Workbook Pneumatics Basic Level

Pneumatics
Basic level
Workbook
TP 101
With CD-ROM
1A1
1B1
1Z1
1Z2
1V3
2
1V2
14
1V1
1
12
2
1
1S1
1V4
1B1
1S2
Festo Didactic
541088 en
Use for intended purpose

The training system from Festo Didactic has been developed and manufactured for training and vocational
education in the field of automation technology. The respective training companies and/or trainers must
ensure that all trainees observe the safety precautions which are described in this workbook.
Festo Didactic hereby excludes any and all liability for damages suffered by trainees, the training company
and/or any third parties, which occur during use of the equipment sets in situations which serve any
purpose other than training and/or vocational education, unless such damages have been caused by Festo
Didactic due to malicious intent or gross negligence.
Order no.
Status:
Authors:
Editor:
Graphics:
Layout:
541088
03/2012
W. Haring, M. Metzger, R.-C. Weber
Frank Ebel
Doris Schwarzenberger
03/2012
Festo Didactic GmbH & Co. KG, D-73770 Denkendorf, Germany, 2013
Internet: www.festo-didactic.com
E-mail: did@de.festo.com
The purchaser shall receive a single right of use which is non-exclusive, non-time-limited and limited
geographically to use at the purchaser's site/location as follows.
The purchaser shall be entitled to use the work to train his/her staff at the purchaser's site/location and
shall also be entitled to use parts of the copyright material as the basis for the production of his/her own
training documentation for the training of his/her staff at the purchaser's site/location with
acknowledgement of source and to make copies for this purpose. In the case of schools/technical colleges
and training centres, the right of use shall also include use by school and college students and trainees at
the purchaser's site/location for teaching purposes.
The right of use shall in all cases exclude the right to publish the copyright material or to make this available
for use on intranet, Internet and LMS platforms and databases such as Moodle, which allow access by a
wide variety of users, including those outside of the purchaser's site/location.
Entitlement to other rights relating to reproductions, copies, adaptations, translations, microfilming and
transfer to and storage and processing in electronic systems, no matter whether in whole or in part, shall
require the prior consent of Festo Didactic GmbH & Co. KG.
Table of contents
Preface _________________________________________________________________________________ V
Introduction ____________________________________________________________________________ VII
Technology module for pneumatics (TP100) ____________________________________________________X
Learning objectives for the basic level (TP101) _________________________________________________ XI
Overview of learning objectives per exercise __________________________________________________ XII
Equipment set for the basic level (TP101) ____________________________________________________ XIV
Allocation of equipment per exercise _______________________________________________________ XVIII
Practical tools for the trainer _______________________________________________________________ XIX
Structure of the exercises _________________________________________________________________ XIX
Designations of the components____________________________________________________________ XIX
CD ROM contents ________________________________________________________________________ XX
Equipment set for the advanced level (TP102) ________________________________________________ XXII
Learning objectives for the advanced level (TP102)____________________________________________ XXIII
Solutions
Exercise 1: Pressing cheeses _________________________________________________________________1
Exercise 2: Opening a fodder silo _____________________________________________________________9
Exercise 3: Clamping boards to a saw bench __________________________________________________ 15
Exercise 4: Sorting packages _______________________________________________________________ 21
Exercise 5: Stopping milk bottles ___________________________________________________________ 31
Exercise 6: Opening and closing a pipeline ___________________________________________________ 37
Exercise 7: Shutting off a pipeline ___________________________________________________________ 45
Exercise 8: Actuating a shut-off device _______________________________________________________ 51
Exercise 9: Expanding the control system for pressing cheeses ___________________________________ 59
Exercise 10: Clamping a workpiece __________________________________________________________ 65
Exercise 11: Loading wire baskets __________________________________________________________ 73
Exercise 12: Actuating a sliding door ________________________________________________________ 79
Exercise 13: Feeding wooden boards ________________________________________________________ 87
Exercise 14: Compacting beverage cans ______________________________________________________ 93
Exercise 15: Packaging of brochures ________________________________________________________ 99
Exercise 16: Mounting locking pins_________________________________________________________ 105
Exercise 17: Labelling paint pots___________________________________________________________ 111
Exercise 18: Cleaning workpieces __________________________________________________________ 117
Exercise 19: Pressing labels into place ______________________________________________________ 123
Festo Didactic GmbH & Co. KG 541088
III
IV
Preface
Festo Didactics training system for automation and technology is geared towards various educational
backgrounds and vocational requirements. The training packages are therefore broken down as follows:
Basic modules impart basic, interdisciplinary, technological knowledge.
Technology modules address the important topics of open and closed-loop control technology.
Function modules explain the fundamental functions of automated systems.
Application modules enable training and further education that is aligned with real-life practice.
The technology modules deal with various technologies including pneumatics, electro-pneumatics,
programmable logic control systems, automation using a personal computer, hydraulics, electrohydraulics,
proportional hydraulics, sensor technology, electric drives and applications technology (handling).
The modular design of the training system makes it possible to focus on applications above and beyond
those covered in the individual modules, such as, for example, PLC actuation of pneumatic, hydraulic and
electric drives.
All training modules have the same structure:
Hardware
Teachware
Software
Seminars
The hardware is comprised of industrial components and systems that are specially designed for training
purposes.
The structure of the teachware corresponds to that of the training hardware. It includes:
Textbooks (with exercises and examples)
Workbooks (with practical exercises, supplementary instructions and solutions)
Transparencies and videos (for dynamic instruction)
The working materials for TP101 consist of 19 exercises and a workbook. Each exercise has its own set of
ready-to-use worksheets. The solutions are included in the workbook, which also has the worksheets and a CD
ROM. The exercises can be purchased without the workbook and are used as consumables. They can thus be
easily made available to trainees. Data sheets for the hardware components are made available along with the
training module and on the CD ROM.
The teaching and learning media are available in several languages. Theyre intended for use in classroom
instruction, but are also suitable for self-study.
Where software is concerned, computer training programs and programming software are made available
for programmable logic controllers.
A wide range of seminars covering the contents of the technology module round off the programme for
training and further education.
VI
Introduction
This workbook is part of the training system for automation and technology from Festo Didactic GmbH & Co.
KG. The system provides a solid basis for practical training and further education. The TP100 technology
module only includes pneumatic control systems.
The TP101 basic level is suitable for basic training in the field of pneumatic control technology. It covers the
fundamentals of pneumatics as well as the function and use of pneumatic equipment. The equipment can be
used to set up simple pneumatic control systems.
The TP102 advanced level comprises vocational training in the field of pneumatic control technology. The
equipment can be used to set up extensive combinatory circuits with linking of the input and output signals
as well as control systems with stepper modules.
A permanent workstation equipped with a Festo Didactic profile plate is a prerequisite for setting up the
control systems. The profile plate has 14 parallel T-slots at 50 mm intervals. A portable compressor with
silencer (230 V, max. 8 bar = 800 kPa) can be used for compressed air supply.
Working pressure should not exceed 6 bar (600 kPa).
Ideal control sequence reliability can be achieved by operating the control system at a working pressure of 5
bar (500 kPa) without oil.
All the control systems for the 19 exercises are set up using the equipment set for the TP101 basic level. The
theoretical fundamentals for understanding this series of exercises are included in the textbook:
Pneumatics, basic level
Data sheets for the individual components are also available (cylinders, valves, measuring instruments etc.).
VII
Work instructions and safety precautions
General
Trainees should only work with the control systems under the supervision of a trainer.
Observe specifications included in the data sheets for the individual components and in particular all
safety instructions!
Mechanical
Mount all the components securely onto the profile plate.
Limit switches must not be actuated frontally.
Danger of injury during troubleshooting!
Use a tool to actuate the limit switches, for example a screwdriver.
Only reach into the set-up when its at a complete standstill.
Electrical
Electrical connections must only be established and interrupted in the absence of voltage!
Only use connector cables with safety plugs for electrical connections.
Only use low-voltage (max. 24 V DC).
Pneumatics
Do not exceed the maximum permissible pressure of 6 bar (600 kPa).
Do not switch on the compressed air until all of the tubing connections have been completed and
secured.
Do not disconnect tubing while under pressure.
Danger of injury when switching compressed air on!
Cylinders may advance and retract automatically.
Danger of accident due to tubing slipping off!
Use shortest possible tubing connections.
Wear safety glasses.
In the event that tubing slips off:
Switch compressed air supply off immediately.
Pneumatic circuit set-up:
Connect the components using plastic tubing with an outside diameter of 4 or 6 mm. Push the tubing
into the push-in connector as far as it will go.
Switch compressed air supply off before dismantling the circuit.
Dismantling the pneumatic circuit:
Press the blue release ring down, after which the tubing can be pulled out.
VIII
The mounting boards for the components are equipped with mounting variant A, B or C:
Variant A, snap-in system
Lightweight components that are not load-bearing (e.g. directional control valves). Simply clip the
components into the slot on the profile plate. Release the component from the slot by actuating the blue
lever.
Variant B, bolt-on system
Components with medium load capacity (e.g. actuators). These are clamped onto the profile plate using
T-head bolts. The blue knurled nut is used for clamping and loosening.
Variant C, screw system
For components with high load capacity and components that are seldom removed from the profile plate (for
example on-off valve with filter regulator). These components are secured with socket head screws and
T-head bolts.
Observe specifications in the data sheets regarding the individual components.
A stopwatch is required in order to evaluate the control systems once they have been set up. The stopwatch is
used to:
Adjust the one-way flow control valves so that the cylinder stroke times comply with the specified
values
Adjust time delay valves
IX
Technology module for pneumatics (TP100)

The TP100 technology module consists of a multitude of training materials and seminars. The subject matter
is focused entirely on pneumatic control systems. Individual components included in the TP100 technology
packet can also be included in any of the other modules.
Important components of the TP100
Permanent workstation with Festo Didactic profile plate
Compressor (230 V, 0.55 kW, max. 8 bar = 800 kPa)
Equipment sets or individual components (e.g. cylinders, directional control valves, preset counters,
stepper modules, logic components, pneumatic proximity switches)
Optional training materials (e.g. optical displays, 5/3-way valve, pulling/pushing load)
Practical training models
Complete laboratory set-ups
Training documentation
Textbooks
TP101 basic level

Fundamentals of pneumatic control technology
Maintenance of pneumatic equipment and systems
Pneumatics/electropneumatics
Workbooks
Optional teachware
TP101 basic level

