Professional Documents
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Workbook TP 111
Festo Didactic
094465 en
Authorised applications and liability
The Learning System for Automation has been developed and prepared
exclusively for training in the field of automation. The training organiza-
tion and / or trainee shall ensure that the safety precautions described in
the accompanying Technical documentation are fully observed.
Festo Didactic hereby excludes any liability for injury to trainees, to the
training organization and / or to third parties occurring as a result of the
use or application of the station outside of a pure training situation, un-
less caused by premeditation or gross negligence on the part of Festo
Didactic.
Preface
The Learning System for Automation by Festo Didactic is formulated
according to various training prerequisites and vocational requirements.
It has been divided into the following training packages:
n Basic packages which convey basic knowledge spanning a wide
range of technologies
n Technology packages which deal with important subjects of open and
closed-loop control technology
n Function packages to explain the basic functions of automated sys-
tems
n Application packages to facilitate practice-orientated vocational and
further training.
The technology packages deal with the technologies of pneumatics,
electro-pneumatics, programmable logic controllers, hydraulics, electro-
hydraulics, proportional hydraulics, closed-loop pneumatics and hydrau-
lics.
Fig. 1:
Mounting frame Pneumatics 2000 –
i.e. mobile workstation
Profile plate
U = 230 V~
p = 6 MPa
Storage tray
Contents
Technology package TP 111 “Closed-Loop Pneumatics“ 11
Component/exercise table 12
Workbook concept 13
Equipment set TP111 14
Safety instructions 16
Symbols for equipment set 17
Section A – Course
I. Non-dynamic closed-loop pressure control circuit
Section B – Fundamentals
Part C – Solutions
Solution 1: Maintenance of a pressure gauge C-3
Solution 2: Spot-welding machine C-5
Solution 3: Packaging machine C-9
Solution 4: Reservoir-charging circuit C-11
Solution 5: Tyre test-rig C-13
Solution 6: Pneumatic press C-15
Solution 7: Quality assurance C-17
Solution 8: Baffle-plate flow sensor C-19
Solution 9: Pneumatic post system C-21
Solution 10: Clamping device C-23
Solution 11: Pneumatic screwdriver C-25
Solution 12: Injection-moulding machine C-29
Solution 13: Forming of moulded packaging C-31
Solution 14: Bending device C-35
Solution 15: Papermaking machine C-39
Solution 16: Testing machine C-43
Solution 17: Stamping machine C-47
Solution 18: Sorting device C-49
Solution 19: Deburring an engine block C-51
Solution 20: Cake production C-55
Solution 21: Pallettizing station C-59
Section D - Appendix
List of applicable guidelines and standards D-2
List of literature D-4
Index D-5
Data sheets D-13
Component/exercise table
Exercises
Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Workbook concept
The workbook is divided into the following sections:
Section A – Course
Section B – Fundamentals
Section C – Solutions
Section D – Appendix
Komparatorkarte 162257 1
PID-Reglerkarte 162254 1
5/3-Wege-Magnetventil, in Ruhestellung gesperrt 167077 1
Druckluftspeicher 152912 2
Analog-Drucksensor 167094 1
5/3-Wege-Proportionalventil 167078 1
Safety instructions
In the interests of your own safety, please follow the instructions given
below:
n Mount all components securely on the plate.
n When commissioning control circuits, always switch on first the elec-
trical power supply and then the compressed air. When switching off,
work in reverse order.
n Do not switch on the compressed air until you have connected up
and secured all the tubing.
n Exercise great care when switching on the compressed air. Cylinders
may advance or retract unexpectedly.
n Shut off the compressed air supply immediately if tubing becomes
detached. This will help to prevent accidents.
n Never disconnect tubing while this is under pressure.
n Never exceed the maximum permissible operating pressure of 8 bar.
You will need a maximum of 6 bar to carry out the exercises in the
course.
n Please also observe the general safety instructions of DIN58126 and
VDE 100.
n Use only extra-low voltage supplies, maximum 24 V DC.
n Before commissioning closed-loop control circuits, check not only the
pneumatic lines but also the electrical cables and connections.
n Please note that the slide of the linear drive is fitted with powerful
magnets. Do not bring any diskettes or other objects sensitive to
magnetic fields into the vicinity of these magnets.
n Observe the data sheets referring to individual components, particu-
larly with regard to safety instructions.
Reservoir
Display Voltmeter
indicator light
Section A – Course
I. Non-dynamic closed-loop pressure control circuit
Fig. A1.1:
Connection diagram,
pneumatic and electrical
symbols for analogue
pressure sensor
Characteristic
A characteristic is a graphic description of the relationship between an
input variable and an output variable. Characteristics can be produced
for components, devices or even complete installations. They are used
for assessment and comparison purposes.
In the case of a pressure sensor, too, the relationship between the input
variable and output variable can be represented by a characteristic, from
which the following characteristic data can be read:
n Input range – The input range is the range between the smallest and
largest input values which can be recorded (Imin, Imax). The pres-
sure sensor used here has an input range of between 0 and 10 bar.
n Output range – The output range is the range between the smallest
and largest output values (Omin, Omax). The pressure sensor used
here has two output ranges: 0 to 10 V and 0 to 20 mA.
n Linear range – The linear range is the part of the characteristic line
which has a constant gradient; in other words, the characteristic is a
straight line in the linear range.
n Hysteresis – Measurements with an increasing input variable often
produce a different characteristic than measurements with a de-
creasing input variable. Each input value is thus associated with two
output values. The rising and falling characteristics form a hysteresis
loop, whose maximum divergence, divided by the input range, gives
the value for the hysteresis. The hysteresis H is specified as a per-
centage and is calculated as follows:
Maximum divergence
Hysteresis = × 100 %
Input range
Fig. A1.2:
Characteristic for a
measuring system
Fig. A1.3:
Positional sketch
Exercise In the course of the maintenance work, the accuracy of the reading of
the pressure gauge must be checked. The following steps must be car-
ried out:
1. Definition of measured variables and selection of measuring system
2. Assembly of measuring circuit
3. Production of characteristic for pressure gauge
4. Determination of hysteresis
WORKSHEET
Fig. A1.4:
Pneumatic circuit diagram
Fig. A1.5:
Electrical circuit diagram
Pressure sensor
voltage [V]
Pressure sensor
voltage [V]
Fig. A1.6:
Diagram
WORKSHEET
Max. divergence
H= × 100 %
Input range
H= × 100% = %
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