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Order no.: 093131
Description: PNEUM.GS.LEHRB
Designation: D.LB-TP101-1-GB
Edition: 10/2002
Layout: B. Huber
Graphics: D. Schwarzenberger, T. Ocker
Author: P. Croser, F. Ebel

© Copyright by Festo Didactic GmbH & Co., 73770 Denkendorf 2002

The copying, distribution and utilization of this document as well as the
communication of its contents to others without expressed authorization
is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved, in particular the right to carry out patent, utility model
or ornamental design registrations.
 


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 13
Chapter A-1

Fig. 1.1
Single-acting cylinder

Pneumatic components can perform the following types of motion:

 Linear
 Swivel
 Rotary

Some industrial applications employing pneumatics are listed below:

 General methods of material handling:
– Clamping
– Shifting
– Positioning
– Orienting
– Branching of material flow
 General applications:
– Packaging
– Filling
– Metering
– Locking
– Driving of axes
– Door or chute control
– Transfer of materials
– Turning and inverting of parts
– Sorting of parts
– Stacking of components
– Stamping and embossing of components

Festo Didactic • TP101

14
Chapter A-1

Fig. 1.2
Points switch for two
conveyor belts

Fig. 1.3
Pneumatic cutter

Pneumatics is used in carrying out machining and working operations.

For example:
 Drilling
 Turning
 Milling
 Sawing
 Finishing
 Forming
 Quality control

TP101 • Festo Didactic

 


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68
Chapter A-5

5.1 Direct control of a pneumatic cylinder

The simplest level of control for the single or double-acting cylinder in-
volves direct control signals. With this, the cylinder is actuated directly
via a manually or mechanically actuated valve, without any intermediate
switching of additional directional control valves. If the port sizes and the
flow values of the valve are too large, the operating forces required may
be too great for direct manual operation.

Reference values for limits of direct cylinder control:

 Cylinder with piston diameter smaller than 40 mm
 Valves with connection sizes smaller than 1/4"

5.2 Example 1: Direct control of a single-acting cylinder

The Problem A single-acting cylinder of 25 mm diameter is to clamp a component

when a push button is pressed. As long as the push button is activated,
the cylinder is to remain in the clamped position. If the push button is
released, the clamp is to retract.

Fig. 5.1
Positional sketch

TP101 • Festo Didactic

 


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72
Chapter A-5

5.4 Indirect control of a pneumatic cylinder

Cylinders with a large piston diameter have a high air requirement. A

control element with high nominal flow rate must be used to actuate
these. If the force should prove too high for a manual actuation of the
valve, then an indirect actuation should be constructed, whereby a signal
is generated via a second smaller valve, which will provide the force
necessary to switch the control element.

5.5 Example 2: Indirect control of a single-acting cylinder

The Problem A single-acting cylinder with a large piston diameter is to clamp a work-
piece following actuation of a push button. The cylinder is to retract once
the push button is released.

Fig. 5.5
Positional sketch

TP101 • Festo Didactic

 


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Chapter B-1

The pressure prevailing directly on the earth’s surface is known as at-

mospheric pressure (pamb). This pressure is also referred to as reference
pressure. The range above this pressure is known as excess pressure
range (pe > 0), the range below is referred to as vacuum range (pe < 0).
The atmospheric differential pressure pe is calculated according to the
formula:
pe = pabs – pamb

This is illustrated by the following diagram:

Fig. 1.1
Air pressure

Atmospheric pressure does not have a constant value. It varies with the
geographical location and the weather.
The absolute pressure pabs is the value relative to pressure Zero - Vac-
uum. It is equal to the sum of the atmospheric pressure and the excess
pressure or vacuum. In practice, pressure gauges which only indicate
the excess pressure are generally used. The absolute pressure value
pabs is approximately 100 kPa (1 bar) higher.
Generally, in pneumatics all data concerning air quantity refers to the so-
called standard state. According to DIN 1343, the standard state is the
status of a solid, fluid or gaseous substance defined by standard tem-
perature and pressure.
 Standard temperature Tn = 273.15 K, tn = 0 °C
 Standard pressure pn = 101325 Pa = 1.01325 bar

Festo Didactic • TP101




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 143
Chapter B-2

Pressure fluctuations in the network make it necessary to ensure that

the pipes are mounted securely in order to avoid leakages at screwed
and brazed connections.

Fig. 2.8
Air supply system

Apart from correct sizing of the piping and the quality of the pipe mate- Piping layout
rial, correct pipe layout is the decisive factor in determining the economic
operation of the compressed-air system. Compressed air is fed into the
system at intervals by the compressor. It is often the case that consump-
tion at consuming devices rises for only a short time. This may lead to
unfavourable conditions in the compressed-air network. It is therefore
recommended that the compressed-air network should be produced in
the form of a ring main. A ring main ensures largely constant pressure
conditions.

Fig. 2.9
Ring circuit

Festo Didactic • TP101

144
Chapter B-2

For ease of maintenance, repair or extension of the network without in-

terfering with the overall air supply, it is advisable to sub-divide the net-
work into individual sections. Branches with T-pieces and manifolds with
plug-in couplings make this possible. It is advisable to fit the branch lines
with standard ball valves or shut off valves.