TP102 advanced level
Set of transparencies
Magnetic symbols, drawing template
FluidSIM pneumatic simulation software
WBT Pneumatics
Set of cutaway models with storage case
Seminars
P100
Basic pneumatics for machine operators
P111
Fundamentals of pneumatics and electropneumatics
P121
Maintenance and troubleshooting for pneumatic and electropneumatic systems
P-OP
Tracking down wastage economic use of pneumatics
P-NEU
Pneumatic refresher and update
IW-PEP
Repair and maintenance in the field of control technology pneumatic and electropneumatic systems
P-AL
Pneumatics for further education
P-AZUBI
Pneumatics and electropneumatics for trainees
Please refer to the current seminar planner for locations, dates and prices.
Youll find further training materials in our catalogue and on the Internet. The training system for automation
and technology is continuously updated and expanded. Transparencies, videos, CD ROMs and DVDs, as well
as textbooks, are offered in several languages.
Learning objectives for the basic level (TP101)
Become familiar with the set-up and mode of operation of a single-acting cylinder.
Become familiar with the set-up and mode of operation of a 3/2-way valve.
Be able to recognise and sketch the various types of actuation for directional control valves.
Be able to explain and set up direct actuation.
Be able to analyse and evaluate circuits.
Become familiar with the set-up and mode of operation of a double-acting cylinder.
Become familiar with the set-up and mode of operation of a 5/2-way valve.
Be able to explain and set up indirect actuation.
Become familiar with the mode of operation of a 5/2-way valve with pneumatic actuation.
Become familiar with the difference between a signalling element and a control element.
Be able to measure pressure in pneumatic control systems.
Be able to differentiate between the various types of flow control and use them in accordance with
specifications.
Be able to adjust cylinder advancing and retracting speeds.
Become familiar with one type of signal storage in pneumatic control systems.
Be able to explain and implement AND/OR/NOT logic operations.
Be able to explain and set up latching circuits.
Become familiar with one option for end-position sensing in cylinders.
Be able to combine logic operations.
Become familiar with the set-up and mode of operation of a magnetic proximity switch.
Be able to differentiate between 5/2-way valves and to select and use them in accordance with
specifications.
Be able to further develop existing circuits.
Become familiar with the set-up and mode of operation of a pressure sequence valve.
Be able to set up pressure-dependent control systems.
Become familiar with the set-up and mode of operation of a pressure regulator.
Be able to analyse existing circuits and optimise them in accordance with specifications.
Become familiar with the set-up and mode of operation of a time delay valve.
Be able to set up circuits with oscillating motion.
Be able to use time delay valves in accordance with specific constraints.
Be able to analyse and set up circuits with two cylinders.
XI
Overview of learning objectives per exercise

Exercise
10
11
12
13
14
15
16
17
18
19
Learning Objective
Become familiar with the set-up
and mode of operation of a
single-acting cylinder.
and mode of operation of a 3/2way valve.
Be able to recognise and sketch
the various types of actuation for
directional control valves.
Be able to explain and set up
direct actuation.
Be able to analyse and evaluate
circuits.

double-acting cylinder.

5/2-way valve.
indirect actuation.
Become familiar with the

difference between a signalling
element and a control element.
Be able to measure pressure in
pneumatic control systems.
Be able to differentiate between

the various types of flow control
and use them in accordance with
specifications.
Be able to adjust cylinder
advancing and retracting speeds.
XII
Exercise
10
11
12
13
14
15
16
17
18
19
Learning Objective
Become familiar with one type of
signal storage in pneumatic
control systems.
Be able to explain and implement
AND/OR/NOT logic operations.
latching circuits.
Become familiar with one option
for end-position sensing in

cylinders.
Be able to combine logic
operations.

magnetic proximity switch.
Be able to differentiate between
5/2-way valves and to select and
use them in accordance with

specifications.
Be able to further develop
existing circuits.

pressure sequence valve.
Be able to set up pressuredependent control systems.

pressure regulator.

and mode of operation of a time
delay valve.
Be able to set up circuits with
oscillating motion.
Be able to use time delay valves

in accordance with specific
constraints.
Be able to analyse and set up
circuits with two cylinders.
XIII
Equipment set for the basic level (TP101)

The equipment set has been put together for basic training in the field of pneumatic control technology. It
includes all the components that are necessary for mastering the specific learning objectives and can be
supplemented with any other equipment sets. A profile plate and a source of compressed air are also
required in order to set up functional control systems.
Equipment set for the basic level (TP101)
XIV
Quantity
Designation
Order no.
3/2-way roller lever valve, normally closed
152866
3/2-way valve with pushbutton, normally open
152861
3/2-way valve with pushbutton, normally closed
152860
3/2-way valve with selector switch, normally closed
152863
3/2-way valve, pneumatically actuated at one end
576302
5/2-way double pilot valve, pneumatically actuated at both ends
576303
5/2-way valve with selector switch
152862
576307
Double-acting cylinder
152888
One-way flow control valve
193967
Pressure gauge
152865
Pressure regulator with pressure gauge
539756
Pressure sequence valve
152884
Single-acting cylinder
152887
On-off valve with filter regulator
540691
Plastic tubing, 4 x 0.75, silver, 10 m
151496
Pneumatic proximity switch with cylinder mounting
539775
Pneumatic timer, normally closed
540694
Quick exhaust valve
539772
10
Push-in sleeve
153251
10
Push-in T-connector
153128
Distributor block
152896
Shuttle valve (OR)
539771
Dual-pressure valve (AND)
539770
Equipment set symbols

Designation
Symbol
Pressure gauge
1
Pneumatic proximity switch
2
12
14
5
5/2-way double pilot valve, pneumatically actuated at both

ends
XV
Designation
Symbol
Shuttle valve
2
1
Dual-pressure valve
2
1
Pneumatic timer, normally closed
2
t
1
Quick exhaust valve
2
1
12
XVI
Designation
Symbol
1
2
Distributor block
Connectors
XVII
Allocation of equipment per exercise

Exercise
10
11
12
13
14
15
16
17
18
19
Equipment
Cylinder, single-acting
Cylinder, double-acting
1
1
Quick exhaust valve
Pressure gauge
3/2-way valve, pushbutton,
normally closed
3/2-way valve, pushbutton,
1
2
2
1
1
normally open
3/2-way valve, selector
switch, normally closed
3/2-way roller lever valve,

normally closed
Pneumatic proximity switch
3/2-way pneumatic valve
3/2-way pneumatic double

pilot valve
5/2-way valve, selector
switch
5/2-way pneumatic valve
5/2-way pneumatic double

pilot valve
Shuttle valve
Dual-pressure valve
1
1
1
2
1
2
Pressure regulator with
pressure gauge
Time delay valve, normally
closed
Distributor block
On-off valve with filter
regulator
XVIII
Practical tools for the trainer

Learning objectives
The basic learning objectives for the exercises in this module are the systematic sketching of circuit diagrams
as well as the practical set-up of a control system on the profile plate. This direct interaction involving both
theory and practice ensures faster, long-term learning. Each exercise has its own individual learning objectives;
the specific learning objectives are documented in the matrix.
Required time
The time required for the exercises depends on the learners previous knowledge of the subject matter. For
training a skilled labourer in metalworking or electrical installation: approx. 2 weeks. For training a
technician or engineer: approx. 1 week.
Equipment sets
The exercises and the equipment sets matched each other. For all 19 exercises youll only need the
components included in the equipment set for TP101 basic level.
Each exercise in the basic level can be set up on a profile plate.
Structure of the exercises

All 19 exercises have the same structure and are broken down into:
Title
Learning objectives
Presentation of the problem
Parameters
Project assignment
Layout
Worksheets
The solutions for all the 19 exercises are included in the trainers manual.
XIX
Designations of the components

Pneumatic components are designated in circuit diagrams to DIN ISO 1219 2. All the components included
in any given circuit have the same primary identifying number. Letters are assigned depending on each
respective type of component. Consecutive numbers are assigned if several components of the same type
are included within a single circuit. Pressure lines are designated with a P and are numbered separately.
Cylinders:
Valves:
Sensors:
Signal inputs:
Accessories:
1A1, 2A1, 2A2 ...

1V1, 1V2, 1V3, 2V1, 2V2, 3V1 ...
1B1, 1B2 ...
1S1, 1S2 ...
0Z1, 0Z2, 1Z1 ...
CD ROM contents
The CD ROM provides you with additional media. The worksheets and solutions have been saved as PDF
files on the CD ROM that is included with the trainers manual.
The CD ROM contains the following folders:
Operating instructions
Demo
Festo catalogue
FluidSIM circuit diagrams
Industrial applications
Presentations
Product information
Videos
Operating instructions
Operating instructions for the various components included in the technology module are available. These
instructions are helpful when using and commissioning the equipment.
FluidSIM demo version
A demo version of the FluidSIM pneumatics software package is included on the CD ROM. Even this demo
version is suitable for testing control systems developed by the user.
XX
Festo catalogue
The relevant pages from the Festo catalogue will be provided with selected components. The
representations and descriptions of the components are intended to demonstrate how the components are
presented in an industrial catalogue. Additional information regarding the components is also included.
FluidSIM circuit diagrams
The FluidSIM circuit diagrams for all 19 exercises included in the technology module are contained in this
directory.
Industrial applications
Photos and graphics representing industrial applications are made available. These can be used to illustrate
individual tasks. Project presentations can also be supplemented with these illustrations.
Presentations
Contains short presentations of the components included in the technology module. These can be used, for
example, to create project presentations.
Product information
This directory contains product information and data sheets from Festo for the components included in the
technology module. This is intended to demonstrate which information and data are available for industrial
components.
Videos
Several videos of industrial applications complete the media provided with the technology module. Short
clips demonstrate the applications in their actual industrial environments.
XXI
Equipment set for the advanced level (TP102)

The equipment set for the advanced level has been put together for further training in the field of pneumatic
control technology. The two equipment sets (TP101 and TP102) include components that are necessary for
mastering the predefined learning objectives and can be supplemented as required with other equipment
sets from the training system for automation and technology.
Equipment set for the advanced level (TP102)
XXII
Quantity
Designation
Order no.
3/2-way roller lever valve with idle return, normally closed
152867
152860
3/2-way valve with mushroom actuator (red), normally open
152864
576302
5/2-way double pilot valve, pneumatically actuated at both ends
576303
152888
193967
Plastic tubing, 4 x 0.75, silver, 10 m
151496
Pneumatic timer, normally open
539759
Non-return valve, piloted non-return function
540715
Back pressure limit valve
152868
10
Push-in sleeve
153251
Stepper module
152886
20
Push-in T-connector
153128
Pneumatic preset counter
152877
Shuttle valve (OR)
539771
Shuttle valve, 3-way (OR)
152882
Dual-pressure valve, 3-way (AND)
152883
Learning objectives for the advanced level (TP102)
Detect end-positions without limit switches

Understand and set up flip-flop circuits (flip-flop, double pilot valve)
Convert a 3/2 and/or a 5/2-way valve
Evaluate, use and adjust various sensors
Explain the function of a back pressure end stop
Explain the function of stepper modules
Develop basic sequence control systems (continuous cycle)
Implement a sequence control system with the following operating modes: automatic/manual, start and
reset
Implement an OR operation for feedback signals
Set and coordinate delays
Be able to abort delay times with an OR operation
Implement a sequence control system with idle step (3 steps)
Describe and set up variable step repetition within a motion sequence using a preset counter
Develop an input circuit with self-latching loop including the following functions: automatic/manual,
start, stop (at end of cycle) and reset
Evaluate and use sensors for material sensing
Actuate the final control element with two steps via a shuttle valve (double cylinder stroke)
Use a proximity switch within the stroke sub-range in order to reverse cylinder motion
Development of an input circuit for a sequence control system with secure pilot air, as well as start,
emergency stop and reset functions
Stop the cylinder within the sub-stroke range (positioning) by pressurising at both ends (preloading)
Adjust proximity switches in the end positions and within the sub-stroke range
Combined use of quick exhaust valve and pressure regulator with pressure gauge
Set up an inverted timer signal
Implement a control system with guide features in combination with sequence control
XXIII
XXIV
Exercise 1: Pressing cheeses

Learning objectives
After completing this exercise youll:
Be familiar with the set-up and mode of operation of a single-acting cylinder.
Youll be able to calculate the piston force of a single-acting cylinder.
Be familiar with the set-up and mode of operation of a normally closed 3/2-way valve.

