Electro-hydraulics

Exercise
Basic Level
FESTECH Education

Table of Contents

Introduction ......................................................................................................... 4

Notes on safety and operation ............................................................................ 6

Symbols for equipment set .................................................................................. 9

Chapter 1. Installation and setting

1.1 General information and specification ........................................................... 15

1.2 Initial setting procedure ................................................................................. 19

1.3 Pressure setting ............................................................................................ 20

1.4 Exercise procedure ....................................................................................... 24

Chapter 2. Practice

Project 1: Lamp control ....................................................................................... 28

Project 2: Relay control and self-holding ............................................................. 32

Project 3: Cylinder control with a single solenoid valve ....................................... 35

Project 4: Cylinder control with a double solenoid valve ...................................... 38

Project 5: Cylinder control using self-holding circuit ............................................ 40

Project 6: Cylinder control by logic ...................................................................... 44

Project 7: Cylinder control with a timer ................................................................ 47

Chapter 3. Applications

Exercise 1: Sorting device .................................................................................. 55

Exercise 2: Component selection on conveyor belt ............................................. 58

Exercise 3: Lifting station .................................................................................... 61

Exercise 4: Bending device ................................................................................. 64

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Exercise 5: Press-fitting device ........................................................................... 67

Exercise 6: Stamping machine ............................................................................ 70

Exercise 7: Door control...................................................................................... 73

Exercise 8: Machining unit .................................................................................. 77

Exercise 9: Feed for drilling machine .................................................................. 80

Exercise 10: Press .............................................................................................. 84

Exercise 11: Feed device .................................................................................... 87

Exercise 12: Assembly device ............................................................................. 91

Exercise 13: Lifting device for packages ............................................................. 95

Chapter 4. Solutions

Solution 1: Sorting device ................................................................................. 100

Solution 2: Component selection on conveyor belt............................................ 104

Solution 3: Lifting station ................................................................................... 108

Solution 4: Bending device ............................................................................... 112

Solution 5: Press-fitting device .......................................................................... 116

Solution 6: Stamping machine ........................................................................... 120

Solution 7: Door control .................................................................................... 124

Solution 8: Machining unit ................................................................................. 128

Solution 9: Feed for drilling machine ................................................................. 133

Solution 10: Press............................................................................................. 138

Solution 11: Feed device ................................................................................... 142

Solution 12: Assembly device ........................................................................... 147

Solution 13: Lifting device for packages ............................................................ 152

Appendix. Datasheets

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Introduction

Hydraulics has some main features. It can realize high precision with non-compressed
fluid and get high power due to the high pressure. So it is usually used in steel
manufacturing, casting and extruding as well as machine tools and heavy equipments.

Hydraulics training set of FESTECH is composed of industrial parts which are used in
real field. Especially it was developed for clean training without leakage that was a
main disadvantage of hydraulic training course.

This training set could be used on basic control and advanced control of hydraulics
based on basic principle and actual cases. Also proportional and servo control is
possible with adding some additional components.

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Training Contents

The following training contents are covered:

- Basic physical principles of electric engineering and hydraulics

- Function and use of electrical and electro-hydraulic components such as switches,
push-buttons and solenoid valves
- Naming and reading of electrical and hydraulic symbols
- Development and reading of standard circuit diagrams
- Representation of control exercises as function diagrams
- Drafting, assembly and commissioning of basic circuits
- Direct and indirect activation of cylinders
- Activation of a hydraulic motor
- Position and pressure-dependent control circuits
- Interlock circuit
- Fault-finding with simple electro-hydraulic control circuits

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Notes on safety

Observe the following in the interests of your own safety:

*Caution!
Cylinders may move unexpectedly when the hydraulic power pack is switched on.

*Do not exceed the maximum permissible hydraulic operating Pressure.

See the relevant data sheets.

*Do not operate electrical limit switches directly by hand when carrying out fault-finding.
Use a tool for this.

*Use only an extra-low voltage of 24 V to operate the components.

*Observe all general safety instructions.

[Electrical Danger]

[Warning]

[Caution]

[Note]

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Notes on operation
Always work in the following sequence when assembling or dismantling an electro-
hydraulic circuit.

Assembly
1. The hydraulic power pack and electrical power supply must be switched off during
the assembly of the circuit.
2. All components must be securely fitted to the profile plate or mounting frame.
3. Connect up the hydraulic hose lines.
All valves, other components and hose lines are fitted with self-closing quick-acting
couplings.
Do not exceed the maximum permissible pressure of 12 MPa (120 bar).
The maximum operating pressure is 6 MPa (60 bar).
4. Connect up the electrical cables.
Connect test leads to the component sockets by means of 4 mm plugs.
5. Before commissioning a hydraulic control circuit, check that all return lines are
connected and that all connectors are secure.
6. Switch on the electrical power supply first and then the hydraulic power pack.
7. Commissioning the control circuit
- Press the START pushbutton
- Set components, etc.
-Compare what you have assembled with the description in the book.

Dismantling
8. Before dismantling the circuit, ensure that pressure in hydraulic components has
been released:
Couplings must be disconnected only under zero pressure!
9. Switch off the hydraulic power pack first and then the electrical power supply.

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Electrical

Power supply:
220 V AC, 60 Hz
- The hydraulic power pack is protected by a 15 A fuse.
- The short-circuit proof electrical power supply has a 5 A fuse.
- The output voltage of this power supply is 24 V DC.
- The output current is limited to a maximum of 5 A.

Wiring:
Universal cable set: red and blue laboratory cables in 4lengths.
All electro-hydraulic components are equipped with 4 mm sockets.
The electrical connections for these components are made using the laboratory cables
with 4 mm plugs.

Function wiring:
All electro-hydraulic components are also equipped with sockets to allow the wiring of
functions.
This considerably reduces the assembly time required and the risk of incorrect
connections.
A distinction should be made between the two designs of electrical limit switches:
- Electrical limit switch, actuated from the left
- Electrical limit switch, actuated from the right
- When cylinder piston speeds are high, the limit switches should be actuated by
cylinder cams only in the specified direction.
- Limit switches must not be actuated from the front.
- Both types of limit switches are shown by the same symbol in the hydraulic and
electrical circuit diagrams.

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Symbol for equipment set electro-hydraulics

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Chapter 1. Installation and setting

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1.1 General Information and specification

1.1.1 Feature of hydraulics working table

Overload protector Electric mounting bar

Profile working panel

Measuring container

Cabinet(drawer)
Hydraulic power unit

▪ Specification of hydraulics working table

Subject Description

Size 1600 * 750 * 1700 (mm)

Weight 162Kg(2 cabinets) without power pack
Frame Aluminum
Cabinet 4 drawers with key lock
Castor 6 castors with push lock
Table board Steel

Note: Hydraulic working table should be installed on flat ground and lock the brakes on each
castors.

※ Specifications and appearances are subject to change without prior notice.

