installation shown in the positional sketch.

Operating conditions
The functioning of the suction cups is to be simulated by lamp. The motion sequences
which recur (see displacement-step diagram 1, steps 3....21), should be brought together
in a subroutine which is to be repeated itself a number of times (see displacement-step
diagram 2).

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Positional sketch
The loading station shown here is not in the initial position.

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Displacement-step diagram 2

Abbreviated notation
A+ C+ D+ D- C- B+ C+ D+ D- B- C- B+ C+ D+ D- B- C- B+ C+ D+ D- C- A-

Displacement-step diagram 1

Abbreviated notation
Main program 3 x Subroutine Main program
A+ C+ D+ D- B- C- B+ C+ D+ D- C- A

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Exercise 18
Rotary indexing station

Training aim
To familiarize the student with parallel program division.

Problem description
Workpieces are drilled vertically and horizontally on an eight-station rotary indexing table.
Six feed units are used for the various machining operations. Two each for drilling,
counterboring and countersinking.
Two transferring units load and unload the machine respectively.
Lifting cylinders A and C descend onto the workpieces. These are picked up by suction
(functioning of the vacuum generator is to be indicated by a lamp) and then lifted.
The stroke of cylinder E then causes the table to index on by one position. At the same
time, transfer cylinders B and D approach the positions for placing on the indexing table
and depositing via the conveyor belt 2.
Then, cylinder E latches the rotary indexing table and the two lifting cylinders A and C
deposit the parts.
At the same time as the lifting cylinder retracts, processing via feed units F to K begins.
When these have reached their forward end positions, the feed units and the transfer
cylinders return to their initial positions.

Operating conditions
Choice between manual and automatic operating modes.
Separate push buttons for START and STOP (continuous cycle).
The start signal must be maintained until the machine has been supplied with lubricant via
a centralised lubrication system (the pump motor is to be simulated by a lamp). Then, the
start signal is to be stored and indicated by a lamp.
Workpiece sensing on conveyor belt 1 is simulated by a switch.
The air blast for swarf removal is to be simulated using a solenoid valve.

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EMERGENCY-STOP
The electrical power to the control must be switched off.
The feed units are to retract.
The transfer units and the cylinder of the indexing table are to complete their movements.
When the vacuum generators are active, they must continue to remain active until, after
the RESET and a renewed START, the controller gives the command to deposit.

RESET
If, after indexing on, processing can no longer take place because the EMERGENCY-
STOP has been actuated, processing must be carried out in RESET mode via a time
control.
All cylinders must be brought into their initial position. In the case of the transport units,
cylinders A and C must retract before cylinder B and D.

Note regarding solution

For the purpose of simulation, this exercise can be solved using four cylinders:
The transfer units are to be represented by double-acting cylinders.
Cylinders A and B are sufficient for this as the movements of the two units are
synchronised.
Cylinder E for indexing of the table E is also represented by a double-acting cylinder.
All feed units are to be represented by a single-acting cylinder.
Only the limit switches of the four cylinders are to be drawn in the electrical circuit diagram.

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Positional sketch

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MEMO

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Chapter 3. Solution

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Solution 1

Circuit diagram, pneumatic

* For the purposes of this exercise, feed unit B is replaced by a double-acting cylinder.
** Detailed representation of the on/off valve with filter regulator.

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Circuit diagram electrical

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Solution description
Since in this case the memory function is via a relay, signle solenoid valves are generally
activated using a latching sequence. It should be remembered that the coil circuit should
be interrupted by a second contact for the return motion, for example, in order to achieve
spring return of the valve to the initial position. (The final step represents an exception to
this since it is possible to dispense with a normally closed contact as all valves are
returned to their initial positions through interruption of all the circuits). This is why a
latching sequence is used since in the case of power failure all cylinders will return to an
accurately defined initial position. This is important for accident prevention, although it is
important to watch out for overlapping of movements which may occur on reaching the
initial position.