Presses are used to press cheeses into moulds during the production process. Develop a control system
with which this process can be executed
Layout
Cheese production
Parameters
Use a double-acting cylinder.
Pneumatically control the cylinder using a manually actuated valve.
1.
2.
3.
4.
5.
6.
7.
Project assignment
Describe the mode of operation of a single-acting cylinder.
Describe the mode of operation of a normally closed 3/2-way valve.
Complete the pneumatic circuit diagram for the pressing tool.
Set up the control system.
Double-check the control system configuration.
Describe the mode of operation of the control system.
Create an equipment list.
1.
2.
3.
4.
5.
Procedure
The cheeses are placed into the tool manually.
When the pushbutton is activated, the cylinder advances and presses the cover onto the tool.
The pushbutton is pressed and held until the pressing operation has been completed.
When the pushbutton is released, the cylinder is retracted and the tool can be accessed.
The cheese can be removed.
Safety note
Limit pressure at the service unit for this exercise to a maximum of3.5 bar (350 kPa). Immediately
deactivate compressed air supply if the tubing slips off.
Set-up and mode of operation of a single-acting cylinder

1
Circuit symbol and schematic diagram of a single-acting cylinder
Compare the circuit symbol shown above with the schematic diagram of the single-acting cylinder.
Determine whether or not the two representations coincide with each other.
The two representations coincide with each other.
Describe the set-up and mode of operation of a single-acting cylinder.

The compressed air flows into the cylinders piston chamber. Pressure is built up in the chamber and
force is applied to the surface of the piston as a result. If this force exceeds static friction, the piston is
advanced. Pressure is not built up to full operating pressure until the piston is fully advanced.
When this pressure drops, the integrated return spring forces the piston back into its initial position.
Spring force is not great enough to move heavy loads attached to the piston rod. Hence single-acting
cylinders only perform work in a single direction.
Match up each component with the corresponding number from the above drawing.
Component
Designation
Cylinder barrel
End cap
Bearing cap
Piston rod
Piston
Spring return
Supply port
Exhaust port
Table of component designations
Calculate the piston force of a single-acting cylinder

Theoretical piston force is calculated using the following formula:
Fth
Fth
A
=
=
=
=
p
D
=
=
Ap
theoretical piston force (N)
effective piston surface (sq. metres)
D2
)
4
working pressure (Pa)
(
cylinder diameter (m)
Piston force Feff is important in actual practice. Frictional resistance has to be taken into consideration when
calculating piston force. Under normal operating conditions (pressure range of 4 to 8 bar or 400 to 800 kPa),
it is assumed that friction forces (FR) amount to roughly 10% of the theoretical piston force.
The following applies to the effective piston force of single-acting cylinders:
Feff
Feff
FR
FF
=
=
=
=
A p (FR + FF)
effective piston force (N)
friction force (approx. 10% of Fth ) (N)
return spring force (N)
Calculate the effective piston force for the advance stroke of the used cylinder with a working pressure
of 6 bar (600 kPa).
A= (
0.022 3.14
) = 0.000314
4
Feff = 0.9 A p FF
Feff = 0.9 (0.000314) 600,000 13.6
Feff = 169.56 13.6 = 155.96 N
Note
TThe piston diameter of the used cylinder is 20 mm and spring return force is 13.6 N.
Mode of operation of a normally closed 3/2-way valve
Complete the circuit symbol of a manually actuated, normally closed 3/2-way valve with spring return.
3
2
Circuit symbol and schematic representation of a normally closed 3/2-way valve
Describe the mode of operation of the 3/2-way valve.

A 3/2-way valve has 3 ports and 2 switching positions. Its represented in the normal position.
Normally closed means that compressed air cannot flow through the valve. When the pushbutton is
actuated the valve is opened, thus allowing air to flow and the piston of a connected cylinder is
advanced.
Complete the pneumatic circuit diagram
Complete the pneumatic circuit diagram for the control system and enter the port designations.
1A1
1S1
3
0Z2
0Z1
1
2
Pneumatic circuit diagram
Sequence description
Set up the control system and describe its working sequence.

Initial position
Valve 1S1 is closed in its initial position. The piston rod of cylinder 1A1 is retracted.
Step 1-2
When the pushbutton on 3/2-way valve 1S1 is pressed, compressed air flows into the piston chamber of
cylinder 1A1 and the piston rod is advanced.
Step 2-3
When the pushbutton is released, valve 1S1 is exhausted and cylinder 1A1 returns to its initial position
due to force applied by the return spring.
Create an equipment list

In addition to the circuit diagram, complete project documentation also includes an equipment list.
Create an equipment list by entering the required components and their quantities in the table below.
Quantity
Designation
Distributor block
Compressed air source
Equipment list
Exercise 2: Opening a fodder silo

Learning objectives
Be familiar with the set-up and mode of operation of a normally open 3/2-way valve.

The slide of a fodder silo is to be opened by pressing a pushbutton. When the pushbutton is released, the
slide is once again closed.
Layout
Fodder silo
Parameters
A single-acting cylinder is to be used.
The cylinder will be pneumatically controlled using a pushbutton.
1.
2.
3.
4.
5.
6.
Project assignment
Answer the questions on the normally open 3/2-way valve.
Create the pneumatic circuit diagram for controlling the slide.
Create the equipment list.
Procedure
1. When the pushbutton is activated, the cylinder is retracted to the retracted end position.
2. The pushbutton is pressed and held for as long as the slide is to remain open.
3. When the pushbutton is released, the cylinder is advanced and the slide closes the opening in the silo.
Safety note
Limit pressure at the service unit to a maximum of 3.5 bar (350 kPa) for this exercise.
10
Mode of operation of a 3/2 way valve
Complete the circuit symbol of the 3/2-way valve. It needs to include the following functions: manual
actuation, spring return, normally open.
2
Circuit symbol, 3/2-way valve, normally open
1
3
Schematic representation of a 3/2-way valve, normally open
Explain the mode of operation of a 3/2-way valve, normally open.

A normally open 3/2-way valve has 3 controlled ports and 2 switching positions. Its represented in the
normal position.
This is a normally open variant of the valve. This means that compressed air flows through the valve to
the cylinder and holds the cylinders piston in the advanced end position. When the pushbutton is
activated, the valve stops the flow of compressed air, the cylinder is exhausted via the valve and the
piston is retracted.
11
Change the pneumatic circuit diagram
Change the pneumatic circuit diagram for the control system and enter the port designations.
1A1
1S1
3
0Z2
0Z1
1
2
Circuit diagram
Note
Please note that control systems must be represented in their initial positions.
12

Initial position
The 3/2-way valve is open in the free-flow direction and the piston chamber is pressurised. The piston at
cylinder 1A1 is advanced.
Step 1-2
If pushbutton 1S1 is activated, the piston is exhausted via the 3/2-way valve and cylinder 1A1 is
retracted.
Step 2-3
When the pushbutton is released, the spring forces the 3/2-way valve into its initial position, the piston
chamber is once again pressurised and cylinder 1A1 advances again.
Safety note
Limit pressure at the service unit for this control system to a maximum of 3.5 bar (350 kPa).
13
Change the equipment list
Change the equipment list shown below such that it corresponds with the requirements for this control
system.
Quantity
Designation
Distributor block
Tubing material
3/2-way valve, manually actuated, normally closed
Equipment list
Quantity
Designation
Distributor block
Tubing material
3/2-way valve, manually actuated, normally open
Equipment list
14
Exercise 3: Clamping boards to a saw bench

Learning objectives
Be able to analyse and optimise control systems.

Boards are manually laid on the saw bench where they are cut to length with a circular saw. The sawing
operation is controlled from a separate control panel and thus the boards are pneumatically clamped to the
saw bench. The control system is implemented with only one cylinder for the test set-up.
Layout
Sawing fixture
15
Parameters
Use one of the control systems from the previous exercises and modify it for this task.
Use, by way of example, only one single-acting cylinder to design the control system.
1.
2.
3.
4.
5.
Project assignment
Complete the pneumatic circuit diagram for the clamping tool.
Change the equipment list.
1.
2.
3.
4.
Procedure
A board is manually laid on the saw bench.
After activating a switch, the cylinder advances and clamps the board.
The cylinder remains in the advanced position, even when the switch has been released.
After turning the switch back to its initial position, the cylinder is retracted to the retracted end position,
where it remains until the switch is activated again.
Safety note
16
Complete the circuit diagrams shown below by entering the required type of actuation.
a)
b)
Circuit diagram
Select the best control system and justify your answer.

The correct solution is a).
Reason:
The cylinder has to be in its retracted end position when the switch is deactivated.
17

Initial position
The valves free-flow direction is closed. The cylinders piston rod is retracted.
Step 1-2
When selector switch 1S1 is activated, compressed air flows into the piston chamber and the cylinder is
advanced.
Step 2-3
When the selector switch is reset, the valve is exhausted and the cylinder returns to its initial position
due to force applied by the return spring.
Safety note
Limit pressure at the service unit for this control system to a maximum of 3.5 bar (350 kPa).
18
Change the equipment list

Change the equipment list by entering the required components in the table below.
Quantity
Designation
3/2-way valve with switch, normally closed
Distributor block
Changed equipment list
19
20
Exercise 4: Sorting packages

Learning objectives
Be familiar with the set-up and mode of operation of a double-acting cylinder.
Be able to calculate the piston force of a double-acting cylinder for both the advance and the return
strokes.
Be familiar with the set-up and mode of operation of a 5/2-way valve.