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1.1.2 Feature of hydraulic power unit

AC Motor pump

Main Drain hole

Pressure gauge

Level & Temperature meter

Tank

▪ Specification of Power Unit

Subject Description

Motor power AC 220, 50Hz, 1.8 KW

TYPE M90 BL4
KL F
CB 80MF
IP 54
Type Gear pump
flow rate 4 ℓ/min
pressure 5 ~ 60 kg/㎠
Tank capacity 35 ℓ
Tank size 580 X 330 X 200
Oil Type General hydraulic oil (ISO VG 32)

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▪ Front view

SUPPLY 2
SUPPLY 1

DRAIN 1

DRAIN 2

▪ Rear view

The main drain hole is connected to the measuring container(15020) with a plastic hose.

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Figure: Bottom side of measuring

container
(Usually all the drain lines are connected
to the measuring container when the
hydraulic circuit is composed on to the
profile panel.)

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1.2 Initial setting procedure

1.2.1 Oil filling

Method 1:
1. Fill general hydraulic oil about 30 litters through the main drain hole using a funnel.
2. Then connect the PVC hose with drain hole and measuring container.

Method 2 (Recommended):
1. Loose the 3 small bolts on top of measuring container.
2. Remove the cover of container.
3. Pour hydraulic oil into the container.

1.2.2 Electric power connection

1. Connect the power plug of hydraulic motor pump with overload protector.
2. Supply the main power through the overload protector.
3. Turn on the main switch of protector to use hydraulic power unit.

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1.3 Pressure setting

Typically initial pressure is set to 6MPa (60 bar) by manufacturer. But if you want to increase or
decrease the pressure, please follow next procedure:

1. Loose the hex nut with 17mm spanner.

2. If the hex nut is removed, there is a thin hex nut.

3. Loose the thin hex nut slightly.

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4. Turn on the power and adjust the screw slowly with a slotted head driver.

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5. Adjust the pressure until the pressure gauge indicates 50~60 bar.

6. Tighten the thin nut with a spanner.

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7. Tighten up the outside nut with the same spanner.

Note: These are procedures to regulate pressure relief valve which is inside of motor pump.
After initial pressure setting, adjust pressure using a pressure relief valve(15050).
Please refer to the next page to see the typical procedure of practical training.

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1.4 Exercise procedure

1. Hydraulic power

Connect the P line from power pump unit(15010).

Left 3 fittings are P and right 3 fittings are T. They are internally connected respectively.

Note1: P means Power and T means Tank(drain).

Note2: If you don’t have distributor, you can use the output port of Power Pump as a P line and
the measuring container(15020) as a T line.

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2. Pressure relief valve and gauge

Attach the Pressure relief valve(15050) first and plug in pressure gauge(15070) on the P port.

After connecting a T connector(15066) on pressure gauge, connect one of the P port of

distributor and T connector.

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3. Valve and cylinder

Attach a 4/2-way single solenoid valve(16012) and double acting cylinder(15031).

And then connect the hose from T connector to P port of solenoid valve. Also, A port connected
to the rear side and B port connected to the front side of cylinder.

Lastly, T port of solenoid valve is connected to T port of distributor or measuring container.

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4. Limit switch(13051, 13052)

Note: There are directions in Limit switch.

5. Electrical wiring

Connect the cable according to the electric circuit on next page.

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▶Electric circuit diagram

Note1: K1 represents a relay and Y1 represents solenoid valve.

Note2: Use N.O(normally open) of S1 and N.C(normally closed) contact of S2.

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6. Power on and regulating

Turn on the hydraulic power using overload protector and DC power supply.
The initial condition of cylinder is retracted.
Regulate the main pressure by means of turning the knob right and left direction.
Push the push-button and watch out if the cylinder moves correctly.

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Chapter 2. Practice

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Project 1 : Lamp control

Duration 1 hour

Training aim 1. Control of a lamp by electric contact and basic logic

2. Understanding and drawing electric circuit
3. Installing and commissioning electric components

Required part list

Item / Order no. QTY’ Image

Power supply 1
13090

Push-button switch set 1

13033

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Electric circuit diagram

(1)A lamp should be turned ON when press the pushbutton switch.

S1

L1

(2)A lamp should be turned OFF when press the pushbutton switch.

S1

L1

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Electric circuit diagram

(3)Lamp L1 should be ON when two pushbutton switches S1 and S2 are pressed both.

AND control logic

1

S1

S2

램램
L1

(4)Lamp L1 should be ON when pushbutton switches S1 or S2 is pressed.

OR control logic
1 2

S1 S2

램램
L1

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Electric circuit diagram

(5)A lamp is to light up, when the pushbuttons S1, S2 and not S3 or the pushbuttons
S4 and S5 are pressed.
If one of the combinations are not fulfilled the lamp must go off.

Logic combination
1 2

S1 S4

S1
S2 S5

S3

램램
L1

Procedure
1. Understanding about structure of each electric contact, function
and symbol
2. Compose system according to the circuit diagram
3. Wire electric cables according to the circuit diagram
4. Turn on the DC power supply
5. Commission and check the system
6. Turn off the electric power after training
7. Dismantle and arrange the components

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Project 2 : Relay control and self-holding

Duration 2 hours

Training aim 1. Understanding structure and feature of a relay

2. Drawing electric relay circuit
3. Installing and commissioning electric components

Required part list

Item / Order no. QTY’ Image

Power supply 1
13090

Push-button switch set 1

13033

Relay unit 1
13030

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Electric circuit diagram

(1)A lamp should be turned on using relay.

+24V 1 2

S1 K1

K1 L1
0V

Procedure
1. Understanding about structure of each electric contact, function
and symbol
2. Compose system according to the circuit diagram
3. Wire electric cables according to the circuit diagram
4. Turn on the DC power supply
5. Commission and check the system
6. Turn off the electric power after training
7. Dismantle and arrange the components

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Electric circuit diagram

(2)When press switch S1, lamp L1 should be turned on continuously. Lamp L1 goes
off by switch S2.

a. Self-holding circuit (Dominant ON)

+24V 1 2 3

S1 K1 K1
Set
S2
Reset

K1 L1
0V

b. Self-holding circuit (Dominant OFF)

+24V 1 2 3

S1 K1 K1
Set

S2
Reset

K1 L1
0V

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Project 3 : Cylinder control with a single-solenoid valve

Duration 2 hours

Training aim 1. Understanding structure and feature of a single-solenoid valve

2. Control of single-acting and double-acting cylinder
3. Installing and commissioning electric components

Required part list

Item / Order no. QTY’ Image

Same as Exercise 2 1

Single-acting cylinder 1
15030

Double-acting cylinder 1
15031

3/2-way solenoid valve 1

16011

4/2-way solenoid valve 1

16012

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Hydraulic and electric circuit diagram

(1) Single-acting cylinder

SOL1

PB1 SOL1

Procedure
1. Understand about structure of each component
2. Prepare the required parts according to the above list
3. Compose system according to the circuit diagram
4. Check the connection part and any leakage of oil
5. Turn on the hydraulic power and DC power supply
6. Push the push-button PB1 for 1 second
7. Push the push-button PB1 and hold for a while
8. Record the result and discuss about it
9. Turn off the power after practice
10. Dismantle and arrange the components