Step 1, Cylinder A+

When START button S is actuated and normally open contact S1 is activated via cylinder
A, the circuit to relay K1 is closed via the normally closed contact of K4, which then goes

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into self-holding (latching) via the parallel contact of K1.

A further normally open contact of K1 switches the circuit to solenoid coil Y1. This in turn
switches the solenoid valve and cylinder A travels into the forward end position.

Step 2, Cylinder B+

When cylinder A has reached its forward end position, it actuates limit switch S2. Then, the
circuit for relay K2 is closed via S2 and the setting condition K1, this then goes into self-
latching via a parallel normally open contact.
A second normally open contact of K2 switches the current to solenoid coil Y2 via normally
closed contact K3; this switches the valve and cylinder B extends.
The principle of the latching sequence is to interrogate the preceding step and its
acknowledgement (limit switch) and then to set a new memory for the next step. Finally,
the complete sequence (the selflatching circuits) is reset by the last step (or cycle) – no
self-latching is required for the last step.

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Components list

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Solution 2

Circuit diagram, pneumatic

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Circuit diagram, electrical(1)

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Circuit diagram, electrical(1)

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Solution description
When the SET button is pressed, relay K7 goes into self-latching and switches relay K8,
which represents the start condition.
If appropriate, the SET button should be latched in such a way that it can only be active at
the time when the main current supply is applied, in order to safeguard the circuit
sequence.
Once the feed has been initiated with S and S3, K1 goes into self-latching and K2 switches,
self-latching at K7 is cancelled via a normally closed contact of K2.
A further possibility is to replace the SET key by a relay (see exercise 13).

Step 1, Cylinder A-

When START button S is actuated, the circuit for relay K1 is closed via the signal from
pressing S3, the limit switch S2, the setting signal for relay K8 and the normally closed
contact K4. The relay goes into self-latching via the parallel normally open K1. At the same

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time, a further normally open contact of K1 switches the circuit for the relay K2.
A normally open contact of K2 switches the circuit in the power section to solenoid coil Y1.
The valve switches and cylinder A travels into the retracted end position and there
actuates limit switch B1.

Step 2, Cylinder B-

Now sensor B1 emits a signal which closes the circuit for relay K3 via the normally open
contact K2 and the normally closed contact K6.
This goes into self-latching via the parallel normally open contact K3.
At the same time, relay K4 is switched via a further normally open contact K3.
Only now, when self-latching of K3 has been established, is the setting condition K1 or K2
reset by normally closed contact K4 and in the power section, the normally open contact
K4 switches the circuit to solenoid coil Y3, which in turn switches the valve, cylinder B
retracts and activates S1 in the end position.
Owing to its additional switching time, relay K4 serves as a delay between the build-up of
self-latching of K3 and the reset of setting condition K2. This guarantees that K3 is in self-
latching before the setting signal is set.
Then, the next step is activated (K5, K6) by S1 via K4. The principle of the latching

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sequence is based on the interrogation of the preceding step and its acknowledgement
(limit switch). The next step is activated on the basis of these conditions; when this
happens, the preceding step is reset.

The reset sequence is particularly suitable for the control of double solenoid valves, since
here the memory behaviour is assumed by the bi-stable solenoid valve.
This can be very important in the case of power failure, in respect of accident prevention.
To be able to start up again after power failure or switch off the main power supply (circuit
dead), relays K7 and K8 must be switched. This happens here via the SET key. The
principle of reversal of the latched sequence which is shown here is completely reliable
owing to the use of an additional relay per step and can be used for every type of relay.
Where there is a late opening or early closing relay, it may be possible to get by without an
additional one. (Normally, only contactors have this type of switching behaviour). In such a
case, the circuit up to step 2 would look as follows. Compare this simplified circuit diagram
with the electrical circuit diagram.