Packages are sorted manually from a roller conveyor into large containers at a sorting station. When the
containers are full, theyre removed and new containers are provided. At this point the material flow should be
interrupted, but the roller conveyor continues to run. The material flow is interrupted by mechanical blocking
(slide). The slide has to be operated at the sorting station.
Layout
Sorting station
21
Parameters
A double-acting cylinder will be used, because work is carried out during both the advance and the
return strokes.
1.
2.
3.
4.
5.
6.
7.
Project assignment
Describe the set-up of a double-acting cylinder.
Describe the mode of operation of a 5/2-way valve.
Create a pneumatic circuit diagram for the package blocking slide.
Procedure
1. When the selector switch is activated, the cylinder advances and pushes the slide into the flow of
material.
2. The cylinder remains in this position after releasing the selector switch and the material flow remains
interrupted.
3. After turning the selector switch to its initial position, the cylinder moves to its retracted end position
and the material flow is resumed. The cylinder remains in this position until the selector switch is
activated again.
Safety note
22
Set-up of a double-acting cylinder

1
Circuit symbol and schematic diagram of a double-acting cylinder
Compare the circuit symbol shown above with the schematic diagram of the double-acting cylinder.
Determine whether or not the two illustrations are the same.
The two illustrations are the same.
Make a note of the characteristics of a single-acting and a double-acting cylinder designs that are the
same as well as those that are different.
Both cylinder designs include cylinder barrel, piston and piston rod.
The double-acting cylinder doesnt have a return spring.
The double-acting cylinder has 2 supply ports.
Match the numbers from the schematic drawing with the individual components of the double-acting
cylinder.
Component
Designation
Supply port, piston chamber
Piston
Cylinder barrel
Supply port, piston rod chamber
Piston rod
Bearing cap
End cap
23
Mode of operation of a double-acting cylinder
Describe the mode of operation of a double-acting cylinder.

As opposed to a single-acting cylinder, more air is consumed. As the piston surfaces differ in size, the
forces vary with identical pressure.
Forward stroke
Compressed air flows into the cylinder through the piston chamber supply port. Pressure is built up in the
chamber and force is applied to the surface of the piston as a result. If this force exceeds static friction,
the piston is advanced. Air in the piston rod chamber escapes through the port at the piston rod end.
Pressure is not built up to full force until the piston is fully advanced.
Return stroke
After reversing, air flows through the supply port at the piston rod chamber where it builds up pressure
until the piston rod is retracted. Air escapes from the piston chamber through the piston chamber port.
24
Calculate the piston force for the advance and return strokes
Theoretical piston force is calculated using the following formula:
Fth
Ap
The following applies to double-acting cylinders:

Advance stroke
Feff
=
(A p) FR
Return stroke
Feff
=
(A' p) FR
Feff
A
A'
=
=
effective piston force (N)

effective piston surface (m2)
effective piston ring surface (m2)
=
p
FR
D
d
=
=
=
=
D2
)
4
(D 2 d 2 )
working pressure (Pa)

friction force (approx. 10% of Fth ) (N)
cylinder diameter (m)
piston rod diameter (m)
Calculate the effective piston force for the advance and return strokes of the cylinder with a working
pressure of 6 bar (600 kPa).
Forward stroke
Feff
Feff
Feff
=
=
=
(A p) FR
0.9 A p
0.9 0.000314 600,000
Feff
169.66 N
Return stroke
Feff
Feff
Feff
=
=
=
(A' p) FR
0.9 (0.000314 0.00005024) 600,000
0.9 0.00026376 600,000
Feff
142.4 N
Note
The piston diameter of the cylinder is 20 mm and the piston rod diameter is 8 mm.
25
Determine the requirements for the directional control valve
Write down the requirements for the directional control valve.

Compressed air must be available in both switching positions, because the double-acting cylinder cannot
be retracted without compressed air. Venting of the other cylinder chamber must be ensured in each
case.
Indicate why the directional control valve has to be actuated with a switch.
A switch has to be used because a pushbutton cannot be held in the activated position for as long as it
takes to replace the containers.
26
Mode of operation of a 5/2 way valve
Complete the circuit symbol of a manually actuated, 5/2-way valve with spring return and locking
function, and enter the port designations.
3
5
Circuit symbol and schematic representation of a 5/2-way valve
Describe the mode of operation of a 5/2-way valve when valve port 2 is connected to the piston rod end
of a double-acting cylinder.
Mode of operation of a 5/2 way valve, unactuated
When the 5/2-way valve is not actuated, the return spring holds the valve in its initial position. The piston
rod end of the cylinder is pressurised and the piston rod is retracted.
Mode of operation of a 5/2 way valve, actuated

When the 5/2-way valve is actuated, the force of the valve return spring is overcome and the valve is
reversed. In this state, the supply port is connected to the piston end of the cylinder via the valve while
the piston rod end is exhausted via the valve. Pressure which is built up at the piston end causes the
piston rod to advance. As soon as the piston rod has reached its advanced end position, maximum
operating pressure is built up at the piston end of the cylinder.
Actuation with a switch

If the valve is actuated with a switch, the valve remains in either of its positions until the switch is
reversed again.
27
Complete the circuit diagram
Complete the circuit diagram shown below.

1A1
1S1
3
0Z2
0Z1
1
2
28

Create an equipment list by entering the required components in the table below.
Quantity
Designation
Distributor block
29
30
Exercise 5: Stopping milk bottles

Learning objectives
Be able to explain and set up indirect actuation.
Be familiar with the mode of operation of a 5/2-way valve with pneumatic actuation.
Be familiar with the difference between a signalling element and a control element.

A filling system fills bottles with milk. The bottles are fed to the system on a conveyor belt and are stopped
underneath the filler using a pneumatic cylinder. The positioning accuracy of the stopping operation will be
checked during a test set-up. The stopping operation will be activated at the systems control panel.
Layout
Milk bottle filling system
31
Parameters
Stopping of the material flow will be carried out at a central control panel.
As compressed air is available at the control panel, a pneumatic solution will be used.
The control valve for the cylinder will be pneumatically actuated.
Project assignment
1. Determine the requirements for the control system with regard to actuating components and the control
element.
2. Complete the pneumatic circuit diagram for stopping the material flow.
3. Set up the control system.
4. Double-check the control system configuration.
5. Describe the mode of operation of the control system.
6. Create an equipment list.
Procedure
1. When the selector switch is activated, the cylinder advances and pushes the slide into the flow of
material, thus stopping the bottles.
2. After setting the selector switch back to its initial position, the cylinder is in its retracted end position
and once again enables material flow.
3. The cylinder remains in this position until the selector switch is activated again.
Additional task
Explain the term indirect control.
32
Complete the circuit diagram shown below and enter the missing connection and component
designations.
1A1
1V1
14
5
1S1
3
0Z2
0Z1
1
2
Note
The on-off valve with filter regulator and the distributor block are not shown. These components are
required in order to set up the control system.
33
Explain the mode of operation of the control system by describing its operating sequence.
Initial position
The signalling element and the control element are in the position generated by the return spring.
Step 1-2
When the selector switch at the 3/2-way valve 1S1 is actuated, pneumatic control port 14 at 5/2-way
valve 1V1 is pressurised with compressed air. The 5/2-way valve is reversed as a result. The left-hand
port (piston end) of the double-acting cylinder is pressurised with compressed air, and the right-hand
port (piston rod end) is exhausted. The cylinder advances.
Step 2-3
When the selector switch is returned to its initial position, the compressed air supply to the 3/2-way
valve is blocked, the 5/2-way valve looses pressure at control port 14 and the valve piston is returned to
its initial position by the return spring. The piston end of the cylinder is thus exhausted and the piston
rod end is pressurised with compressed air. The cylinder travels to its retracted end position.
34

Quantity
Designation
Pneumatic 5/2-way valve with spring return
Normally closed 3/2-way valve with selector switch
Distributor block
35
Additional task
Explain the term indirect control.

Indirect control
Cylinders with large piston diameters have high air consumption rates. Control elements with high
nominal flow rates must be used to actuate them. If the force is too great for manual actuation of the
valve, indirect actuation must be set up. In doing so, a signal is generated by a second, smaller valve,
which then provides the force required in order to switch the control element.
36
Exercise 6: Opening and closing a pipeline

Learning objectives
Be able to measure pressure in pneumatic control systems.
Be able to differentiate between the various types of flow control and use them in accordance with
specifications.

The gate in a pipeline needs to be opened and closed. Actuation is via a valve with selector switch. A
double-acting cylinder will be used as an actuator.
Layout
Wastewater treatment
37
Parameters
The gate must be opened and closed slowly because the pipeline would otherwise be overloaded (the
forming of waves should be avoided).
The speed of the opening and closing strokes should be steady.
1.
2.
3.
4.
5.
6.
Project assignment
Create a pneumatic circuit.
Observe pressure conditions upstream and downstream of the flow control and document them.
Procedure
1. When the selector switch is activated, the cylinder is advanced and opens the gate.
2. When the selector switch is returned to its initial position, the cylinder is retracted to its initial position
and the gate is closed.
Additional tasks
At which pressure level do you observe jerking motion?
Explain how jerking motion occurs.
Safety note
38
Mode of operation of a one-way flow control valve
2
Circuit symbol and schematic diagram of a one-way flow control valve
Describe the mode of operation of a one-way flow control valve.

Air is restricted in one direction only with a one-way flow control valve. The non-return valve inhibits the
flow of air in one direction and air can only flow through the selected cross-section. Air flows freely in the
other direction through the open non-return valve. These valves are used primarily for controlling the
speed of the pneumatic cylinders. The speed of the piston rod can be controlled with one-way flow
control valves by adjusting the volumetric flow rate.
Describe two types of flow control used with double-acting cylinders.

Supply air flow control
In the case of supply air flow control, the one-way flow control valves are installed such that air being fed
to the cylinder is restricted. Exhaust air can escape freely on the downstream side via the non-return
valve. Feed speed irregularities occur as the result of even the smallest load fluctuations at the piston
rod, for example in the case of limit switch overtravel. A load in the direction of cylinder motion
accelerates the cylinder beyond the selected value.
Exhaust air flow control

In the case of exhaust air flow control, supply air flows freely to the cylinder and the flow control in the
exhaust line resists the escaping air. The piston is held between two air cushions, which are generated as
a result of supply air pressure and resistance caused by the flow control. This one-way flow control valve
arrangement contributes significantly to improved feed characteristics. Exhaust air flow control should be
used with double-acting cylinders.
Explain how a one-way flow control valve is tested for correct functioning.
A one-way flow control valve is tested for correct functioning by means of two pressure gauges. The
pressure gauges are connected directly upstream and downstream from the valve under test.
39
Create the pneumatic circuit diagram
Complete the circuit diagram shown below. Complete the symbols for the one-way flow control valves..
Observe the specified basic conditions when doing so.
1A1
1Z2
1V1
1Z1
1S1
1V2
40

Quantity
Designation
Pressure gauge
Distributor block
41
Set up the control system and describe its operating sequence.