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Hydraulic and electric circuit diagram

(2) Double-acting cylinder

회로도1

SOL1

PB1 SOL1

Procedure
1. Understand about structure of each component
2. Prepare the required parts according to the above list
3. Compose system according to the circuit diagram
4. Check the connection part and any leakage of oil
5. Turn on the hydraulic power and DC power supply
6. Push the push-button PB1 for 1 second
7. Push the push-button PB1 and hold for a while
8. Record the result and discuss about it
9. Turn off the power after practice
10. Dismantle and arrange the components

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Project 4 : Cylinder control with a double-solenoid valve

Duration 1 hour

Training aim 1. Understanding structure and feature of a double-solenoid valve

2. Installing and commissioning electric components

Required part list

Item / Order no. QTY’ Image

Same as project 2 and 1

essential components
Double-acting cylinder 1
15031

4/2-way double solenoid 1

valve
16013

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Hydraulic and electric circuit diagram

회로도1

SOL1 SOL2

PB1 SOL1

PB2 SOL2

Procedure
1. Understand about structure of each component
2. Prepare the required parts according to the above list
3. Compose system according to the circuit diagram
4. Check the connection part and any leakage of oil
5. Turn on the hydraulic power and DC power supply
6. Push the push-button PB1 for 1 second
7. Push the push-button PB2 for 1 second
8. Push the push-button PB1 and hold for a while
9. Push the push-button PB2 and hold for a while
10. Record the result and discuss about it
11. Turn off the power after practice
12. Dismantle and arrange the components

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Project 5 : Cylinder control using self-holding circuit

Duration 2 hours

Training aim 1. Understanding of electric self-holding

2. Control of continuous cycle of cylinder movement
3. Installing and commissioning electric components

Required part list

Item / Order no. QTY’ Image

Same as project 2 and 1

essential components
Double-acting cylinder 1
15031

4/2-way solenoid valve 1

16012

4/3-way double solenoid 1

valve (PT connected)
16016

Electric limit switch (left) 1

13051

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Electric limit switch (right) 1

13052

Hydraulic and electric circuit diagram

(1)Single solenoid valve

A LS1

SOL1

PB1
LS1
CR1

CR1

CR1 SOL1

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Hydraulic and electric circuit diagram

(1)4/3-way double solenoid valve

A LS1 LS2

SOL1 SOL2

PB1 CR2
CR1

CR1

LS2
CR2

CR2
LS1
CR3

CR3

CR1 SOL1

CR3 SOL2

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Procedure
1. Understand about structure of each component
2. Prepare the required parts according to the above list
3. Compose system according to the circuit diagram
4. Check the connection part and any leakage of oil
5. Turn on the hydraulic power and DC power supply
6. Push the push-button PB1 for 1 second
7. Push the push-button PB1 and hold for a while
8. Record the result and discuss about it
9. Turn off the power after practice
10. Dismantle and arrange the components

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Project 6 : Cylinder control by logic

Duration 2 hours

Training aim 1. Understanding of electric logic operation

2. To know about proximity sensors
3. Installing and commissioning electric components

Required part list

Item / Order no. QTY’ Image

Same as project 2 and 1

essential components
Double-acting cylinder 1
15031

4/2-way solenoid valve 1

16012

Inductive sensor 1
13040

Capacitive sensor 1
13041

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Optical sensor 1
13042

Hydraulic and electric circuit diagram

SOL1

a b c
K1 K1 K2

K2 K3 K3

A1 A1 A1
K1 K2 K3 Y1
A2 A2 A2

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Procedure
1. Understand about structure of each component
2. Prepare the required parts according to the above list
3. Compose system according to the circuit diagram
4. Check the connection part and any leakage of oil
5. Turn on the hydraulic power and DC power supply
6. Push the push-button a, b and c individually and observe the
operation of cylinder
7. Push 2 push-buttons optionally and observe the operation of
cylinder
8. Push all push-buttons at the same time and observe the
operation of cylinder
9. Record the result and discuss about it
10. Change the push-buttons into sensors and repeat procedure
from number 6.
11. Turn off the power after practice
12. Dismantle and arrange the components

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Project 7 : Timer

Duration 2 hours

Training aim 1. Understanding the functions and features of timer

2. To know about concept of on-delay and off-delay
3. Installing and commissioning electric components

Required part list

Item / Order no. QTY’ Image

Same as project 2 and 1

essential components
Double-acting cylinder 1
15031

4/2-way solenoid valve 1

16012

Digital time relay 1

13031

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Hydraulic and electric circuit diagram

(1)On-delay timer

LS1

SOL1

PB1
T
CR1 1

CR1
2

LS1
T 3

CR1 SOL1
4

[ ladder circuit ]

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1 2 3 4

13 23
PB K1 K1
14 S1 24

K2

K1 K2 Y1

[ ISO circuit ]

Procedure
1. Understand about structure of each component
2. Prepare the required parts according to the above list
3. Compose system according to the circuit diagram
4. Check the connection part and any leakage of oil
5. Turn on the hydraulic power and DC power supply
6. Push the push-button PB1 and observe the operation of
cylinder
7. Change the timer value and test it
8. Record the result and discuss about it
9. Turn off the power after practice
10. Dismantle and arrange the components

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Hydraulic and electric circuit diagram

(2)Off-delay timer

PB1
T 1

PB2
2

SOL1
T
3

[ ladder circuit ]

1 2 3 4

S1 S2 K1

A1
K1 Y1
A2

[ ISO circuit ]

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Procedure
1. Understand about structure of each component
2. Prepare the required parts according to the above list
3. Compose system according to the circuit diagram
4. Check the connection part and any leakage of oil
5. Turn on the hydraulic power and DC power supply
6. Push the push-button PB1 and PB2, and observe the operation
of cylinder
7. Change the timer value and test it
8. Record the result and discuss about it
9. Turn off the power after practice
10. Dismantle and arrange the components

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Chapter 3. Applications

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Simple control circuits without limit switches

Exercise 1: Sorting device

Double-acting cylinder, directly actuated, manually

Exercise 2: Component selection on conveyor belt

Double-acting cylinder, directly actuated, manually

Exercise 3: Lifting station

Single-acting cylinder, directly actuated, manually

Exercise 4: Bending device

Double-acting cylinder, latching

Exercise 5: Press-fitting device

Double-acting cylinder, latching, return stroke using pressure switch

Exercise 6: Stamping machine

Double-acting cylinder, differential circuit

Exercise 7: Door control

Double-acting cylinder, interlock, INCHING operation

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Control circuits with limit switches

Exercise 8: Machining unit
Differential circuit, return stroke using limit switch

Exercise 9: Feed for drilling machine

Rapid-traverse feed circuit, speeds controlled by limit switch

Exercise 10: Press

Pressure control circuit with limit switch and pressure switch

Exercise 11: Feed device

Pressure less pump bypass with limit switch

Control circuits with two actuators

Exercise 12: Assembly device

Pressure-dependent sequence control with cylinder and hydraulic motor

Exercise 13: Lifting device for packages

Position-dependent sequence control with two cylinders

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Exercise 1

Sorting device

A sorting device is used to sort heavy steel work pieces.