Fig. 2.10
Interconnected network

Despite the best water separation in the pressure generating system,

pressure drops and external cooling may produce condensate in the
pipe system. In order to discharge this condensate, the pipes should be
inclined 1-2%; this can also be carried out in stages. The condensate
can then be discharged from the system via water separators at the low-
est point.

2.6 Service unit

The individual functions of compressed air preparation, i.e. filtering,

regulating and lubricating, can be fulfilled by individual components.
These functions have often been combined into one unit, i.e. the service
unit. Service units are connected upstream of all pneumatic systems.
Generally, the use of a lubricator is not necessary in advanced systems.
This is to be used for specific requirements only, primarily in the power
section of a system. Compressed air in a control section should not be
lubricated.

TP101 • Festo Didactic

 


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158
Chapter B-3

3.2 Double-acting cylinders

Fig. 3.3
Double-acting cylinder

The construction principle of a double-acting cylinder is similar to that of

the single-acting cylinder. However, there is no return spring, and the
two ports are used alternatively as supply and exhaust ports. The dou-
ble-acting cylinder has the advantage that the cylinder is able to carry
out work in both directions of motion. Thus, installation possibilities are
universal. The force transferred by the piston rod is somewhat greater
for the forward stroke than for the return stroke as the effective piston
surface is reduced on the piston rod side by the cross-sectional area of
the piston rod.

Design development Pneumatic cylinders have developed in the following directions:

 Contactless sensing requirements - hence the use of magnets on
pistons for reed switch operation
 Stopping heavy loads
 Rodless cylinders where space is limited
 Alternative manufacturing materials such as plastic
 Protective coatings against harsh environments, i.e. acid-resistant
 Increased load carrying capacity
 Robotic applications with special features such as non-rotating pis-
ton rods, hollow piston rods for vacuum suction cups

TP101 • Festo Didactic

 


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160
Chapter B-3

Tandem The tandem cylinder incorporates the features of two double-acting cyl-
double-acting cylinder inders which have been joined to form a single unit. By this arrangement
and with the simultaneous loading of both pistons, the force on the pis-
ton rod is almost doubled. This design is suitable for such applications
where a large force is required but the cylinder diameter is restricted.

Fig. 3.5
Tandem
double-acting cylinder

Cylinders with This cylinder has a piston rod on both sides, which is a through piston
through piston rod rod. The guide of the piston rod is better, as there are two bearing
points. The force is identical in both directions of movement.
The through piston rod can be hollow, in which case it can be used to
conduct various media, such as compressed air. A vacuum connection
is also possible.

Fig. 3.6
Cylinders with
through piston rod

TP101 • Festo Didactic

 


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162
Chapter B-3

Actuation of a valve causes pressure to build up in chamber A. If the

cylinder moves in direction Z, the full piston surface is exposed. The air
from chamber A is able to flow quickly via the large cross section C. The
piston is greatly accelerated.

Rotary cylinders With this design of double-acting cylinder, the piston rod has a gear-
tooth profile. The piston rod drives a gear wheel, and a rotary movement
results from a linear movement. The range of rotation varies from 45o,
90o, 180o, 270o to 360o. The torque is dependent on pressure, piston
surface and gear ratio; values of roughly up to 150 Nm are possible.

Fig. 3.9
Rotary cylinders

TP101 • Festo Didactic

 


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164
Chapter B-3

3.3 Rodless cylinders

Three different operational principles are used for the construction of

rodless cylinders:
 Band or cable cylinder
 Sealing band cylinder with slotted cylinder barrel
 Cylinder with magnetically coupled slide

Compared with conventional double-acting cylinders, rodless cylinders

are shorter in length. This eliminates the risk of a buckling piston rod and
movement can take place over the entire stroke length. The cylinder
design can be used for extremely large cylinder lengths of up to 10 m.
Devices, loads etc, can be attached directly to the mounting surface pro-
vided for this on a carriage or outer slide. The force is identical in both
directions of movement.

Band cylinder In the case of band cylinders, the piston force is transferred to a slide via
a circulating band. When leaving the piston chamber, the band passes
through a seal. In the cylinder caps, the band is reversed via guide roll-
ers. Wipers ensure that no contamination reaches the guide rollers via
the band.

Fig. 3.11
Band cylinder

TP101 • Festo Didactic

 165
Chapter B-3

With this type, the cylinder barrel is provided with a slot across the entire Sealing band cylinder
length. The force is transmitted via a slide permanently connected to the
piston. The connection from piston to slide is directed outwards via the
slotted cylinder barrel. The slot is sealed by means of a sealing band,
which seals the inside of the slot. The sealing band is guided between
the piston seals and passed under the slide. A second cover strip covers
the slot from the outside in order to prevent the ingress of dirt.