Initial position
In the initial position, the piston is in the retracted end position. The piston chamber is exhausted via
5/2-way valve 1S1.
Step 1-2
When the 5/2-way valve is reversed, the piston chamber in the cylinder is pressurised via the one-way
flow control valve. The cylinder travels to its advanced end position.
Step 2-3
After resetting the switch, the cylinders piston rod chamber is pressurised via the one-way flow control
valve and the 5/2-way valve. The cylinder travels to its retracted end position.
The required retraction time is adjusted with the one-way flow control valve. Use a stopwatch to this end.
42
Additional tasks
At which pressure level do you observe jerking motion?

Jerking motion occurs in the case of very low operating pressure or excessive restriction.
Explain how jerking motion occurs.

Its caused by pressure building up and working against static friction and sliding friction. Pressure builds
up at the stationary piston and works against static friction. If force due to pressure exceeds the friction
coefficient, the piston is advanced and minimal sliding friction comes into play. But then the air increases
again and pressure drops, because it cant be built back up quickly enough; the piston stops. This
sequence is repeated. The piston stammers.
43
44
Exercise 7: Shutting off a pipeline

Learning objectives
Be able to adjust cylinder advancing and retracting speeds.
Be able to differentiate between the various types of flow control and use them appropriately.

A filling system fills bottles with milk. The pipes through which the milk flows are opened and closed using a
gate. The gate should be opened slowly in order to prevent any spillage at the beginning of the filling
process. Closing, on the other hand, should take place as quickly as possible.
Layout
Milk bottle filling
45
Basic condition
Speed control should enable a smooth opening process.
1.
2.
3.
4.
5.
6.
Project assignment
Select the appropriate type of flow control.
Create a pneumatic circuit diagram for the shut-off mechanism.
Procedure
1. A gate valve is opened slowly after activating a selector switch.
2. The gate valve is closed quickly when the selector switch is returned to its initial position.
Safety note
46
Select the type of flow control

Determine whether supply air or exhaust air flow control is required for the application.
Justify your selection and write your reasons down.

Exhaust air flow control is the right selection for the application. Load-independent, uniform feed speed
is ensured by means of exhaust air flow control.
47
Create the pneumatic circuit diagram
Complete the circuit diagram shown below. Observe the specific constraints when doing so.
1A1
1V1
1S1
48
Quantity
Designation
Distributor block
49
Set up the control system and describe its operating sequence.

Initial position
The pistons initial position is the retracted rear end position. The piston chamber is exhausted via 5/2way valve 1S1.
Step 1-2
When the 5/2-way valve is reversed, the piston chamber in the cylinder is pressurised with compressed
air. The piston rod chamber is exhausted via 5/2-way valve 1S1. The cylinder travels slowly to its
advanced end position. The required advancing time is adjusted with the one-way flow control valve.
Step 2-3
After resetting the switch, the cylinders piston rod chamber is pressurised via the one-way flow control
valve and the 5/2-way valve is pressurised without flow control. The piston chamber is exhausted via
5/2-way valve 1S1. The cylinder travels to its retracted end position.
Note
This control system works with exhaust air flow control. Use a stopwatch in order to set the required time
value. The setting can be secured with a lock nut.
50
Exercise 8: Actuating a shut-off device

Learning objectives
After completing this exercise:
Youll be familiar with one type of signal storage in pneumatic control systems.
Youll be able to adjust cylinder advancing and retracting speeds.

The gate in a filling system for plastic pellets needs to be closed quickly. However, it should be opened slowly.
Layout
Plastic pellet filling system
51
Parameters
A double-acting cylinder will be used.
The closing operation should be executed by the cylinders forward stroke.
1.
2.
3.
4.
5.
6.
7.
Project assignment
Describe the mode of operation of a quick exhaust valve.
Describe the mode of operation of a 5/2-way double pilot valve.
Draw a pneumatic circuit diagram for the shut-off mechanism.
Procedure
1. A shut-off mechanism (ball valve) is opened slowly after activating a pushbutton.
2. The shut-off mechanism is closed quickly after activating a second pushbutton.
Safety note
52
Mode of operation of a quick exhaust valve

3
2
1
Circuit symbol and schematic diagram of a quick exhaust valve
Describe the mode of operation of a quick exhaust valve.

Increased piston speeds during the return stroke can be achieved with single and double-acting cylinders
using quick exhaust valves, because flow resistance is thus reduced for the exhaust air.
Compressed air flows from the pilot valve to the cylinder via the quick exhaust valve. Exhaust port 3 is
closed at this time.
When pressure at port 1 drops, exhaust flow occurs from 2 to 3. In order to implement optimised quick
exhaust, the valve must be connected directly to the cylinders supply port.
53
Mode of operation of a 5/2-way double pilot valve
14
12
Schematic diagram of a 5/2-way double pilot valve
Explain the mode of operation of the 5/2-way double pilot valve.

A 5/2-way double pilot valve has 5 working ports and 2 switching positions. The valve is equipped with a
latching function; a short signal (pulse) suffices for reversal.
The valve piston is moved to the opposite switching position by means of a compressed air pulse at one
of the two pilot ports (12/14). The valve piston is held in this position by the compressed air at the
working port until a compressed air pulse at the other side of the valve reverses the valve back to its
previous position. If signals are present at both pilot ports, the first signal to arrive is dominant.
A pneumatic signal at pilot port 12 causes flow from port 1 to port 2. A pneumatic signal at pilot port 14
causes flow from port 1 to port 4.
Describe the performance of the valve depicted above when port 14 is briefly pressurised with
compressed air.
When port 14 is pressurised, the valve piston is moved to the right and directs compressed air from port
1 to port 4. Port 2 is exhausted via port 3. When port 14 is once again unpressurised, the valve position
remains in this position by compressed air from port 1.
54

1A1
1Z1
1V3
1V2
1V1
2
12
1S2
14
1S1
55

Initial position
The pistons initial position should be the retracted end position. The piston chamber is exhausted via
5/2-way double pilot valve 1V1 and the piston rod chamber is pressurised. If the piston is in the
advanced end position, it has to be moved to the retracted end position by actuating 1S2.
Step 1-2
After actuating 3/2-way valve 1S1, the 5/2-way double pilot valve is reversed and the cylinders piston
chamber is pressurised via the one-way flow control valve. The double-acting cylinder travels to its
advanced end position. The piston rod chamber is vented via the quick exhaust valve. The piston remains
in this end position, even when 1S1 is released again.
Step 2-3
The 5/2-way double pilot valve is reversed by actuating 3/2-way valve 1S2. The cylinders piston rod
chamber is pressurised via the quick exhaust valve. The cylinders piston chamber is exhausted via the
one-way flow control valve and the 5/2-way double pilot valve. The cylinder travels to its retracted end
position.
Retracting time
The required retraction time is adjusted using the one-way flow control valve. Use a stopwatch to this
end. This setting can be secured with the lock nut.
56

Create an equipment list by entering the required components to the table below.
Quantity
Designation
Quick exhaust valve
Pressure gauge
5/2-way double pilot valve
Distributor block
57
58
Exercise 9: Expanding the control system for pressing cheeses

Learning objectives
Be able to expand existing control systems.
Be able to analyse a proposed solution.
Be able to implement an OR operation.

Presses are used to press cheeses into moulds during a cheese production process. The cheese presses are
operated by using one of two pushbuttons, so that pressing can be done at the loading or unloading end.
There is a possible solution which, however, does not achieve the piston force required to press a cheese.
Layout
Cheese production
59
Parameters
Design pneumatic control of the cylinder using an additional manually actuated valve.
Operation should be possible using either of the valves.
1.
2.
3.
4.
Project assignment
Analyse the proposed solution.
Complete the pneumatic circuit diagram for the pressing device.
Update the equipment list.
1.
2.
3.
4.
5.
Procedure
The cheeses are placed into the press manually.
After actuating a pushbutton at the loading or unloading end of the system, the cylinder advances and
presses the lid onto the press.
The pushbutton is pressed and held until the pressing operation has been completed.
When the pushbutton is released, the cylinder is retracted and the press can be accessed.
The cheese can be removed.
Safety note
Limit pressure at the service unit for this exercise to a maximum of 3.5 bar (350 kPa).
60
Analyse the pneumatic circuit diagram

The required functional expansion has been achieved with the help of the control system shown below.
However, it has been noticed that the piston force required to press the cheese is not reached. Piston force
is only adequate when both pushbuttons are activated simultaneously.
1A1
Circuit diagram for proposed solution
Analyse the control system depicted above and explain why the required piston force is not achieved.
The required piston force is not reached because part of the operating pressure escapes via the exhaust
port of the unactuated valve.
61
Mode of operation of a shuttle valve

2
2
1
Circuit symbol and schematic diagram of a shuttle valve
Describe the mode of operation of the required components.

The shuttle valve is used for the OR operation. Pneumatic signals at one or both of the inputs 1 cause a
signal at the signal output 2.
If theres no input signal, theres no output signal.
If a signal is present at both inputs, the earlier signal arrives at the output.
62
Complete the circuit diagram below.

1A1
1V1
1
1S1
1S2
63
Update the equipment list

The equipment list for the original control system must be changed in order to document the current control
system.
Quantity
Designation
Distributor block
Existing equipment list
Fill in the table below.
Quantity
Designation
Shuttle valve
Distributor block
Updated equipment list
64
Exercise 10: Clamping a workpiece

Learning objectives
Be able to implement an AND operation.
Be familiar with one option for end-position sensing in cylinders.

A rotary indexing machine is used for feeding workpieces in production process. The workpieces have to be
clamped in the individual workpiece holders for machining. A clamping tool is to be developed and tested by
means of a test set-up.
Layout
Rotary indexing machine
65
Parameters
The clamping process can only be started when the cylinder is in the retracted end position.
After activating a second pushbutton, the cylinder returns to the retracted end position and releases the
workpiece.
Pressure gauges will be installed between the one-way flow control valve and each of the cylinders two
working ports in order to indicate pressure.
1.
2.
3.
4.
5.
6.
7.
Project assignment
Describe the mode of operation of a dual-pressure valve.
Describe the mode of operation of a 3/2-way roller lever valve.
Complete the pneumatic circuit.
Procedure
1. A double-acting cylinder can only be advanced when a pushbutton is activated and the cylinder is in the
retracted end position; otherwise its not possible to insert a workpiece for machining.
2. The clamping cylinder should be held in the advanced end position until the workpiece has been
machined. Machining time may vary.
3. The workpiece is released by pressing a second pushbutton.
Safety note
Additional task
What happens if the 3/2-way roller lever valve is readjusted?
66
Mode of operation of a dual-pressure valve

2
2
1
1
1
Circuit symbol and schematic diagram of a dual-pressure valve
Describe the mode of operation of a dual-pressure valve.