When a START pushbutton is pressed, the piston rod of a double acting cylinder pushes
the adjacent work piece off the conveyor belt.
When the START pushbutton is released, the piston rod returns to its retracted end
position.

Parameter
Only a small number of hydraulic and electrical components should be used.

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WORKSHEET

Complete the hydraulic circuit diagram.

Complete the list of hydraulic components.

Qty Description
Hydraulic power pack

Cylinder
Hose line with quick-release coupling, 600 and 1000

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WORKSHEET

Complete the electrical circuit diagram.

Complete the list of electrical components.

Qty. Description
Push button switch set
Cable set
Power supply unit

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Exercise 2

Component selection on conveyor belt

A double-acting cylinder is used to push unsealed cartons from one conveyor onto
another.
The advance stroke of the cylinder is manually controlled.
The advance-stroke speed is adjustable, while the return-stroke speed is fixed.
The pressure should be measured upstream of the cylinder and of the directional control
valve.

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WORKSHEET

Complete the hydraulic circuit diagram.

Complete the list of hydraulic components.

Qty. Description
Hydraulic power pack
Pressure gauge
Pressure relief valve

T Connector (Branch tee)

Hose line with quick-release coupling, 600 and 1000

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WORKSHEET

Complete the electrical circuit diagram.

Complete the list of electrical components.

Qty. Description

Pilot lamp & buzzer unit

Cable set
Power supply unit

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Exercise 3

Lifting station

Crates arriving on a conveyor belt must be raised to the height of a packing conveyor by
means of a lifting table. The raising and lowering of the lifting table are to be controlled
manually by means of a single-acting hydraulic cylinder.

The advance stroke is adjustable, while the return stroke cannot be adjusted and is
governed by the weight of the lifting table. The pressure should be measured upstream
of the cylinder and of the directional control valve.

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WORKSHEET

Complete the hydraulic circuit diagram.

Complete the list of hydraulic components.

Qty. Description
Hydraulic power pack
Pressure gauge

Loading weight, 9 kg
T Connector (Branch tee)
Hose line with quick-release coupling, 600 and 1000

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WORKSHEET

Complete the electrical circuit diagram.

Complete the list of electrical components.

Qty. Description
Relay unit, 3-fold
Pushbutton switch set
Pilot lamp & buzzer unit
Cable set
Power supply unit

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Exercise 4

Bending device

A bending device with a double-acting cylinder is used to produce U- Shaped sheet-

metal work pieces.
The start signal for this operation is given by a pushbutton.
After the work piece has been shaped, a second pushbutton is used to initiate the return
stroke of the cylinder.
No provision will be made in this exercise for the safety devices required in normal
practice. The advance and return strokes must be executed at a slow adjustable speed.
What type of flow control valve should you use to allow the speed to be adjusted
independently of load?

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WORKSHEET

Complete the hydraulic circuit diagram.

Complete the list of hydraulic components.

Qty. Description

Exercise - Basic level Electro Hydraulics | 65

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WORKSHEET

Complete the electrical circuit diagram.

Complete the list of electrical components.

Qty. Description

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Exercise 5
Press-fitting device

A press-fitting device is to be used to assemble work pieces.

If the preset press pressure is exceeded (for example, because work pieces are
incorrectly aligned), the piston rod must be retracted for safety reasons.
After a correct press-fitting operation, the return stroke should be initiated when the
value preset on the pressure switch of 3MPa (30 bar) is reached. A one-way flow
control valve is fitted in the supply line of the cylinder. Describe the point in time after
the circuit is switched on at which the pressure switch is triggered if the pressure is
measured upstream of the throttle valve.
What is the correct point at which to measure the pressure?

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WORKSHEET

Complete the hydraulic circuit diagram.

Complete the list of hydraulic components.

Qty. Description

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WORKSHEET

Complete the electrical circuit diagram.

Complete the list of electrical components.

Qty. Description

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Exercise 6

Stamping machine

A hydraulic power pack with a very low pump delivery rate is all that is available to
operate a stamping machine.
A suitable circuit must be used to increase the advance-stroke speed.
The power pack output is sufficient to allow this.

Note
A flow control valve is installed at a suitable point in the circuit.
This reduces the flow rate to the cylinder.

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WORKSHEET

Complete the hydraulic circuit diagram.

Complete the list of hydraulic components.

Qty. Description

Exercise - Basic level Electro Hydraulics | 71

FESTECH Education

WORKSHEET

Complete the electrical circuit diagram.

Complete the list of electrical components.

Qty. Description

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Exercise 7

Door control

A double-acting hydraulic cylinder is used to open and close a furnace door.

INCHING operation allows the door to be driven to any desired intermediate position.
The cylinder is hydraulically clamped in all such positions.

Exercise - Basic level Electro Hydraulics | 73

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WORKSHEET

Complete the hydraulic circuit diagram.

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WORKSHEET

Complete the list of hydraulic components.

Classify the components by stating whether they are non-return valves, pressure valves,
flow control valves, directional control valves, actuators, or other hydraulic components.

Qty. Description
1 Hydraulic power pack

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WORKSHEET

Complete the electrical circuit diagram.

Complete the list of electrical components.

Qty Description

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Exercise 8

Machining unit

The edges of work pieces must be chamfered. It has been possible to reduce the
machining time by using improved tools.
The feed speed is therefore to be increased by using a differential circuit.
The clamping device can accept up to 5 work pieces at the same time.
In order to reduce the working stroke when the number of work pieces is less than 5, the
cylinder return stroke is to be initiated by an adjustable limit switch.

Note
Install a flow control valve at a suitable point in the circuit so that the effect of the
differential circuit can clearly be seen.

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WORKSHEET
Complete the hydraulic circuit diagram.

Complete the list of hydraulic components.

Qty. Description

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WORKSHEET

Complete the electrical circuit diagram.

S1, S2= Limit switches

S3: = START pushbutton

Complete the list of electrical components.

Qty. Description

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Exercise 9

Feed for drilling machine

The feed of a drilling machine is to be automated.

When carrying out drilling with large-diameter drilling bits, it is necessary to achieve
constant feed characteristics and a finely-adjustable feed speed.
The machine is therefore to be equipped with hydraulic feed, which must provide a
rapid-traverse feed motion and a infinitely-adjustable working feed motion. The return
stroke is to be initiated by pressing a second pushbutton. During this phase, the flow
control valve is to be bypassed by means of a non-return valve.

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WORKSHEET

Complete the function diagram.

S1, S2 = Limit switches

S3 = START pushbutton
S4 = RETURN pushbutton

Exercise - Basic level Electro Hydraulics | 81

FESTECH Education

WORKSHEET

Complete the hydraulic circuit diagram.

Complete the list of hydraulic components.

Qty. Description

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WORKSHEET

Complete the electrical circuit diagram.

S1, S2 = Limit switches

S3 = START pushbutton
S4 = RETURN pushbutton

Complete the list of electrical components.

