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Worksheets Electropneumatics Basic Level
Worksheets Electropneumatics Basic Level
Learning objectives
After completing this exercise:
• You’ll be familiar with the setup and function of a single-acting cylinder.
• You’ll be familiar with the setup and function of a 3/2-way solenoid valve.
• You’ll be able to recognize and sketch the various types of actuation used for directional control valves.
• You’ll be able to explain and set up direct actuation.
Layout
General conditions
• A single-acting cylinder will be used.
• The cylinder will be controlled by means of a pushbutton.
• In the event of a power failure, the cylinder’s piston rod should be retracted to the rear end position.
Work assignments
1. Describe the function of pneumatic power components.
2. Complete the circuit symbols for solenoid valves.
3. Describe the meaning and the function of the port designations for valves.
4. Describe how the neutral positions of directional control valves influence the motion sequence of a
cylinder.
5. Describe the functions of various valve types.
6. Explain the difference between direct and indirect actuation.
7. Describe the design and function of electrical switches.
8. Complete the pneumatic and electrical circuit diagrams.
9. Complete the equipment list.
10. Set up the controller’s pneumatic and electrical sections.
11. Double check the controller configuration.
12. Describe the controller’s work sequence.
Work aids
• Books of tables
• Textbook: Fundamentals of pneumatics and electropneumatics
• Component data sheets
• FluidSIM® P design and simulation software
• WBT: Electropneumatics
Information
Pneumatic power components can be subdivided into two groups:
• Power components with motion in a straight line
• Power components with rotary motion
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Function
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Function
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Function
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– Complete the circuit symbols with the help of the descriptions of the respective components.
Directly actuated 3/2-way solenoid valve, normally open, with manual override, pneumatic spring return
Pilot-actuated 3/2-way solenoid valve, normally closed, with manual override, mechanical spring return
Information
In order to prevent incorrect tubing connections at directional control valves, the valve ports
(working and pilot lines) are identified in accordance with ISO 5599-3 on the valves themselves, as
well as in the circuit diagram.
– Explain the meanings and functions of the port designations listed below.
2, 4
3, 5
12
14
10
82/84
Information
An electrically actuated 3/2-way solenoid valve has two switching positions. It can be in the neutral
position (unactuated) or the switched position (actuated). The valve can be either closed or open in
its neutral position.
– A single-acting cylinder is controlled by an electrically actuated 3/2-way solenoid valve. Describe how
the two different neutral positions effect the motion sequence of the cylinder:
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Information
Electrically actuated directional control valves are switched with the help of solenoid coils
(electromagnets). In principle, they can be subdivided into two groups:
• Solenoid valves with spring return
• Double solenoid valves
– Explain the difference between the two groups with regard to function and performance in the event of
electrical power failure.
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– Explain the difference between direct and indirect actuation based on the following application:
Electrical actuation of a 3/2-way solenoid valve with return spring by means of a pushbutton.
Direct actuation
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Indirect actuation
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Design
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Function
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Design
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Function
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Design
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Function
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– Complete the pneumatic and electrical circuit diagrams for the inspection unit. Supplement any
incomplete circuit symbols. Label the individual components and enter the missing port designations.
– Complete the equipment list. Enter the quantity, identification and designation of the required
components to the table below.
Pneumatic components
1 – 24 V DC power pack
Electrical components
10. Setting up the pneumatic and electrical sections of the control system
Observe the following points when setting up the control system:
• Use the circuit diagrams.
• Designate the components.
• Lay compressed air tubing using the shortest possible routes.
• Push the compressed air tubing into the push-in connector as far as it will go.
• Mark the connected compressed air tubing on the pneumatic circuit diagram.
• Establish the electrical connections with laboratory safety cables.
• Mark the connected laboratory safety cables on the electrical circuit diagram.
Initial position
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Step 1-2
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Step 2-3
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Learning objectives
After completing this exercise:
• You’ll be familiar with the setup and function of a double-acting cylinder.