Circuit diagram, simplified

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Components list

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Solution 3

Circuit diagram, pneumatic

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Circuit diagram, electrical(1)

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Circuit diagram, electrical(2)

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Solution description
When S3 or S4 and S5 are activated, the control system is started up. Cylinder A retracts
and the bottles move along. If S6 is actuated, the cylinder extends again. Then, the
indexing table (cylinder B) inches round one position. Once a bottle has reached the filling
station, it is filled until the time delay closes the container (cylinder C), and the control
system is brought back into the initial start position. If no bottle is reported as being
present at the filling station, the control can be returned to the initial start position via S8.
Then the indexing table can be supplied with bottles until a signal is received from S7.

Components list

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Solution 4

Circuit diagram, pneumatic

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Circuit diagram, electrical(1)

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Circuit diagram, electrical(2)

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Circuit diagram, electrical(3)

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Solution description

This solution corresponds to a reset sequence of 6 steps with single cycle operation. Only
when the last step has been set via the SET button, can another single cycle be started.
The signal generators are directly switched to limit the number of relays.

Components list

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Solution 5

Circuit diagram, pneumatic

* For the purposes of this exercise, feed unit C is replaced by a single-acting cylinder. A 3/2-way solenoid valve
may also be used as a final control element.

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Circuit diagram, electrical(1)

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Circuit diagram, electrical(2)

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Circuit diagram, electrical(3)

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Circuit diagram, electrical(4)

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Solution description

The preselect counter receives pulses from S2. When the preselect figure or the end of the
drill life has been reached, the sequencer is stopped. It will not continue running until the
drill has been changed (counter reset).

Signal generators S1 and S2 must be switched indirectly to ensure reliable sensing.

Otherwise, self-latching would supply a continuous signal (see example) when a latching
sequence is being used.

Example
Kn+1 can be set without acknowledgement S1 being activated since current can flow via
the self-latching of K3 and Kn .

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The signal generators indirectly switched (as in the solution to the exercise).

Alternative circuit (1)

As the connection is interrupted here by K4 via K3, Kn+1 may only be set if Kn and S1 are
activated.

Alternative circuit (2)

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Components list

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Solution 6

Circuit diagram, pneumatic

* For the purposes of this exercise, feed unit B is replaced by a double-acting cylinder.

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Circuit diagram, electrical (1)

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Circuit diagram, electrical (2)

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Circuit diagram, electrical (3)

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Solution description

In this exercise, two problems can be solved with minimal modifications to the reset
sequence:
Memorising of the start signal (K1) for the movement A+,
Resetting of the final step (K14) via START button S.
The pressure switch does not switch over until the clamping pressure has been reached;
consequently the sequencer stops until the required pressure has built up.
In this exercise, sensor B1 and B2 can be interrogated directly several of times without
faulty actuation of the control taking place (compare with exercise 5).

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Components list

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Solution 7

Circuit diagram, pneumatic

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Circuit diagram, electrical (1)

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Circuit diagram, electrical (2)

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Solution description

If the EMERGENCY-STOP switch ES is not activated, current path (1) is supplied with
current. In order to switch relay K2, the two push buttons S3 and S4 must be actuated
simultaneously (START signal).
If one of the push buttons is pressed before the other, the time relay with switch-on delay
is energised which then switches after 0.5 secs.
(For safety reasons, the switch-on delay must not exceed 0.5 seconds). The result of this
is that the normally closed contact K3 in current path 3 opens and, thus the connection to
K2. If two buttons are actuated simultaneously so that the time relay does not switch
through, relay K2 is switched and cylinder A extends.
When the EMERGENCY-STOP switch is actuated, the current to path 1 is interrupted and
the solenoid coils are no longer supplied with current. The result of this is that the reset
springs reverse the solenoid valves and the cylinders return to the initial position.

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Components list

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Solution 8

Circuit diagram, pneumatic

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Circuit diagram, electrical (1)

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Circuit diagram, electrical (2)

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Solution description

By pressing the START button, the program is started in accordance with the
displacement-step diagram.

Manual step mode

By pressing push button S3, it is possible to carry out one movement per actuation in
accordance with the program or control sequence.