Qty. Description

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Exercise 10

Press

A hydraulic press is used to shape work pieces.

An initial pressure of p1 = 1.5 MPa (= 15 bar) is used to shape the material slowly.
After a press stroke of approx. 100 mm, a switchover must be made as a function of
position to a higher pressure of p2 = 4 MPa (= 40 bar).
After the pressing operation is complete, the pressure rises to the maximum value set on
the pressure switch, p3 = 5 MPa (= 50 bar).
When this value is reached, the pressure switch initiates a return stroke of the press. The
flow rate is to be adjustable by means of a flow control valve.

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WORKSHEET

Complete the hydraulic circuit diagram.

Complete the list of hydraulic components.

Qty. Description

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WORKSHEET

Complete the electrical circuit diagram.

S1 = START pushbutton
S2 = Limit switch
B1 = Pressure switch

Complete the list of electrical components.

Qty. Description

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Exercise 11

Feed device

A double-acting hydraulic cylinder is used to eject pressed forgings from a metal tool.
The cooling time of the forgings has increased considerably due to the fact that a
different material is now being used.
To prevent an unnecessary rise in the temperature of the hydraulic fluid, the circuit must
be switched to pressure less pump bypass after the ejection operation.

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WORKSHEET

Complete the function diagram.

S1 = START pushbutton
S2, S3 = Limit switches

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 FESTECH Education

WORKSHEET

Complete the hydraulic circuit diagram.

Complete the list of hydraulic components.

Qty. Description

Exercise - Basic level Electro Hydraulics | 89

FESTECH Education

WORKSHEET

Complete the electrical circuit diagram.

S1= START pushbutton

S2, S3= Limit switches

Complete the list of electrical components.

Qty. Description

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Exercise 12

Assembly device

An assembly device is used to press-fit a plastic bush into steel Work piece. A screw is
then inserted to secure the connection.
When the START pushbutton S1 is pressed, the vertical double-acting press cylinder A
presses the plastic bush into the steel work piece.
When the pressure in the piston chamber of the press cylinder reaches 4.5 MPa (45 bar),
the horizontal hydraulic motor screws in the left hand threaded coarse-pitch screw.
When the RETURN pushbutton S2 is pressed, the press cylinder A retracts and the
motor M stops.

Parameters
The cylinder must not slip when the hydraulic power pack is switched off.
Measures must be taken to ensure that the motor cannot rotate clockwise under any
circumstances.
The speed of the press-fitting motion of the cylinder must be adjustable.
A visual indicator must show the position of the detente RETURN pushbutton S2. The
visual indicator must not go out, allowing a restart, until the switch has been unlocked.

Exercise - Basic level Electro Hydraulics | 91

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WORKSHEET

Plot the function lines in the function diagram.

S1 = START pushbutton
S2 = RETURN pushbutton
B1 = Pressure switch, p1 = 2.5 MPa = 25 bar

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WORKSHEET

Complete the hydraulic circuit diagram.

Complete the list of hydraulic components.

Qty. Description

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FESTECH Education

WORKSHEET

Complete the electrical circuit diagram.

Complete the list of electrical components.

Qty. Description

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Exercise 13

Lifting device for packages

Packages are fed in by means of a gravity roller conveyor X and are lifted by cylinder A.
Cylinder B then ejects the packages onto roller conveyor Y for further transport.
Following this, the two double-acting cylinders return to their initial positions.

Exercise - Basic level Electro Hydraulics | 95

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WORKSHEET

Plot the signal lines in the function diagram.

S = START pushbutton
S1, S2, S3, S4 = Limit switches

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 FESTECH Education

WORKSHEET

Complete the hydraulic circuit diagram.

Complete the list of hydraulic components.

Qty. Description

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FESTECH Education

WORKSHEET

Complete the electrical circuit diagram.

S = START pushbutton
S1, S2, S3, S4= Limit switches

Complete the list of electrical components.

Qty. Description

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Chapter 4. Solution

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Solution 1: Sorting device

Double-acting cylinder, directly actuated, manually

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Solution description

When the START pushbutton S is pressed, the circuit for the solenoid coil Y is closed
and the 4/2-way solenoid valve is reversed.
The piston rod of the double-acting cylinder advances to its forward end position.
When the pushbutton S is released, the circuit for solenoid coil Y is interrupted and the
4/2-way solenoid valve returns to its initial position.
The piston rod of the cylinder returns to its retracted end position.

* Note on hydraulic circuit diagram

Components are shown in this diagram by symbols.
The 4/2-way solenoid valve is shown in the circuit diagram with
- the parallel position on the left and
- the crossover position on the right.
This means that there are no intersecting lines in the circuit diagram.

* Note on electrical circuit diagram

In circuits with direct actuation, without relays, the control and power circuits are not
separate.

* Note on "Practical assembly, hydraulic" drawing

Components are also shown in the "Practical assembly, hydraulic" drawing by
symbols.
The 4/2-way solenoid valve is shown in the same way as the symbol on the valve
itself.
- Parallel position on the right
- Crossover position on the left
A line intersection thus occurs in the "Practical assembly, hydraulic" drawing.

* Electrical components can also be mounted in the mounting frame if desired.

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Practical assembly, hydraulic

Components list, hydraulic

Item no Qty. Description

1 1 Hydraulic power pack
2 1 4/2-way solenoid valve
3 1 Cylinder
– 4 Hose line with quick-release coupling
600 and 1000

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Practical assembly, electrical

Components list, electrical

Qty. Description
1 Push-button switch set
1 Cable set, universal
1 Electrical power supply unit

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Solution 2: Component selection on conveyor belt

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Solution description

When the START pushbutton S1 is pressed, the relay K1 is energized.

The normally-open contact K1 supplies current to the solenoid coil Y1 and the 4/2-way
solenoid valve is reversed.
This causes the piston rod of the cylinder to advance. As soon as the START
pushbutton S1 is released, the piston rod retracts again.
The piston rod cannot stop in the vicinity of the conveyor system if S1 is not pressed.
The one-way flow control valve can be used to adjust the advance-stroke speed.

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Practical assembly, hydraulic

Components list, hydraulic

Item no. Qty. Description
1 1 Hydraulic power pack
2, 2.1 2 Pressure gauge
3 1 Pressure relief valve
4 1 4/2-way solenoid valve
5 1 One-way flow control valve
6 1 Cylinder
– 2 T connectors (Branch tee)
– 5 Hose line with quick-release coupling,
600 and 1000

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Practical assembly, electrical

Components list, electrical

Qty. Description
1 Relay unit
1 Push-button switch set
1 Pilot lamp & buzzer unit
1 Cable set, universal
1 Electrical power supply unit

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Solution 3: Lifting station

Circuit diagram, hydraulic

Circuit diagram, electrical

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Solution description

When the START pushbutton S1 is pressed, the relay K1 is energized.

The normally-open contact K1 supplies current to the solenoid coil Y1 of the 3/2-way
solenoid valve. The piston rod now advances.
When the pushbutton S1 is released, the circuit with K1 and Y1 is interrupted, the valve
closes by spring force and the piston rod retracts due to the loading weight. The
advance-stroke speed can be adjusted by means of the one-way flow control valve.