The dual-pressure valve is used for the AND operation. Pneumatic signals at both inputs 1 cause a signal
at output 2. If theres only one input signal or none at all, theres no output signal.
If the input signals are generated at different times, the later signal arrives at the output. If the input
signals have different pressure values, the signal with the lower pressure value arrives at the output.
67
Mode of operation of a 3/2-way roller lever valve

2
Circuit symbol for a 3/2-way roller lever valve
Describe the mode of operation of a 3/2-way roller lever valve.

A 3/2-way roller lever valve has 3 working ports and 2 switching positions. The roller lever is actuated by,
for example, a trip cam on a cylinder. Reduced actuation force is achieved by means of pilot control.
Explain how the roller lever valve has to be mounted in order to ensure correct functioning of the control
system.
The roller lever valve must be mounted so that its actuated when the cylinder piston is in the retracted
end position. If the valve is mounted in front of or underneath the cylinder cam, the roller lever is not
actuated and the AND operation cannot be fulfilled. The control system is not started.
68

1A1
1B1
1Z1
1Z2
1V3
1V2
14
1V1
1
1S1
12
5
1B1
1V4
1S2
69

Initial position
Pressure is present. The piston chamber of the double-acting cylinder is exhausted and the piston rod
chamber is pressurised. 3/2-way roller lever valve 1B1 is actuated. The cylinder is in its retracted end
position.
Step 1-2
When 3/2-way valve 1S1 is actuated, compressed air is applied to both inputs at dual-pressure valve
1V1. Compressed air is now also present at the output of the dual-pressure valve. 5/2-way double pilot
valve 1V2 is reversed by the signal at pilot port 14. The cylinder is thus also reversed and the piston
advances. 3/2-way roller lever valve 1B1 is switched to its normal position and the output signal at the
dual-pressure valve is deactivated. The cylinder is held in the advanced end position by the self-locking
loop.
Step 2-3
After activating the pushbutton at 3/2-way valve 1S2, 5/2-way double pilot valve 1V3 is reversed again
(signal at pilot port 12). The cylinders piston rod chamber is pressurised. The cylinder travels to its
retracted end position. 3/2-way roller lever valve 1B1 is actuated again.
70

Quantity
Designation
Pressure gauge
5/2-way valve, double piloted
Distributor block
71
72
Exercise 11: Loading wire baskets

Learning objectives
Be able to implement a latching circuit with OR operation.

Wire baskets are loaded with packages at a loading station. They are positioned at two supply points along
the conveyor belt so that the continuous flow of packages doesnt have to be interrupted. When one wire
basket is full, the flow of packages is diverted to the other supply point by means of a deflector, so that the
full wire basket can be removed and an empty one moved into place.
Layout
Loading cage boxes
73
Parameters
Material flow will be controlled by two valves with pushbutton, one for disabling and one for enabling. Due to
the fact that the pushbutton signals are of short duration, a control system must be set up which stores the
signal.
1.
2.
3.
4.
5.
6.
1.
2.
3.
4.
74
Project assignment
Describe the mode of operation of a shuttle valve.
Procedure
When the pushbutton is activated, the cylinder advances and pushes the deflector into the flow of
material.
The cylinder remains in this position after the pushbutton has been released and the material flow is
diverted.
After activating the second pushbutton, the cylinder is retracted to the retracted end position and the
material flow reverts to the original supply point.
The cylinder remains in this position until the pushbutton is activated again.
Develop the required latching circuit and complete the circuit diagram shown below.
1A1
1V4
1V3
1V5
14
5
1V2
12
1
1S2
1
1V1
1
1S1
2
1
75
Mode of operation of a latching circuit
Describe the mode of operation of a latching circuit.

A latching circuit is used to convert a brief signal into a continuous signal. The valve group consisting of
1S1, 1S2, 1V1 and 1V2 is such a latching circuit. Activating pushbutton 1S1 causes a continuous signal at
the output of valve 1V2.
If the pushbutton at valve 1S1 is activated, shuttle valve 1V1 allows compressed air to flow. As valve 1S2
is normally open, the compressed air actuates input 12 at 3/2-way valve 1V2. As a result, input 14 at 5/2way valve 1V3 is also actuated. Directional control valve 1V3 is reversed, and the cylinders piston
advances. However, valve 1V2 is held in the actuated state at the same time by the return line to shuttle
valve 1V1.
When 3/2-way valve 1S2 is actuated, the self-latching loop is interrupted. Theres no longer a signal at
input 12 at valve 1V2, and the valve is switched to its normal position. Input 14 at 5/2-way valve 1V3 and
the return line to the shuttle valve are exhausted. Valve 1V3 is switched to its normal position and the
cylinder piston returns to its initial position.
In the event that pushbuttons 1S1 and 1S2 are both activated at the same time, theres no signal at the
output either. This type of control system is called an RS flip-flop.
76
Create an equipment list by entering the required components in the table below. Take all components
into consideration that are required for the set-up.
Quantity
Designation
5/2-way valve, pneumatic, with spring return
3-2 way valve, pneumatic, normally closed
Shuttle valve (OR)
Distributor block
On-off valve with filter -regulator
77
78
Exercise 12: Actuating a sliding door

Learning objectives
Youll be able to combine logic operations.
Youll be familiar with the set-up and mode of operation of a pneumatic proximity switch.
Youll be able to differentiate between 5/2-way valves and select and use them in accordance with
specifications.

A sliding door between two rooms needs to be opened and closed using a pushbutton. Only one pushbutton
should be located at each side of the door in order to prevent operator error in case of an emergency.
Layout
Sliding door
Festo Didactic GmbH & Co. KG
79
Parameters
Either process can only be started when the door is in one of its end positions.
Pressure must be limited to 3 bar (300 kPa) for safety reasons (danger of pinching).
1.
2.
3.
4.
5.
Project assignment
Create a pneumatic circuit diagram for the sliding doors control system.
Procedure
When the sliding door is in one of its defined end positions, it can be moved to the other end position by
pressing the pushbutton. The door can thus be opened and closed.
The opening and closing processes cannot be started as long as the door is not in one of its end positions.
Safety note
Limit pressure at the service unit to a maximum of 3 bar (300 kPa) for this exercise.
80
Additional tasks
What happens if compressed air supply fails during advance or return motion?
How can the control system be put back into operation, what must be done?
Mode of operation of a pneumatic proximity switch
S
N
N
S
Circuit symbol and schematic diagram of a pneumatic proximity switch
Describe the mode of operation of the pneumatic proximity switch.

A pneumatic proximity switch is a 3/2-way valve which is actuated by a permanent magnet mounted on
the piston of a cylinder. If the permanent magnet is in close proximity to the proximity switch, the 3/2way valve is actuated and generates a pneumatic signal. Proximity switches are mounted directly on the
cylinder barrel.
81

1A1
1B1
1V5
1V4
1B2
14
12
5
1V2
1V3
1
1V1
1S1
1B2
1S2
1B1
1V6
82
Create a sequence description

Initial position
The cylinder is in the retracted end position. Pneumatic proximity switch 1B1 is actuated. A pneumatic
signal is applied to one input of dual-pressure valve 1V2.
Step 1-2
If one of the two pushbuttons is activated, shuttle valve 1V1 generates an output signal. A signal is now
applied to pilot port 14 at the 5/2-way double pilot valve and the valve is switched. The cylinder
advances.
When the cylinder reaches the advanced end position, pneumatic proximity switch 1B2 is attenuated.
Step 2-3
If one of the two pushbuttons is activated, shuttle valve 1V1 generates an output signal. A signal is now
applied to pilot port 12 at the 5/2-way double pilot valve and the valve is switched. The cylinder is
retracted. When the cylinder reaches the retracted end position, pneumatic proximity switch 1B1 is
attenuated.
83

84
Quantity
Designation
5/2-way double pilot valve, pneumatic
Proximity sensor, pneumatic
Shuttle valve (OR)
Distributor block
Additional task: malfunction due to pressure failure

Compressed air supply to the control system fails during forward or reverse motion of the sliding door. What
happens, and how can the control system be placed back into service?
Describe the consequences of a pressure failure and explain how the control system can be placed back
into service.
The door remains in its current position. It must be manually pushed into one of its end-positions in order
to restart the control system, because otherwise the start condition is not fulfilled (door is in one of its
two end-positions).
85
86
Exercise 13: Feeding wooden boards

Learning objectives
Be familiar with the NOT operation.
Be able to combine logic operations.
Be able to further develop existing control systems.

Wooden boards need to be fed from a magazine to a machining process. Workpieces should not be pushed
out of the magazine if the picking area is occupied.
Layout
Stacking magazine
87
1.
2.
3.
4.
5.
Parameters
A roller lever valve is used to mechanically determine whether or not a board is located in the picking
area. The cylinder is throttled while advancing and retracting.
Project assignment
Procedure
1. The ejecting process is started by means of a pushbutton when the cylinder is in its retracted end
position. The ejecting cylinder only pushes a workpiece out of the magazine when the roller lever valve
in the picking area indicates that the picking area is NOT occupied.
2. If the picking area is empty, the cylinder advances to the advanced end position with restricted exhaust
air, pushes the workpiece out and immediately returns to its retracted end position with restricted
exhaust air.
Additional task
How would you have to change the control system if the ejecting process could only start when a workpiece
is in the magazine AND the picking area is empty?
88

1A1
1B1
1V4
1V3
1B2
14
12
5
1V2
1V1
1B1
1S1
1V5
1S2
1B2
Note
You can use a 3/2-way valve with selector switch in the control system instead of a 3/2-way roller lever
valve, if you want to simulate whether the picking area is empty or occupied.
89

Initial position
Compressed air is present. The cylinder is in the retracted end position. Pneumatic proximity switch 1B1
is attenuated and switched to the free-flow direction. The piston rod chamber is pressurised.
Step 1-2
If the picking area is occupied, 3/2-way roller lever valve 1S2 is not actuated. Dual-pressure valve 1V1
does not generate an output signal and the 5/2-way double pilot valve cannot be reversed.
If the picking area is empty, 3/2-way roller lever valve 1S2 is actuated. Dual-pressure valve 1V1
generates an output signal. If the pushbutton at 3/2-way valve 1S1 is activated, dual-pressure valve 1V2
generates an output signal. A signal is applied to pilot port 14 at 5/2-way double pilot valve 1V3. The
5/2-way double pilot valve is reversed and the cylinder advances.
Step 2-3
Pneumatic proximity switch 1B2 is attenuated and switches to the free-flow direction. A signal is applied
to pilot port 12 at the 5/2-way double pilot valve. 5/2-way double pilot valve 1V3 is switched and the
cylinder travels to its retracted end position. Pneumatic limit switch 1B1 is attenuated and switches to
the free-flow direction.
Step 3-1
Same as step 1
90

Quantity
Designation
Distributor block
91
Adapt the control system

The control system must be changed so that the ejecting process can only be started when a workpiece is in
the magazine AND the picking area is empty.
Explain how the control system has to be changed in order to meet this requirement.
An additional sensor will have to be connected for workpiece sensing. A suitable sensor is therefore
required (roller lever valve) as well as a dual-pressure valve (AND). An AND operation will be added for
the two sensors instead of using 3/2-way valve 1S2.
92
Exercise 14: Compacting beverage cans

Learning objectives
Youll be familiar with the set-up and mode of operation of a pressure sequence valve.
Youll be able to set up pressure-dependent control systems.