• You’ll be able to explain and set up direct actuation.
An actuation option for the shut-off valve will be sought out by means of a test setup.
Layout
Shut-off device
General conditions
• A double-acting cylinder will be used.
• The cylinder will be controlled with a pushbutton.
• In the event of a power failure, the cylinder’s piston rod should be retracted to the rear end position.
Work assignments
1. Compare directly actuated and pilot-actuated solenoid valves.
2. Describe the function of a solenoid valve.
3. Explain the meaning of the term IP.
4. Describe the significance of the circuit symbols for pneumatic cylinders.
5. Complete the pneumatic and electrical circuit diagrams.
6. Complete the equipment list.
7. Set up the controller’s pneumatic and electrical sections.
8. Double check the controller configuration.
9. Describe the controller’s work sequence.
Work aids
• Books of tables
• Textbook: Fundamentals of pneumatics and electropneumatics
• Component data sheets
• FluidSIM® P design and simulation software
• WBT: Electropneumatics
– With regard to the type of valve piston actuation, differentiation is made between directly actuated and
pilot-actuated solenoid valves.
Compare these two valve types and list their respective advantages and disadvantages.
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Pilot-actuated valve
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Information
A valve symbol indicates how the respective valve functions, i.e. how many ports it has, its
switching positions and type of actuation – but it says nothing about its engineering design.
– Describe the function of the directional control valve which is represented by means of the following
circuit symbol and cutaway view.
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Function
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3. IP designation
Information
Electrical equipment is protected by housings and covers depending on installation and
environmental conditions. The required level of protection against dust, moisture and foreign
matter must be identified.
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Information
Cylinders with piston rods which move in straight lines can be subdivided into two groups.
• Single-acting cylinders
• Double-acting cylinders
– Describe the significance of the circuit symbols shown below for pneumatic cylinders.
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– Complete the pneumatic and electrical circuit diagrams for the shut-off device. Supplement any
incomplete circuit symbols. Label the individual components and enter the missing port designations.
– Complete the equipment list. Enter the quantity, identification and designation of the required
components to the table below.
Pneumatic components
1 – 24 V DC power pack
Electrical components
Initial position
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Step 1-2
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Step 2-3
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Learning objectives
After completing this exercise:
• You’ll be familiar with the setup and function of a relay.
• You’ll be able to make use of indirect electrical actuation.
Layout
Note
Safety devices that are
required in actual
practice are not shown.
Sealing cans
General conditions
• A double-acting cylinder will be used.
• Control of the cylinder will be executed indirectly by means of a pushbutton.
• In the event of an electrical power failure, the cylinder’s piston rod should be retracted to the rear end
position.
Work assignments
1. Describe the setup and function of a relay.
2. Complete the pneumatic and electrical circuit diagrams.
3. Complete the equipment list.
4. Set up the controller’s pneumatic and electrical sections.
5. Double check the controller configuration.
6. Describe the controller’s work sequence.
Work aids
• Books of tables
• Textbook: Fundamentals of pneumatics and electropneumatics
• Component data sheets
• FluidSIM® P design and simulation software
• WBT: Electropneumatics
Information
Relays are amongst the components used in the signal processing section. A relay is an
electromagnetically actuated switch with several contacts.
a) Match the numbers in the cutaway view of the relay to the components in the table.
Number Component
Coil winding
Contact set
Return spring
Armature
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c) A relay coil can be used to switch one or more contacts. Depending upon the required function, relays
with normally closed, normally open or changeover contacts are used.
Describe the layouts, the contact line-ups and the functions of the depicted relays.
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Function
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d) List the different ways in which relays can be used in electrical and electro-pneumatic controllers.
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– Complete the pneumatic and electrical circuit diagrams for the lid press. Supplement any incomplete
circuit symbols. Label the individual components and enter the missing port designations.
– Complete the equipment list. Enter the quantity, identification and designation of the required
components to the table below.