An electro-hydraulic 4/2-way valve can be used to produce a number of different

functions.
Which ports must be used to produce a given function? (The other ports remain closed.)

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Practical assembly, hydraulic

Components list, hydraulic

Item no. Qty. Description

1 1 Hydraulic power pack
2, 2.1 2 Pressure gauge
3 1 Pressure relief valve
4 1 4/2-way solenoid valve
5 1 One-way flow control valve
6 1 Cylinder
7 1 Loading weight, 9 kg
– 3 T connectors (Branch tee)
– 7 Hose line with quick-release coupling,
600 and 1000

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Practical assembly, electrical

Contact allocation on relay panel

Changeover contact connected as Changeover contact connected as

normally-open contact normally-closed contact

Components list, electrical

Qty. Description
1 Relay unit
1 Push-button switch set
1 Pilot lamp & buzzer set
1 Cable set, universal
1 Electrical power supply unit

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Solution 4: Bending device

Circuit diagram, hydraulic

Circuit diagram, electrical

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Solution description

When the START pushbutton S1 is pressed, the relay K1 is energized;

The normally-open contact of K1 latches to maintain the power supply for the relay K1.
Simultaneously, current is fed to the coil Y1 via a further contact of K1. The solenoid
reverses the 4/2-way solenoid valve and the piston rod advances and remains at its
forward end position until the RETURN pushbutton S2 is pressed, which interrupts the
circuit for the relay K1.
This also causes the circuit for the coil Y1 to be interrupted, and the piston rod returns
to its initial position.
A flow control valve must be fitted to ensure that the speed does not vary as a function
of load. This flow control valve should be fitted upstream of the directional control
valve and will then control both the advance and return strokes.

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Practical assembly, hydraulic

Components list, hydraulic

Item no. Qty. Description

1 1 Hydraulic power pack
2, 2.1 2 Pressure gauge
3 1 Pressure relief valve
4 1 2-way flow control valve
5 1 4/2-way solenoid valve
6 1 Cylinder
– 2 T connectors( Branch tee)
– 7 Hose line with quick-release coupling,600 & 1000

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Practical assembly, electrical

S1 = START pushbutton
S2 = RETURN pushbutton

Components list, electrical

Qty. Description
1 Relay unit
1 Push-button switch set
1 Pilot lamp & buzzer set
1 Cable set, universal
1 Electrical power supply unit

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Solution 5: Press-fitting device

Circuit diagram, hydraulic

Circuit diagram, electrical

S1 = START pushbutton
B1 = Pressure switch

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Solution description

When the START pushbutton S1 is pressed, the relay K1 is energized;

The 1st normally-open contact of K1 maintains the power supply for the relay K1.
Simultaneously, the circuit for the coil Y1 is closed via a further contact of K1.
The 4/2-way valve reverses and the piston rod advances until the pressure preset on the
pressure switch B1 is reached.
The pressure switch acts via K2 to cancel the latching of K1.
This also interrupts the circuit for the coil Y1, causing this to become de-energized.
The 4/2-way solenoid is reversed back by spring force and the piston rod returns to its
initial position.
Fit the pressure sensor upstream of the one-way flow control valve:
If the advance-stroke speed is controlled by a throttle valve, the throttle valve represents
such a large resistance that, when the circuit is switched on, the pressure upstream of
this valve rises to over 30 bar.
The result of this is that the pressure switch initiates the return stroke before the correct
press-fitting pressure has been reached.
The pressure must therefore be measured directly upstream of the cylinder supply port.

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Practical assembly, hydraulic

Components list, hydraulic

Item no. Qty. Description

1 1 Hydraulic power pack
2, 2.1 2 Pressure gauge
3 1 Pressure relief valve
4 1 4/2-way solenoid valve
5 1 One-way flow control valve
6 1 Cylinder
7 1 Pressure switch
– 2 T connectors (Branch tee)
– 7 Hose line with quick-release coupling, 600 & 1000

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Practical assembly, electrical

S1 = START pushbutton
B1 = Pressure switch

Components list, electrical

Qty. Description
1 Relay unit
1 Push button switch set
1 Pilot lamp & buzzer set
1 Cable set, universal
1 Electrical power supply unit

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Solution 6: Stamping machine

Circuit diagram, hydraulic

Circuit diagram, electrical

S1 = START pushbutton
S2 = RETURN pushbutton

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Solution description

When the START pushbutton S1 is pressed, the relay K1 is energized;

The 1st normally-open contact of K1 maintains the power supply for the relay K1.
Simultaneously, the circuit for the coil Y1 is closed via a further contact of K1.
The 4/2-way valve is reversed and the piston rod advances until the pressure preset on
the pressure switch B1 is reached.
The pressure switch acts via K2 to cancel the latching of K1.
This also causes the circuit for the coil Y1 to be interrupted, de-energizing the solenoid
coil Y1.
The 4/2-way valve reverses by spring force and the piston rod returns to its initial
position.
Fit the pressure sensor upstream of the one-way flow control valve:
If the advance-stroke speed is controlled by a throttle valve, the throttle valve represents
such a large resistance that, when the circuit is switched on, the pressure upstream of
this valve rises to over 30bar.
The result of this is that the pressure switch initiates the return stroke before the correct
stamping pressure has been reached.
The pressure must therefore be measured directly upstream of the cylinder supply port.

Note
The "Practical assembly, hydraulic" drawing shows a 4/2-way solenoid valve instead of
the 3/2-way valve.

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Practical assembly, hydraulic

Components list, hydraulic

Item no Qty. Description

1 1 Hydraulic power pack
2, 2.1 1 Pressure gauge
3 1 Pressure relief valve
4 1 4/2-way solenoid valve
5 1 2-way flow control valve
6 1 Cylinder
– 2 T connectors (Branch tee)
– 7 Hose line with quick-release coupling, 600 & 1000

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Practical assembly, electrical

S1 = START pushbutton
S2 = RETURN pushbutton

Components list, electrical

Qty. Description
1 Relay unit
1 Push-button switch set
1 Pilot lamp & buzzer unit
1 Cable set, universal
1 Electrical power supply unit

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Solution 7: Door control

Circuit diagram, hydraulic

Circuit diagram, electrical

S1 = "Close door" pushbutton

S2 = "Open door" pushbutton

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Solution description

The hydraulically-piloted non-return valve prevents the piston rod from being pulled out
by the attractive load.
The piloted non-return valve opens and allows the piston rod to advance only when the
"Close door" pushbutton S1 is pressed, causing the 3/2-way valve to reverse.
When the pushbutton S1 is released, the 3/2-way valve returns to its initial position and
the piloted non-return valve closes immediately.
The piston rod is hydraulically clamped and remains where it is.
The hydraulic clamping ensures that the piston rod cannot be pulled out by a attractive
load.
When S1 is pressed again, the piston rod moves forward until the desired end position is
reached.
When the "Open door" pushbutton S2 is pressed, the piston rod moves back. When S2
is released, the 4/3-way valve reverses, while the piston rod stays where it is and is
hydraulically clamped.
The two pushbuttons S1 and S2 are mechanically interlocked.
If both of these are pressed at the same time or if one is held down and the other pressed,
the piston rod stops.
The one-way flow control valve is installed on the piston-rod side in order to ensure that
a back-pressure develops as the door closes.
This pressure is used firstly to provide counter-holding and secondly to ensure reliable
opening of the pilot-operated non-return valve.