Beverage cans are pressed into bales so that they take up minimal storage space at a recycling plant. The
compacting process is started using a pushbutton. The return stroke can be triggered with another
pushbutton. The compacting process should only be started when enough pressure is available.
Layout
Can press
93
Parameters
The initial position of the compacting cylinder is the retracted end position.
The compacting process should only be started when system pressure is greater than 6 bar (600 kPa).
The return stroke can be triggered manually if the compacting cylinder does not fully reach the
advanced end position due to the quantity of cans to be compacted.
1.
2.
3.
4.
5.
Project assignment
Complete the pneumatic circuit diagram for the can press.
Procedure
1. A pressure sequence valve is switched when the specified pressure value is reached and supplies
compressed air to the control system. The control system should not be operable at a pressure of less
than 4.5 bar (450 kPa).
2. It should only be possible to start the compacting process using a start button when the compacting
cylinder is in the retracted end position. The compacting cylinder moves to the advanced end position or
as far as it can depending on the amount of material to be compacted.
3. The return stroke is triggered either by a limit switch or a pushbutton.
Note
The required protective guard is not shown.
94
Mode of operation of a pressure sequence valve
12
Circuit symbol for a pressure sequence valve
3 2 1
12
Schematic diagram of a pressure sequence valve
Describe the mode of operation of a pressure sequence valve.

If pressure at pilot port 12 exceeds a certain adjustable value, the actuated 3/2-way valve is switched
and compressed air is applied to working port 2.
The 3/2-way valve switches back to its initial position when pressure at the pilot port drops back below
the selected value.
95

1A1
1B1
1V6
1B2
2
1V5
14
12
5
1V3
3
1V4
2
1
1B1
1V7
1S1
1S2
1V2
1B2
12
1V1
96

Quantity
Designation
Shuttle valve (OR)
Pressure regulator valve with gauge
Distributor block
97
Set up the control system and put it into operation.
Describe the control systems working sequence.

Initial position
The double-acting cylinder is in its retracted end position. Pneumatic proximity switch 1B1 is actuated
and switched to the free-flow direction. Compressed air is present. The required pressure level has been
pre-selected at the pressure regulator in the service unit. The desired pressure value has been set at the
pressure sequence valve.
Step 1-2
The pushbutton at valve 1S1 is activated. The condition at dual-pressure valve 1V3 (AND) is changed to
TRUE as a result. 5/2-way double pilot valve 1V5 is switched to the operating position. The double-acting
cylinder advances.
Step 2-3
Pneumatic limit switch 1B2 is actuated and switches to the operating position. 5/2-way double pilot
valve 1V5 is reset by shuttle valve 1V4 (OR).
Alternatively, this process can be started using the pushbutton at valve 1S2. The 5/2-way double pilot
valve is reset by shuttle valve 1V4 (OR).
The double-acting cylinder returns to its initial position. The process is finished when pneumatic limit
switch 1B1 is actuated.
98
Exercise 15: Packaging of brochures

Learning objectives
Youll be familiar with the set-up and mode of operation of a pressure regulator.
Youll be able to set up pressure-dependent control systems.

Sets of 10 brochures each are to be wrapped in plastic film. The brochures have to be clamped in order for
the film to seal properly. An operating pressure of at least 4 bar (400 kPa) is required in order to be able to
clamp the brochures securely. However, the maximum operating pressure of 6 bar (600 kPa) should not be
exceeded as otherwise the brochures risk being damaged.
The advance and reverse strokes are triggered using a pushbutton. The retracted end position of the
clamping cylinder is sensed via a pneumatic proximity switch.
Layout
Brochure production
99
Parameters
The process can only be started when the clamping cylinder is in the retracted end position.
The operating pressure has to be greater than 6 bar (600 kPa) before the control system can be started up.
The return stroke is triggered manually, because the duration of the packaging process varies.
1.
2.
3.
4.
5.
Project assignment
Complete the pneumatic circuit diagram for the packaging unit.
Procedure
1. A pressure sequence valve is switched when the specified pressure value is reached and supplies
compressed air to the control system.
2. The tensioning process starts when the clamping cylinder is in the retracted end position and a
pushbutton is activated. The cylinder is advanced and remains in the advanced position.
3. The process ends when a second pushbutton is activated and the cylinder returns to the retracted end
position.
100
Mode of operation of a pressure regulator
p1
p2
1 3
Circuit symbol for a pressure regulator
Schematic diagram of a pressure regulator
Describe the mode of operation of a pressure regulator.

Input pressure (primary pressure) at the pressure regulator must always be higher than output pressure
(secondary pressure). Pressure regulation itself takes place via a diaphragm. Output pressure acts on
one side of the diaphragm and the force of a spring on the other. Spring force can be adjusted with an
adjusting screw.
If pressure at the secondary side is increased, for example due to a load change at the cylinder, the
diaphragm is pressed against the spring and the outlet cross-section of the valve seat is reduced or
closed. The valve seat of the diaphragm is opened and compressed air is able to escape into the
atmosphere through the relief ports in the housing.
If pressure drops at the secondary side, the valve is opened by the force of the spring. Thus regulating air
pressure to the pre-selected operating pressure means that the valve seat is continuously opened and
closed, which is triggered by the volume of air that flows through. Operating pressure is indicated by a
measuring instrument.
101

1A1
1B1
1V7
1V6
1V5
1
2
1V4
14
12
5
1V3
1
1B1
1
1S1
1S2
1V2
1V1
12
102

Quantity
Designation
Pressure regulator (on-off valve with filter regulator).
Distributor block
103
Mode of operation of the one-way flow control valve
Describe the function of the one-way flow control valve which is connected in parallel to the pressure
regulator.
One-way flow control valve 1V5 functions as a bypass for the pressure regulator. The flow control is fully
closed. Compressed air can escape via the non-return valve when the cylinder is retracted, because its
unable to escape via the pressure regulator.
104
Exercise 16: Mounting locking pins

Learning objectives
Be able to set up pressure-dependent control systems.
Be able to analyse and optimise existing control systems.

Locking pins are to be mounted on plug connector housings at an automated assembly machine. So far,
pressure has been set using a pressure regulator at the assembly machine. This has led to repeated
malfunctions in the assembly process.
The assembly process will now be examined using a test set-up. Each assembly step is triggered manually.
The control system will be changed so that it only functions when pressure does not exceed a certain value.
Layout
Automated assembly machine for plug connector housings
105
Parameters
Pressure at the working port of the assembly cylinder must have a value of at least 3.5 bar (350 kPa), in
order to ensure that the locking pins are securely mounted.
It should not be possible to start the process if pressure is greater than 3.8 bar (380 kPa).
The return stroke of the assembly cylinder is started automatically when it reaches the advanced end
position.
1.
2.
3.
4.
5.
1.
2.
3.
4.
Project assignment
Complete the pneumatic circuit diagram for the automated assembly machine.
Procedure
The process will be started with a pushbutton when the assembly cylinder is in the retracted end
position.
The cylinder should move to the advanced end position with minimal force.
It actuates a limit switch in this position.
It should then quickly return to the retracted end position.
Analyse the pneumatic circuit diagram
Analyse the circuit diagram shown below and determine whether or not its suitable for the required task.
The circuit diagram is suitable.
What are the advantages or disadvantages of the characteristics of the required control system?
There is a danger that pressure can be incorrectly set at the pressure regulator in the supply line to the
cylinder which would result in the pins being damaged.
106
1A1
1B1
1V7
1V6
1V5
1
2
1V4
14
12
5
1V3
1
1B1
1
1S1
1S2
1V2
1V1
12
107
Complete the pneumatic circuit diagram shown below, taking all required conditions into consideration.
1A1
1B1
1V7
1B2
2
1V6
14
12
5
1V5
1V4
1V3
1V8
12
1
1V2
12
1V1
2
1B1
1S1
1B2
2
1
3
1
108

Quantity
Designation
3-2 way valve, pneumatic, normally open
Pressure regulator
Distributor block
Equipment list
109
Describe the control systems working sequence.

Initial position
The double-acting cylinder is in its retracted end position. Pneumatic proximity switch 1B1 is attenuated.
Compressed air is present. The desired pressure value has been set at the regulator and at the pressure
sequence valve.
Step 1-2
Pushbutton 1S1 is activated and pneumatic proximity switch 1B1 is attenuated; the condition at the first
dual-pressure valve, 1V3 (AND), thus becomes TRUE. After the pressure sequence valve has been
switched with sufficient pressure, the 3/2-way valve is switched to the operating position. The condition
at the second 2-way valve, 1V5 (AND), thus becomes TRUE and the 5/2-way double pilot valve is
switched to the operating position. The double-acting cylinder advances.
Step 2-3
Pneumatic proximity switch 1B2 is attenuated and switches to the operating position. The 5/2-way
double pilot valve is switched. The double-acting cylinder returns to its initial position. The process is
finished when pneumatic proximity switch 1B1 is attenuated.
110
Exercise 17: Labelling paint pots

Learning objectives
Be able to set up time-dependent control systems.
Be familiar with the set-up and mode of operation of a time delay valve.

Paint pots are labelled at a gluing machine. The gluing process is triggered using a pushbutton at the machine.
A drying time of approximately 10 seconds is required for the adhesive to become effective. The system is
not ready to start until the piston of the pressing cylinder is in the retracted end position.
Layout
Farbe rau
lichtg 35
0
RAL 7
Farbe au
lichtgr 35
RAL 70
Labelling fixture
111
Parameters
As the label has to be glued to the paint pot with minimal pressure, working pressure must be
adjustable.
The cylinder should be retracted as quickly as possible.
Working pressure must be adjustable within a range of 3 to 7 bar (300 and 700 kPa).
Pressure should be indicated by a pressure gauge upstream of the cylinder.
1.
2.
3.
4.
5.
Project assignment
1.
2.
3.
4.
112
Procedure
The process will be started using a pushbutton when the cylinder is in the retracted end position.
The cylinder should advance to the advanced end position with minimal force and speed and remain in
this position for an adjustable period of time.
It should then quickly return to the retracted end position.
Pressure during the forward stroke should be indicated at a pressure gauge.
Mode of operation of a time delay valve

2
t
1
Circuit symbol for a time delay valve
Describe the mode of operation of a time delay valve and enter the most important technical data in the
table.
The time delay valves switches input pressure applied to port 1 to port 2 after the preset delay time has
expired. If the supply of compressed air is interrupted at port 1, working port 2 is once again switched to
the unpressurised state. The time delay valve is automatically reset within 200 ms. Delay time is infinitely
adjustable via an adjusting knob.
Technical data
Pressure range
2 to 6 bar (200 to 600 kPa)
Switch-on pressure
> 1.6 bar (160 kPa)
Standard nominal flow rate
50 l/min.
Delay time
2 to 30 sec. (adjustable)
Setting accuracy
0.6 sec.
Pause period for reset
> 200 ms
113

1A1
1B1
1B2
1Z1
1V6
3
1V5
1
1V4
14
12
5
1V2
3
1V3
1
t
1V1
2
1B1
1S1
1B2
2
1
3
1
114

Quantity
Designation
Quick exhaust valve
Time delay valve
Pressure gauge
Distributor block
Equipment list
115

Initial position
The double-acting cylinder is in its retracted end position. Pneumatic proximity switch 1B1 is attenuated.
Compressed air is present. The required pressure value has been set at the pressure regulator.
Step 1-2
Pushbutton 1S1 is activated and pneumatic proximity switch 1B1 is attenuated; the condition at the first
dual-pressure valve, 1V2 (AND), thus becomes TRUE and 5/2-way double pilot valve 1V4 is switched to
the operating position. The double-acting cylinder is advanced with minimal pressure and with flow
control.
Step 2-3
Pneumatic proximity switch 1B2 is attenuated and switches to the operating position. Compressed air is
fed to time delay valve 1V3 as a result, which then switches through after a preset period of time. The
5/2-way double pilot valve is reset. The double-acting cylinder returns to its initial position with minimal
pressure. The piston chamber is vented via the quick exhaust valve. The process is finished when
pneumatic proximity switch 1B1 is attenuated.
116
Exercise 18: Cleaning workpieces

Learning objectives
Be able to set up control systems with oscillating motion.
Be able to use time delay valves in accordance with specific constraints.