Pneumatic components
1 – 24 V DC power pack
Electrical components
Initial position
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Step 1-2
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Learning objectives
After completing this exercise:
• You’ll e able to set up indirect actuation.
• You’ll be familiar with logic operations
• You’ll be able to select solenoid valves based on the specified requirements.
• You’ll be able to convert solenoid valves.
Layout
General conditions
• A single-acting cylinder will be used.
• Control of the cylinder will be executed indirectly and by means of a pushbutton.
• In the event of an electrical power failure, the cylinder’s piston rod should be advanced to the forward
end position.
Work assignments
1. Answer the questions concerning the conversion of solenoid valves.
2. Select a suitable solenoid valve for the application.
3. Explain the OR function.
4. Complete the pneumatic and electrical circuit diagrams.
5. Complete the equipment list.
6. Set up the controller’s pneumatic and electrical sections.
7. Double check the controller configuration.
8. Describe the controller’s work sequence.
Work aids
• Books of tables
• Textbook: Fundamentals of pneumatics and electropneumatics
• Component data sheets
• FluidSIM® P design and simulation software
• WBT: Electropneumatics
Information
A great variety of different demands are placed upon valves in actual industrial use. If a valve with
all of the desired characteristics is not available, a valve with a different number of ports can often
be used in order to fulfill the specified function. The following table shows a selection of directional
control valves which are frequently used in industrial applications.
Tick off all of the solenoid valves which can be replaced by a 5/2-way solenoid valve of the type shown
above.
Complete the circuit symbols such that the desired valve function is achieved.
Substitution possible
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Substitution possible
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Substitution possible
Pilot-actuated 3/2-way solenoid valve with spring
return and manual override, normally closed
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Substitution possible
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Note
The term “conversion” includes even very simple measures, for example closing working port 2 or 4 with
a blanking plug.
Information
A valve is selected on the basis of the following criteria:
• Task
• Required performance in the event of power failure
• Lowest possible overall costs
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Reason
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Note
In addition to the costs mentioned above, the overall costs of a valve also include expenses for
installation and maintenance, as well as warehousing costs for replacement parts.
Information
It will be necessary to cause the piston rod of a cylinder to retract with two pushbuttons, namely
-SF1 and -SF2. If at least one of these pushbuttons is activated, solenoid coil -MB1 is energized. As
a result, solenoid valve -QM1 is switched to the actuated position and the cylinder’s piston rod is
retracted.
When both pushbuttons are released, the solenoid valve is switched to its initial position and the
piston rod is advanced.
0 (not actuated)
0 (not actuated)
1 (actuated)
1 (actuated)
Functions table
Logic symbol
Note
0 means pushbutton is not activated and the piston does not advance.
1 means pushbutton is activated and the piston advances.
– Complete the hydraulic and pneumatic and electrical circuit diagrams for the flap. Supplement any
incomplete circuit symbols. Label the individual components and enter the missing port designations.
– Complete the equipment list. Enter the quantity, identification and designation of the required
components to the table below.
Pneumatic components
1 – 24 V DC power pack
Electrical components
Initial position
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Step 1-2
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Learning objectives
After completing this exercise:
• You’ll be familiar with the setup and function of a double-acting cylinder.
• You’ll be familiar with the setup and function of a double solenoid valve.
• You’ll be able to represent a simple control sequence in GRAFCET.
Layout
Diverter
General conditions
• A double-acting cylinder will be used.
• The cylinder will be controlled indirectly by means of a pushbutton. In the event of an electrical power
failure, the cylinder’s piston rod should remain in the current end position.