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Practical assembly, hydraulic

Components list, hydraulic

Item no Qty. Description

1 1 Hydraulic power pack
2 1 Pressure gauge
3 1 Pressure relief valve
4 1 4/3-way solenoid valve closed in mid-position
5 1 4/2-way solenoid valve
6 1 Cylinder
7 1 Non-return valve
8 1 One-way flow control valve
– 3 T connectors (Branch tee)
– 9 Hose line with quick-acting coupling, 600 & 1000

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Practical assembly, electrical

S1 = "Close door" pushbutton

S2 = "Open door" pushbutton

Components list, electrical

Qty. Description
1 Relay unit
1 Push-button switch set
1 Pilot lamp & buzzer unit
1 Cable set, universal
1 Electrical power supply unit

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Solution 8: Machining unit

Function diagram

S1, S2 = Limit switches

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Circuit diagram, hydraulic

Circuit diagram, electrical

S1, S2= Limit switches

S3= START pushbutton

Exercise - Basic level Electro Hydraulics | 129

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Solution description

The circuit is started by pressing S3.

The 4/3-way valve then reverses, and the fluid from the piston-rod side is used together
with the pump delivery to power the advance stroke of the cylinder.
When the limit switch S2 is reached, the 4/3-way valve and 4/2-way valve are reversed
and the piston rod retracts again.
When the piston rod reaches the limit switch S1 at its retracted end position, the 4/2-
way valve switches back to its initial position. A new processing cycle can now be
started.
In this circuit, the flow control valve is used only to restrict the pump delivery to allow
a clearer demonstration of the effects of a differential circuit.

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Practical assembly, hydraulic

Components list, hydraulic

Item no. Qty. Description

1 1 Hydraulic power pack
2 1 Pressure gauge
3 1 Pressure relief valve
4 1 4/3-way solenoid valve closed in mid-position
5 1 2-way flow control valve
6 1 4/2-way solenoid valve
7 1 Cylinder
- 2 T connectors (Branch tee)
- 9 Hose line with quick-release coupling

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Practical assembly, electrical

S1, S2 = Limit switches

S3 = START pushbutton

Components list, electrical

Qty. Description
1 Relay unit
1 Push-button switch set
1 Limit switch, electrical, actuated from the left
1 Limit switch, electrical, actuated from the right
1 Pilot lamp & buzzer set
1 Cable set, universal
1 Electrical power supply unit

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Solution 9: Feed for drilling machine

Function diagram

S1, S2 = Limit switches

S3 = START pushbutton
S4 = RETURN pushbutton

Exercise - Basic level Electro Hydraulics | 133

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Circuit diagram, hydraulic

Circuit diagram, electrical

S1, S2 = Limit switches

S3 = START pushbutton
S4 = RETURN pushbutton

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Solution description

During the rapid traverse motion, the 2-way flow control valve is bypassed via the 2/2-
way directional control valve.
Switchover from rapid to feed speed is position-dependent and is initiated by the limit
switch S2, which feeds an electrical signal via the relay K2 to the solenoid coil Y2.
The return stroke is initiated by the pushbutton S4. In the retracted end position of the
piston rod, the limit switch S1 switches the 2/2-way valve back to rapid traverse, thus
fulfilling the condition for a restart.
During the return stroke, the flow control valve is bypassed by the non-return valve,
item 7.

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Practical assembly, hydraulic

Components list, hydraulic

Item no. Qty. Description

1 1 Hydraulic power pack
2, 2.1 2 Pressure gauge
3 1 Pressure relief valve
4 1 4/3-way solenoid valve closed in mid-position
5 1 4/2-way solenoid valve
6 1 2-way flow control valve
7 1 Non-return valve, 1 bar
8 1 Cylinder
-- 7 T connectors (Branch tee)
– 11 Hose line with quick-release coupling, 600 & 1000

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Practical assembly, electrical

S1, S2 = Limit switches

S3 = START pushbutton
S4 = RETURN pushbutton

Components list, electrical

Qty. Description
1 Relay unit
1 Push-button switch set
1 Limit switch, electrical, actuated from the left
1 Limit switch, electrical, actuated from the right
1 Pilot lamp & buzzer set
1 Cable set, universal
1 Electrical power supply unit

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Solution 10: Press

Circuit diagram, hydraulic

Circuit diagram, electrical

S1 = START pushbutton
S2 = Limit switches
B1 = Pressure switch

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Solution description

Pre-settings
Set the components before switching on the electrical and hydraulic power supplies.
1 7 Close one-way flow control valve fully, then open 1/4 turn
2 5 Bring 2-way flow control valve to mid-position
3 3.1 Close pressure relief valve 2/3
4 3 Close pressure relief valve 1/3
5 8 Open pressure switch fully

Commissioning
After switching on the electrical and hydraulic power supplies, press the START
pushbutton repeatedly to restore the circuit to its initial setting.
The following settings must be made:
1 1 Pump safety valve to 6 MPa (60 bar)
2 5 2-way flow control valve to mid-position
3 3.1 Pressure relief valve to 1.5 MPa (15 bar)
4 3 Pressure relief valve to 4 MPa (40 bar)
5 8 Pressure switch to approx. 3.6 MPa (36 bar)

When the START pushbutton S1 is pressed, the relay K1 is energized and latches via its
normally-open contact in current path 2.
A further normally-open contact of K1 energizes the solenoid coil Y1 of the 4/2-way
valve and the piston rod advances.
The 2/2-way valve is still open, with the result that the pressure relief valve, with its
lower pressure setting, becomes operative.
When the piston rod reaches the limit switch S2, the 2/2-way valve is deactivated,
producing a switchover to the pressure set on the 2nd pressure relief valve.
When the piston rod reaches its forward end position, the pressure continues to rise until
the preset pressure is reached.
The pressure switch cancels the latching of K1 and K2. K1 reverses the 4/2-way valve
to initiate the piston return stroke. The relay K2, which has also been de-energized, acts
via the normally-closed contact in current path 7 to switch the system back to low
pressure.
A re-start can now be carried out.