Step repetition
When, after pressing S3, cylinder A has advanced via K3 and cylinder B via K4, self-
latching at K4 can be reset via K7 by means of push button S4. As a result of this, K4 is
de-energised and cylinder B retracts. Cylinder B is now able to advance again via S3.

Components list

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Solution 9

Circuit diagram, pneumatic

* For the purposes of this exercise, linear drive B is replaced by a double-acting cylinder.

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Circuit diagram, electrical (1)

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Circuit diagram, electrical (2)

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Circuit diagram, electrical (3)

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Solution description

Line 1 is supplied with current via relay K4 (provided the EMERGENCY-STOP button has
not been pressed). The cycle is started via S3 or S4. A latching sequence is then
constructed for this motion sequence through current paths 9 to 18.

When the EMERGENCY-STOP switch has been actuated, the gripper is to remain in its
current position, whether open or closed. The signal "close gripper" is acquired via relay
K6. This signal must be stored after actuation of EMERGENCY-STOP to keep the gripper
in a closed position (see current paths 21 and 22). However, this memory must be erased
if, at the time of the EMERGENCY-STOP actuation, the control had opened the gripper. In
this case, the "open" signal K8 MUST BE STORED (SEE CURRENT PATHS 23 AND 24).
Relay K13 is required to ensure that the reset button for gripper S7 is only active when the
EMERGENCY-STOP key has already been switched off and the controller has been
stopped. This is only released when no start signal or EMERGENCY-STOP signal is
present and push button S7 has been actuated.

Coil Y2 is actuated by signal K7 and the linear drive proceeds. Selflatching of relay K10 is
required to switch the linear drive to unpressurised on actuation of the EMERGENCY-
STOP and to memorise this status. This is then reset by RESET button S6 and the unit is
returned once again to the initial start position.
A new start signal is not memorised until the gripper has actuated limit switch S2 (K5).
The cycle only starts if parts are present in the outlet channel (sensor B3) and the initial
position of the linear drive (sensor B1) is being signalled.
Owing to multiple sensing, limit switch S2 must be switched indirectly via relay K5.

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Components list

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Solution 10

Circuit diagram, pneumatic

* In order to assemble this control system on the profile plate, feed unit A is replaced by a
double-acting cylinder and feed unit C by a single-acting cylinder.

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Circuit diagram, electrical (1)

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Circuit diagram, electrical (2)

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Solution description

Relay K1 is switched via the PROGRAM SELECTOR BUTTON PS.

This is only possible prior to actuation of the START button. If program 2 (drilling and
reaming) is selected, the latched sequence runs through as usual.
However, if program 1 (drilling) is required, it is simply necessary to press the start button.
If S2 and contact K2 switch the relay K4, the sequencer is reset by K4 and cylinder A
retracts.

Components list

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Solution 11

Circuit diagram, pneumatic

* For the purposes of this exercise, cylinder A is replaced by a single-acting cylinder.

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Circuit diagram, electrical (1)

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Circuit diagram, electrical (2)

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Solution description

The cycles of the control are counted to enable cylinder C to extend. Where there is a
preselected figure 2, cylinder C is extended together with cylinder B on the second cycle of
the control system in order to bring the part past position 2.
If cylinder C has extended, start condition K1 is reset via B 4 (K 10) and the counter is
reset to zero.

Components list

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Solution 12

Circuit diagram, pneumatic

* For the purposes of this exercise, cylinder A is replaced by a single-acting cylinder and feed unit C
by a double-acting cylinder. The inductive proximity sensor B4 is switched to mid-position by the trip
cam.