Work assignments
1. Select a solenoid valve for the application.
2. Describe the function of a solenoid valve.
3. Calculate the current consumption of a solenoid coil.
4. Complete the pneumatic and electrical circuit diagrams.
5. Complete the equipment list.
6. Set up the controller’s pneumatic and electrical sections.
7. Double check the controller configuration.
8. Describe the controller’s work sequence.
9. Represent the control sequence as a GRAFCET.
Work aids
• Books of tables
• Textbook: Fundamentals of pneumatics and electropneumatics
• Component data sheets
• FluidSIM® P design and simulation software
• WBT: Electropneumatics
Information
Two factors need to be taken into consideration when deciding which type of valve will be used for
a specific application.
• Duration or time frame
• Number or frequency
of the required switching operations
In order to make most efficient possible use of a directional control valve, it must be decided from
case to case which is more economical for the respective application:
• A double solenoid valve, or
• A solenoid valve with spring return
– Decide whether a double solenoid valve or a solenoid valve with spring return is more economically
suited for each of the applications listed below, and give reasons for your selection.
Application 1
The clamping cylinder in a milling fixture must clamp a workpiece for the duration of the milling
process (roughly 10 minutes with 60 clamping operations per day).
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Application 2
The ejector cylinder in a sorting device will push defective workpieces from a conveyor belt (duration
of roughly 1 second with 600 clamping operations per day).
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Reason
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– Describe the function of the directional control valve which is represented by means of the following
circuit symbol and cutaway view.
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Function
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a) A solenoid valve with spring return will be switched with pushbutton -SF1.
Calculate current consumption and power for solenoid coil -MB1 based on 24 V DC supply power and a
coil resistance of 48 Ω (Ohm).
b) If the solenoid coil in question were connected to 24 V AC, would power consumption at -MB1 be higher
or lower. Give reasons for your answer.
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– Complete the pneumatic and electrical circuit diagrams for the diverter. Supplement any incomplete
circuit symbols. Label the individual components and enter the missing port designations.
– Complete the equipment list. Enter the quantity, identification and designation of the required
components to the table below.
Pneumatic components
1 – 24 V DC power pack
Electrical components
Initial position
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Step 1-2
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Step 2-3
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Information
For a technology-independent representation of the GRAFCET, use the designations of the
pushbuttons, for example, as input variables, and the designation of the drive as output variables.
a) Represent the diverter’s control sequence as a GRAFCET. Supplement the step enabling conditions
(transition conditions) for triggering each respective following step. Add comments to the steps and the
step enabling conditions.
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Learning objectives
After completing this exercise:
• You’ll be able to allocate the components of an electropneumatic control system to the pneumatic
and/or the electrical circuit diagram.
• You’ll be familiar with the setup and function of a limit switch.
• You’ll be familiar with one of the options for end position sensing in cylinders.
• You’ll be able to prepare switching element tables for relays.
Layout
Stacking magazine
General conditions
• The cylinder’s front end position needs to be sensed.
Work assignments
1. Allocate the components of an electropneumatic system to the pneumatic and electrical circuit
diagrams.
2. Explain the design and function of limit switches.
3. Create switching element tables for the specified circuit diagrams.
4. Complete the pneumatic and electrical circuit diagrams.
5. Complete the equipment list.
6. Set up the controller’s pneumatic and electrical sections.
7. Double check the controller configuration.
8. Describe the controller’s work sequence.
Work aids
• Books of tables
• Textbook: Fundamentals of pneumatics and electropneumatics
• Component data sheets
• FluidSIM® P design and simulation software
• WBT: Electropneumatics
– The components of an electropneumatic system are represented in the pneumatic and/or electrical
circuit diagrams.
Cylinder
Valves
Solenoid coils
Relay
Indicator units
Number Component
Guide bolt
Contact blade
Roller lever
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c) Describe the design and function of the components represented by the following
circuit symbols.
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a) One way of recording the contacts controlled by a relay is to list them in a switching elements table.
-KF6
-KF9
Information
Another way of recording the contact sets controlled by a relay is shown in the following circuit
diagram.
b) Complete the entries for the relays listed in the table. Designate the current path within which the
respective contact is used, as well as the function fulfilled by the set of contacts (normally open or
normally closed).