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Practical assembly, hydraulic

Components list, hydraulic

Item no. Qty. Description

1 1 Hydraulic power pack
2,2.1 2 Pressure gauge
3,3.1 2 Pressure relief valve
4 1 4/3-way solenoid valve closed in mid-position
5 1 4/2-way solenoid valve
6 1 2-way flow control valve
7 1 One-way flow control valve
8 1 Pressure switch
9 1 Cylinder
-- 3 T connectors (Branch tee)
-- 8 Hose line with quick-release coupling, 600 and 1000

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Practical assembly, electrical

S1 = START pushbutton
S2 = Limit switches
B1 = Pressure switch

Components list, electrical

Qty. Description
2 Relay unit
1 Push-button switch set
1 Limit switch, electrical, actuated from the right
1 Pilot lamp & buzzer set
1 Cable set, universal
1 Electrical power supply unit

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Solution 11: Feed device

Function diagram

S1 = START pushbutton
S2, S3 = Limit switches

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Circuit diagram, hydraulic

Circuit diagram, electrical

S1= START pushbutton

S2, S3= Limit switches

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Solution description

When the START pushbutton S1 is pressed, the coil of relay K1 is energized.

Relay K1 latches via its 1st normally-open contact.
The normally-closed contact of K1 de-energizes relay K3, causing the normally- open
contact of K3 to open and de-energies the solenoid valveY2.
As a result, the 2/2-way valve reverses, shutting off the pressure less pump bypass, The
pump delivers directly into the system.
Since the normally-open contact of K1 which supplies the solenoid coil Y1 is also
closed, the 4/2-way valve reverses and the piston rod advances to the limit switch S2.
S2 acts via K2 to cancel the latching of K1, thus de-energizing the solenoid coil Y1 and
switching the 4/2-way valve over for the return stroke.
When the piston rod reaches the limit switch S3 at the retracted end position, the 2/2-
way valve is once again switched to pressure less bypass.
The result of this is that the pump delivery is discharged to the tank not at the system
pressure of 50 bar but only against the resistance of the 2/2-way valve.

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Practical assembly, hydraulic

Components list, hydraulic

Item no. Qty. Description

1 1 Hydraulic power pack
2 1 Pressure gauge
3 1 Pressure relief valve
4 1 4/2-way solenoid valve
5 1 2-way flow control valve
6 1 4/3-way solenoid valve closed in mid-position
7 1 Cylinder
– 4 T connectors (Branch tee)
– 8 Hose line with quick-release coupling,600 and 1 000

Exercise - Basic level Electro Hydraulics | 145

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Practical assembly, electrical

S1 = START pushbutton
S2, S3 = Limit switches

Components list, electrical

Qty. Description
1 Relay unit
1 Push-button switch set
1 Limit switch, electrical, actuated from the left
1 Limit switch, electrical, actuated from the right
1 Pilot lamp & buzzer set
1 Cable set, universal
1 Electrical power supply unit

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Solution 12: Assembly device

Function diagram

S1 = START pushbutton
S2 = RETURN pushbutton
B1 = Pressure switch, p1 = 2.5 MPa = 25 bar

Exercise - Basic level Electro Hydraulics | 147

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Circuit diagram, hydraulic

Circuit diagram, electrical

S1= START pushbutton

S2= RETURN pushbutton
B1= Pressure switch

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Solution description

When the START pushbutton S1 is pressed, the relay K1 is energized and latches. The
normally-open contact of K1 in current path 7energizes the solenoid coil Y1 of the 4/3-
way valve. This causes the piston rod of cylinder A to advance.
When the pressure set on B1 is reached, the relay K3 is energized.
As a result, the normally-open contact of K3 in current path 9 closes and the hydraulic
motor rotates counterclockwise.
The piston rod remains advanced until the switch S2 is actuated.
When the switch S2 is actuated, its detente position is shown by a visual indicator.
S2 cancels the latching of K1 and K3, causing the 4/3-way valve to switch over and
initiate the return stroke of the cylinder.
Simultaneously, the pressure falls. The pressure switch causes the relay K3 to become
de-energized, which results in the opening of the normally-open contact of K3 in current
path 9.
Y3 accordingly becomes de-energized and the 4/2-way valve is reversed by spring force.
The motor stops.
Only after the switch S2 is released (indicator lamp goes out) does the 4/3-way valve
switch to its mid-position, allowing a new working cycle to be started.

Note
In practice, a pressure sensor would not be used alone to determine whether cylinder A
has reached its end position. An additional limit switch would also be used to provide
reliable detection of the end position.

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Practical assembly, hydraulic

Components list, hydraulic

Item no. Qty. Description

1 1 Hydraulic power pack
2,2.1 2 Pressure gauge
3 1 Pressure relief valve
4 1 4/3-way solenoid valve closed in mid-position
5 1 Non-return valve, piloted
6 1 Pressure switch
7 1 Cylinder
8 1 Hydraulic motor, 8 l/min
9 1 4/2-way solenoid valve
10 1 One-way flow control valve
11 1 Non-return valve, 5 bar
-- 5 T connectors (Branch tee)
-- 12 Hose line with quick-release coupling, 600 and 1000

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Practical assembly, electrical

S1 = START pushbutton
S2 = Return pushbutton
B1 = Pressure switch

Components list, electrical

Qty. Description
1 Relay unit
1 Push-button switch set
1 Pilot lamp & buzzer set
1 Cable set, universal
1 Electrical power supply unit

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Solution 13: Lifting device for packages

Function diagram

S = START pushbutton
S1, S2, S3, S4 = Limit switches

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Circuit diagram, hydraulic

Circuit diagram, electrical

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Solution description

When the START pushbutton S1 is pressed, the relay K1 is energized and latches.
The normally-open contact of K1 in current path 9 energizes the solenoid coil Y1 of the
4/3-way valve. This causes the piston rod of cylinder A to advance until it reaches the
limit switch S2.
S2 energizes the relay K2 as long as cylinder A is advanced.
The normally-open contact of K2 in current path 10 energizes the solenoid coil Y3 of
the 4/2-way valve and the piston rod of cylinder B advances until it reaches the limit
switch S4 at its end position.
S4 energizes K3, whose normally-closed contacts in current paths 1 and 3 de-energies
the relays K1 and K2. S4 thus cancels the latching contacts K1 for Y1 and K2 for Y3,
while energizing Y2. Y2 causes the 4/3-way valve to reverse, and the piston rod of
cylinder A retracts.
Due to the fact that Y3 has become de-energized, the 4/2-way valve is reversed by
spring force and the piston rod of cylinder B also retracts.
Only after both piston rods have reached their retracted end positions is Y2 de-
energized, and the 4/3-way valve is brought into its mid-position by spring force.

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Practical assembly, hydraulic

Components list, hydraulic

Item no. Qty. Description

1 1 Hydraulic power pack
2 1 Pressure gauge
3 1 Pressure relief valve
4 1 4/3-way solenoid valve closed in mid-position
5,5.1 2 One-way flow control valve
6,6.1 2 Cylinder
7 1 4/2-way valve
-- 4 T connectors (Branch tee)
-- 12 Hose line with quick-release coupling, 600 and 1000

Exercise - Basic level Electro Hydraulics | 155

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Practical assembly, electrical

S= START pushbutton
S1, S2, S3, S4= Limit switches

Components list, electrical

Qty. Description
1 Relay unit
1 Push-button switch set
1 Limit switch, electrical, actuated from the left
1 Limit switch, electrical, actuated from the right
1 Pilot lamp & buzzer set
1 Cable set, universal
1 Electrical power supply unit

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Appendix

• Datasheets

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