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Circuit diagram, electrical (1)

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Circuit diagram, electrical (2)

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Circuit diagram, electrical (3)

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Solution description

When the installation is started up and the initial position of cylinder B (S1) and a
workpiece (S3) are signalled, cylinder A extends. Then cylinder B extends and clamps the
part. When the clamping pressure has been reached, cylinder C is extended via K5.
Sensor B5 is activated in the forward end position. This in turn activates relay K6. Then
feed cylinder C retracts again. In addition, K6 passes on a counting pulse to the preselect
counter.
Sensor B4 is activated when the cylinder has retracted by a half. This then reverses the
valve via further contacts (K6, K7, K9) and cylinder C extends again. This sequence is
carried out until the preselected figure has been reached. If B4 is activated on the return
stroke, the valve may not switch since counter contact K9 interrupts the circuit. The
sequence is switched on via a second counter contact.

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Components list

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Solution 13

Circuit diagram, pneumatic

* For the purposes of this exercise, cylinder A is replaced by a single-acting cylinder.

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Circuit diagram, electrical (1)

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Circuit diagram, electrical (2)

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Circuit diagram, electrical (3)

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Circuit diagram, electrical (4)

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Solution description

When the "MAN/AUT" switch S6 or relay K1 is not actuated, voltage is applied at line 1
(MANUAL mode). The cylinder can be extended individually via push buttons S3, S4 and
S5.
Cylinder A extends and remains in the extended position for as long as push button S3 is
actuated or an additional push button is pressed. Movement is prevented if two or three
push buttons are pressed simultaneously.
To ensure that there is no interference with AUTOMATIC mode, the lines to the normally
closed contacts of relays K13, K14 and K15 are each interrupted by a normally closed
contact of K1.
As soon as line 2 (AUTOMATIC mode) is supplied with current, selflatching is set via the
normally closed contact K12 in current path 12. At the same time, when K10 goes into self-
latching, relay K12 is switched via a normally open contact K10. This also goes into
selflatching and the normally closed contact K12 in current path 21 opens. Thus, the last
step which is normally required as a start condition can be activated without the use of a
SET button.

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Components list

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Solution 14

Circuit diagram, pneumatic

* For the purposes of this exercise, the double-acting cylinder is replaced by a single-acting cylinder.

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Circuit diagram, electrical (1)

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Circuit diagram, electrical (2)

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Circuit diagram, electrical (3)

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Solution description

The two-hand safety control is realised in current paths 1 to 4. Relay K2 serves here as a
delaying element. The maximum time duration allowable between the actuation of S1 and
S2 is dependent on the switching time of this relay.
If the two push buttons S1 and S2 are activated simultaneously, cylinder A extends. These
buttons must remain depressed until the cylinder has reached its forward end position.
The start condition is decided by the connections in current paths 24 - 26. It has been
established that the signal from signal generator B5 only becomes effective when the
extractor unit leaves the working area, i.e. on the return stroke of cylinder B.
Relay K15 starts the operation of the vaccum generator which must be specially stored as
the sequence is set before the retraced end position of cylinder B is reached.

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Components list

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Solution 15

Circuit diagram, pneumatic

* For the purposes of carrying out this exercise on the profile plate, cylinder C is replaced by a
single-acting cylinder.

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Circuit diagram, electrical (1)

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Circuit diagram, electrical (2)

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Circuit diagram, electrical (3)

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Circuit diagram, electrical (4)

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Solution description

If one of the magazines is empty, then the installation remains stationary at position 1 or 2
by resetting the START signal, and waits there until the magazine has been filled and a
new START signal is issued (see current paths 1, 4, 22.).
In order to fulfil the gear sensing, it is necessary to establish whether a gear housing is
available (starting precondition). When the assembly has been completed, the gear
housing must be removed.
Without this, it will no longer be possible to start the installation (see current path 1, 4, 34).