Relay -KF9
Relay -KF10
– Complete the pneumatic and electrical circuit diagrams for the ejector device. Supplement any
incomplete circuit symbols. Label the individual components and enter the missing port designations.
– Complete the equipment list. Enter the quantity, identification and designation of the required
components to the table below.
Pneumatic components
1 – 24 V DC power pack
Electrical components
Initial position
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Step 1-2
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Step 2-3
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Learning objectives
After completing this exercise:
• You’ll be able to calculate piston forces on the basis of specified values.
• You’ll be able to calculate characteristic electrical values.
• You’ll be able to make use of indirect actuation.
• You’ll be familiar with the logic AND operation and will be able to set it up.
• You’ll be able to describe a controller sequence in GRAFCET.
Layout
General conditions
• A double-acting cylinder will be used.
• Control of the cylinder will be executed indirectly with pushbuttons and electro-mechanical limit
switches.
• Advancing can only be started when the piston rod is in the rear end position.
Work assignments
1. Calculate the piston force of a double-acting cylinder.
2. Calculate the characteristic electrical values of a relay coil.
3. Explain the AND function.
4. Complete the electrical circuit diagram.
5. Complete the equipment list.
6. Describe the inspection unit sequence in GRAFCET
7. Set up the controller’s pneumatic and electrical sections.
8. Double check the controller configuration.
9. Describe the controller’s work sequence.
Work aids
• Books of tables
• Textbook: Fundamentals of pneumatics and electropneumatics
• Component data sheets
• FluidSIM® P design and simulation software
• WBT: Electropneumatics
Information
Theoretical piston force is calculated using the following formula:
Fth = A ⋅ p
– Calculate effective piston force during the return stroke for the cylinder in question at a working
pressure of 600 kPa (6 bar).
Calculating piston force, forward stroke Calculating piston force, return stroke
Note
Consult the cylinder data sheet for the necessary data.
Information
The following applies to electrical power:
U2
P= U ⋅ I or P= or = I2 ⋅R
P
R
– It is known that the coil in a relay has a power rating of 1 W. Measurement of resistance between
terminals A1 and A2 resulted in a value of 580 Ω.
Information
It will be necessary to cause the piston rod of a cylinder to advance with two pushbuttons, namely -
SF1 and -SF2. When both pushbuttons are activated simultaneously, solenoid coil -MB1 is
energized, solenoid valve -QM1 switches to the actuated position and the piston rod advances.
When at least one of the two pushbuttons is released, the valve is switched back to its initial
position and the piston rod is retracted.
– Create the associated functions table and draw the logic symbol.
Functions table
logic symbol
Note
0 means pushbutton is not activated and the piston does not advance.
1 means pushbutton is activated and the piston advances.
b) Complete the electrical circuit diagram for the sorting device. Supplement any incomplete circuit
symbols. Label the individual components and enter the missing port designations.
– Complete the equipment list. Enter the quantity, identification and designation of the required
components to the table below.
Pneumatic components
1 – 24 V DC power pack
Electrical components
a) Create the GRAFCET for the sorting device. Enter the step enabling conditions and actions to this end.
Add comments to the steps and step enabling conditions.
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Initial position
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Step 1-2
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Step 2-3
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Learning objectives
After completing this exercise:
• You’ll be familiar with logic functions and be able to set them up.
• You’ll be able to explain and set up an electrical latching circuit with dominant breaking signal.
Layout
General conditions
• A double-acting cylinder will be used.
• The cylinder will be controlled indirectly.
Work assignments
1. Describe different signal storage options.
2. Analyze performance of a circuit in the event of a power failure.
3. Explain the NOT function.
4. Complete the pneumatic and electrical circuit diagrams.
5. Complete the equipment list.
6. Set up the controller’s pneumatic and electrical sections.
7. Double check the controller configuration.
8. Describe the controller’s work sequence.
Work aids
• Books of tables
• Textbook: Fundamentals of pneumatics and electropneumatics
• Component data sheets
• FluidSIM® P design and simulation software
• WBT: Electropneumatics
1. Signal storage
Information
If the piston rod of a cylinder needs to be advanced even when the pushbutton is pressed only
briefly, activation of the pushbutton must be stored. The signal can be stored either in the power
section or in the signal control section of the circuit.