A wire basket with workpieces needs to be moved up and down in a cleaning bath. The process is started
using a pushbutton.
Layout
Automatic cleaning system
117
Parameters
A roller lever valve will be used in order to detect the retracted end position.
The cleaning process should be limited to a period of 20 seconds.
1.
2.
3.
4.
5.
6.
Project assignment
Convert a 5/2-way double pilot valve to a 3/2-way double pilot valve.
Complete the pneumatic circuit diagram for the automatic cleaning system.
Procedure
1. The process is started using a pushbutton when the lifting cylinder is in its retracted end position.
2. The cylinder for the lifting device moves to the advanced end position. It then goes back to the midposition and returns to the advanced end position. This motion sequence is repeated until the process
is stopped by the time delay valve.
3. The cylinder then returns to its retracted end position.
118
Convert a 5/2-way double pilot valve

4
14
12
5
Circuit symbol for a 5/2-way double pilot valve
Convert a 5/2-way double pilot valve to a 3/2-way double pilot valve.

Describe what has to be done.
Output 4 is closed using a blanking plug.
119

1B1 1B3
1B2
1A1
1V6
2
1V5
2
1V4 4
14
12
5
1V3
2
1
1
1B1 2
1B3
1B2 2
1V2 2
10
12
1
1V1
3
1S1
t
1
Pneumatic circuit diagram (solution)
120

Initial position
In the initial position, the cylinder is in its retracted end position and it actuates 3/2-way roller lever valve
1B1. Final control element 1V4 (5/2-way double pilot valve) is advanced to the right switching position.
Signal latch 1V2 (3/2-way double pilot valve) is also in the right switching position. The required pressure
value has been set at the pressure regulator.
Step 1-2
After activating start button 1S1, signal latch 1V2 is switched. Compressed air is fed to the input at time
delay valve 1V1. The 5/2-way double pilot valve 1V4 is switched by 3/2-way roller lever valve 1B1 and
shuttle valve 1V3 (OR) and the cylinder is advanced. Travel beyond pneumatic proximity switch 1B3 at
the mid-position has no effect, because the same control port of the final control element is actuated.
Step 2-3
Pneumatic proximity switch 1B2 is actuated in the advanced end position. The final control element (5/2way double pilot valve) is switched. The cylinder is retracted and actuates pneumatic proximity switch
1B3 at the mid-position.
Step 3-4
The cylinder is once again reversed when pneumatic proximity switch 1B3 at the mid-position is actuated.
Reversing only takes a few milliseconds, and thus the trip cam does not travel beyond pneumatic
proximity switch 1B3.
Step 4-5
See step 2-3.
Oscillating motion
The cylinder moves back and forth between pneumatic proximity switches 1B3 and 1B2 until time
specified at time delay valve 1V1 has elapsed.
Steps n-2 through n

After the time delay valve has switched through, signal latch 1V2 (3/2-way double pilot valve) is
reversed. Pneumatic proximity switch 1B3 and 3/2-way roller lever valve 1B1 are no longer supplied with
compressed air. The cylinder travels to its initial position (retracted end position). The process is finished
when 3/2-way roller lever valve 1B1 is actuated.
121

Quantity
Designation
Time delay valve
Shuttle valve (OR)
Distributor block
Note
A pneumatic 5/2-way double pilot valve is converted to a pneumatic 3/2-way double pilot valve.
122
Exercise 19: Pressing labels into place

Learning objectives
Be able to analyse and set up control systems with two cylinders.

Rating plates are pressed into valve housings at a workstation. First of all, the labels are inserted into
recesses in the valve housings. Then theyre pressed into place with a pressing cylinder.
The valve housings are clamped by pressing a pushbutton. The pressing process is started once the valve
housing has been clamped. Both cylinders should be retracted after the pressing cylinder has reached its
advanced end-position.
Layout
Labelling fixture
123
Parameters
A single-acting cylinder will be used to clamp the valve housings.
A roller lever valve will be used to detect whether or not the clamping cylinder has reached its advanced
end position.
A double-acting cylinder will be used as a pressing cylinder.
The feed speeds of both the clamping and the pressing cylinders should be adjustable.
1.
2.
3.
4.
5.
Project assignment
Analyse the pneumatic circuit diagram for the pressing fixture.
1.
2.
3.
4.
Procedure
The pressing process is started using a pushbutton.
A limit switch will be used to detect whether or not the clamping cylinder has reached its position.
The pressing cylinder should not advance until the clamping cylinder has reached its advanced end
position.
After the plastic cap has been pressed into place, both cylinders are retracted.
Note
Necessary protective guards are not taken into consideration.
124

2A1
2B1
1A1
1V3
2V2
1
1V2
2
2V1
12
10
1
1V1
1
1S1
14
12
5
2
1
1B2
2B1 2
2B2
1B2
2B2
125

Quantity
Designation
Distributor block
Equipment list
Note
A pneumatic 5/2-way double pilot valve is converted to a pneumatic 3/2-way double pilot valve.
126

Initial position
Pressure is present. In the initial position, both cylinders are in the retracted end position. The piston in
the double-acting cylinder attenuates pneumatic proximity switch 2B1, which is switched to the free-flow
direction. Final control elements 1V2 and 2V1 (5/2-way double pilot valve and 3/2-way double pilot
valve) travel to the right switching position.
Step 1-2
When pushbutton 1S1 is activated, the condition at dual-pressure valve 1V1 (AND) becomes TRUE. The
3/2-way double pilot valve 1V2 is reversed. The single-acting cylinder advances with restricted supply air.
Step 2-3
When the single-acting cylinder reaches its advanced end position, roller lever valve 1B2 is actuated and
reverses 5/2-way double pilot valve 2V1. The double-acting cylinder moves to its advanced end position
where it attenuates pneumatic proximity switch 2B2, which is switched to the free-flow direction.
Step 3-4
5/2-way double pilot valve 2V1 and 3/2-way double pilot valve 1V2 are reversed. Both cylinders are
retracted. The process is finished when the piston in the double-acting cylinder attenuates pneumatic
proximity switch 2B1, which then switches to the free-flow direction.
Note
Single-acting cylinder 1A1 is retracted slightly earlier than double-acting cylinder 2A1. This is due to
overlapping of the control signals at pilot ports 14 and 12 at 5/2-way double pilot valve 2V1. The 5/2-way
double pilot valve 2V1 can only reverse when single-acting cylinder 1A1 has left its advanced end
position and 3/2-way roller lever valve 1B2 is no longer actuated.
127
Proximity switch failure

What happens if the position of pneumatic proximity switch 1B2 is shifted along the cylinder?
Make a note of the resulting consequences.

Pneumatic proximity switch 1B2 is not attenuated and the 5/2-way double pilot valve and the 3/2-way
double pilot valve are thus no longer reset. The cylinder no longer returns to the retracted end position.
As a result, proximity switch 1B1 is not attenuated and the control system can no longer be started.
128

Workbook Pneumatics Basic Level

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Workbook Pneumatics Basic Level

Uploaded by

Copyright:

Available Formats

Pneumatics

Use for intended purpose

Festo Didactic GmbH & Co. KG 541088

Festo Didactic GmbH & Co. KG 541088

Festo Didactic GmbH & Co. KG 541088

Festo Didactic GmbH & Co. KG 541088

Pneumatics, basic level

Festo Didactic GmbH & Co. KG 541088

Work instructions and safety precautions

Festo Didactic GmbH & Co. KG 541088

Festo Didactic GmbH & Co. KG 541088

Technology module for pneumatics (TP100)

TP101 basic level

TP101 basic level

Basic pneumatics for machine operators

Fundamentals of pneumatics and electropneumatics

Maintenance and troubleshooting for pneumatic and electropneumatic systems

Tracking down wastage economic use of pneumatics

Pneumatic refresher and update

Pneumatics for further education

Pneumatics and electropneumatics for trainees

Festo Didactic GmbH & Co. KG 541088

Learning objectives for the basic level (TP101)

Festo Didactic GmbH & Co. KG 541088

Overview of learning objectives per exercise

Become familiar with the set-up

Become familiar with the set-up

Become familiar with the

Be able to differentiate between

Festo Didactic GmbH & Co. KG 541088

Be able to explain and set up

for end-position sensing in

and mode of operation of a

use them in accordance with

Become familiar with the set-up

Become familiar with the set-up

Become familiar with the set-up

Be able to use time delay valves

Festo Didactic GmbH & Co. KG 541088

Equipment set for the basic level (TP101)

3/2-way roller lever valve, normally closed

3/2-way valve with pushbutton, normally open

3/2-way valve with pushbutton, normally closed

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

3/2-way valve, pneumatically actuated at one end

5/2-way double pilot valve, pneumatically actuated at both ends

5/2-way valve with selector switch

5/2-way valve, pneumatically actuated at one end

One-way flow control valve

Pressure regulator with pressure gauge

Pressure sequence valve

On-off valve with filter regulator

Plastic tubing, 4 x 0.75, silver, 10 m

Pneumatic proximity switch with cylinder mounting

Pneumatic timer, normally closed

Quick exhaust valve

Shuttle valve (OR)

Dual-pressure valve (AND)

Festo Didactic GmbH & Co. KG 541088

Equipment set symbols

3/2-way valve with pushbutton, normally closed

3/2-way valve with pushbutton, normally open

5/2-way valve with selector switch