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Components list

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Solution 16

Circuit diagram, pneumatic

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Circuit diagram, electrical (1)

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Circuit diagram, electrical (2)

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Circuit diagram, electrical (3)

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Circuit diagram, electrical (4)

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Solution description

Initial position: Cylinder A is retracted and is located above the work surface and lamp H4
is illuminated. Cylinder A can be extended via the up/down switch (current path 41). Once
the initial start position has been regained, the cycle is started with the start button. Then
lamp H4 is switched off and the time t1 expires. This switches lamp H1 (bath 1 reached)
and allows cylinder A to extend via relay K2.
Counting pulses are passed on to the counter via B3 (current paths 31-34). Additionally,
B3 reverses the valve so that cylinder A retracts as far as B2. As a result, cylinder A is
switched back to "Extend" (current paths 37-40). This oscillating movement of cylinder A is
repeated until the counter switches and interrupts the signal of sensor B2.
When the cylinder has retracted, time delay t1 is activated once again by relay K5, which
switches relay K6 when it has completed its cycle.
Lamp H2 is illuminated and cylinder A extends. Next, the delay period t2 of the basket in
bath 2 is switched via K7. Then, relay K8 switches, cylinder A retracts once again and the
time t1 is repeated.
When the time relay has switched, the cylinder enters bath 3 and the motion sequence
carried out for bath 1 is repeated. Time period t1 is then activated a final time and signals
the initial start position via lamp H4.

Note
The time t1 must be longer than the time which the cylinder requires for its return stroke.

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Components list

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Solution 17

Circuit diagram, pneumatic

* For the purposes of this exercise, the rotary actuator (D) is replaced by a single acting cylinder,
and the rodless cylinder (A) by a double-acting cylinder.

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Circuit diagram, electrical (1)

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Circuit diagram, electrical (2)

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Circuit diagram, electrical (3)

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Circuit diagram, electrical (4)

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Solution description

The loading station is located in step 21 of the subroutine.

Main program
When the START button has been pressed, K1 causes cylinder A to extend. Then cylinder
C is extended via K2 and cylinder A is switched to the unpressurised condition.
Next, the jump from K3 to K12 into the subroutine takes place.
When the subroutine has run through, the return jump through K18 and K19 to K4 in the
main program takes place. Cylinder D advances and is retracted by K5. The, cylinder C is
retracted by K6 and cylinder A by K7.

Subroutine
Movements D+, D-, B- (with every B- movement, cylinder A which has been switched
unpressurised, is pushed back by a partial stroke), C-, B+, C+ are executed in the
subroutine and repeated three times via a counter. When the counter has reached the
preselected figure, the return jump to the main program is carried out.

Comment
In the case of this motion sequence, costs make it necessary to realize this by means of a
repetition of a program section (subroutine).
Increased expenditure on planning is justified here by a considerable saving on relays and
very much simpler circuitry, so that in this case, the solution shown is more economical
than a solution with the full sequence which requires less planning.

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Components list

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Solution 18
Circuit diagram, pneumatic

Note: For the purposes of this exercise, cylinders C and D are not constructed.
Feed units F to K are represented in the construction by a single-acting cylinder. The on/off valve
with filter regulator and manifold are not represented.

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Circuit diagram, electrical (1)

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Circuit diagram, electrical (2)

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Circuit diagram, electrical (3)

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Circuit diagram, electrical (4)

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Solution description

Current paths 1 to 3 fulfill the following functions: START and STOP via push buttons,
display of the start signal and simulation of the central lubrication system.
Power to the installation is switched off with the EMERGENCY-STOP in order to add a
memory and secure the movement B-. Otherwise, cylinder B would retract as a result of
the automatic setting condition if cylinder A is already located in its initial start position.
The status of the vacuum generator is stored by current paths 33 and 34. After
EMERGENCY-STOP, the unit is reset and a restart can be made. If the fact that the
vacuum generator is active has now been stored, steps 1 and 2 (A+, A-) are now skipped
because a workpiece has already been collected.
In manual mode, the initial start position of the machining station can be achieved via the
RESET button, cylinder B only being able to retract when cylinder A is in its initial position.
In addition, processing is started via the RESET key if memory K18 reports that no
processing has yet been carried out. Memory K21 (EMERGENCY-STOP actuated) is reset.

Note
In order to limit the cost incurred through additional equipment, relay K21 can be replaced
by the counter (preselected figure 1).

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Components list

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Appendix
•Datasheet

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