Fig. 3.12
Sealing band cylinder

Festo Didactic • TP101




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168
Chapter B-3

The materials for the double-cup packing seals (8) are:

Perbunan for – 20 °C to + 80 °C
Viton for – 20 °C to + 150 °C
Teflon for – 80 °C to + 200 °C
0-rings (9) are normally used for static sealing.

Fig. 3.15
Cylinder seals

TP101 • Festo Didactic

 169
Chapter B-3

The type of mounting is determined by the manner in which the cylinder Mounting
is to be fitted to a machine or fixture. The cylinder can be designed with
a permanent type of mounting if it does not have to be altered at any
time. Alternatively, the cylinder can utilise adjustable types of mounting
which can be altered at a later date by using suitable accessories on the
modular construction principle. This results in considerable simplification
in storage, especially where a large number of pneumatic cylinders are
used as only the basic cylinder and optional mounting parts need to be
stored.

Fig. 3.16
Mounting arrangements
for cylinders

The cylinder mounting and the piston rod coupling must be matched
carefully to the relevant application since cylinders must be loaded only
in the axial direction.

Festo Didactic • TP101




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172
Chapter B-3

Stroke length The stroke lengths of pneumatic cylinders should not be greater than
2 m and for rodless cylinders 10 m.
With excessive stroke lengths the mechanical stress on the piston rod
and on the guide bearings would be too great. To avoid the danger of
buckling, the buckling diagram should be observed with large stroke
lengths.

Fig. 3.18
Buckling diagram

TP101 • Festo Didactic

 


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174
Chapter B-3

Air consumption For the preparation of the air, and to obtain facts concerning power
costs, it is important to know the air consumption of the system. The air
consumption is specified in litres of air drawn in per minute. For a par-
ticular operating pressure, piston diameter, stroke and stroke number,
the air consumption is calculated by:
Air consumption =
Compression ratio • Piston surface • Stroke • Stroke number per minute
101.3 + Operating pressure (in kPa)
Compression ratio =
101.3

Fig. 3.20
Air consumption chart

The formulae for the calculation of air consumption in accordance with

the air consumption diagram are as follows:
for single-acting cylinders
qB = s • n • qH

for double-acting cylinders

qB = 2 • s • n • qH

qB = Air consumption (l/min)

s = Stroke (cm)
n = Number of strokes per minute (1/min)
qH = Air consumption per cm of stroke (l/cm)

TP101 • Festo Didactic

 


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176
Chapter B-3

3.6 Motors

Devices which transform pneumatic energy into mechanical rotary

movement with the possibility of continuous motion are known as pneu-
matic motors. The pneumatic motor with unlimited angle of rotation has
become one of the most widely used working elements operating on
compressed air. Pneumatic motors are categorised according to design:
 Piston motors
 Sliding-vane motors
 Gear motors
 Turbines (high flow)

Fig. 3.21
Air motor

Piston motors This type of design is further subdivided into radial and axial piston mo-
tors. The crank shaft of the motor is driven by the compressed air via
reciprocating pistons and connecting rods. To ensure smooth running
several pistons are required. The power of the motor depends on input
pressure, number of pistons, piston area, stroke and piston speed.
The working principle of the axial piston motor is similar to that of the
radial piston motor. The force from 5 axially arranged cylinders is con-
verted into a rotary motion via a swash plate. Compressed air is applied
to two pistons simultaneously, the balanced torque providing smooth
running of the motor.
These pneumatic motors are available in clockwise or anti-clockwise
rotation. The maximum speed is around 5000 rpm, the power range at
normal pressure being 1.5 - 19 kW (2 - 25 hp).

TP101 • Festo Didactic

 


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Chapter B-6

Analogue control system Form of information

A control system which operates predominantly with analogue signals representation
within the signal processing section. Signal processing is effected pri-
marily with continuously acting function elements.

Digital control system

A control system which operates chiefly using numerical digital signals
within the signal processing section. The information is represented nu-
merically. The function units are: Counters, registers, memories, arith-
metic units.

Binary control system

A control system which operates predominantly with binary signals
within the signal processing section and where the signals are not part
of numerically represented data.

Fig. 6.2
Differentiation between the
control systems: in the
form of representation of
information

Festo Didactic • TP101




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242
Chapter B-6

Fluidic Muscle The Fluidic Muscle is a membrane contraction system. An impervious,

flexible tube is covered with tightly woven threads in a diamond-shaped
pattern. This creates a three-dimensional grid structure. The air flowing
inwards deforms the grid structure. A tensile force is generated in the
axial direction, which causes a contraction of the muscle in the event of
increasing internal pressure.
In the extended state, the Fluidic Muscle generates up to ten times more
force than a conventional pneumatic cylinder and uses only 40% of the
energy while offering the same force. A third of the diameter is sufficient
for the same force, while the stroke is shorter for the same overall
length.

Fig. 6.16
Application example with
the Fluidic Muscle

Handling technology Handling and assembly operations frequently require components that
can perform movements in two or three different directions. This sector
was previously dominated by special designs. Today, standard handling
modules that can be combined for specific applications are being used
more and more.

TP101 • Festo Didactic

 


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