– Describe how signal storage is implemented in the power section or the signal control section.
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– Describe the performance of the circuit shown below (pilot-actuated 5/2-way solenoid valve with spring
return and manual override, double-acting cylinder) in the event of electrical power failure and
compressed air supply failure.
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Information
Signal lamp -PF1 should always light up when pushbutton -SF1 is not activated.
-SF1 -PF1
Functions table
Logic symbol
Note
0 means pushbutton -SF1 not activated or lamp -PF1 off.
1 means pushbutton -SF1 activated or lamp -PF1 on.
– Complete the pneumatic and electrical circuit diagrams for the shifting fixture. Supplement any
incomplete circuit symbols. Label the individual components and enter the missing port designations.
– Complete the equipment list. Enter the quantity, identification and designation of the required
components to the table below.
Pneumatic components
1 – 24 V DC power pack
Electrical components
Initial position
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Step 1-2
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Step 2-3
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Learning objectives
After completing this exercise:
• You’ll be familiar with latching circuits with varying performance features.
• You’ll be familiar with various types of end position monitoring.
• You’ll be able to select the appropriate type of end position monitoring for a pneumatic cylinder.
Layout
General conditions
• The utilized latching circuit should demonstrate dominant off characteristics.
Work assignments
1. Store the signals with a latching circuit.
2. Describe the setup and function of a magnetic proximity switch.
3. Select end position monitoring for a pneumatic cylinder.
4. Complete the pneumatic and electrical circuit diagrams.
5. Complete the equipment list.
6. Set up the controller’s pneumatic and electrical sections.
7. Double check the controller configuration.
8. Describe the controller’s work sequence.
Work aids
• Books of tables
• Textbook: Fundamentals of pneumatics and electropneumatics
• Component data sheets
• FluidSIM® P design and simulation software
• WBT: Electropneumatics
Information
A relay circuit with self-latching loop is required in order to store a signal in the signal control
section. The relay coil is energized when pushbutton -SF1 (normally open) is activated.
In order to clear self-latching, supply power to the relay coil must be interrupted. Additional
pushbutton -SF2 (normally closed) is required to this end. Depending upon how this NC contact is
arranged, we differentiate between two types of self-latching:
• Dominantly setting self-latching
• Dominantly resetting self-latching
a) Complete the circuit diagrams shown below such that the relay is self-latching after pushbutton -SF1 is
released. Self-latching must be cleared when pushbutton -SF2 is activated.
Electrical circuit diagram, left: dominantly resetting self-latching, right: dominantly setting self-latching
Information
Different signal storing circuits demonstrate different characteristics:
• In the event of simultaneous occurrence of setting and resetting conditions
• In the event of failure of electrical control energy or wire break
b) Expand the table and indicate how each respective valve responds.
Signal storage by means of Signal storage by means of electrical latching circuit combined
a double solenoid valve with spring return valve
Magnetic proximity switch (reed switch) – circuit symbol and cutaway views
a) Describe the setup and function of a magnetic proximity switch (reed switch).
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Information
Limit switches and proximity switches are assigned the task of acquiring information and
forwarding it to signal processing.
They include:
• Mechanical position switches (limit switches)
• Magnetic proximity switches
• Inductive proximity switches
• Optical proximity switches
• Capacitive proximity switches
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Information
The front end position of a pneumatic cylinder is to be monitored with a proximity sensor. The
proximity sensor must fulfill the following requirements:
• The proximity sensor should provide an electrical output signal.
• The piston rod’s end position must be sensed in a contactless fashion.
• The proximity sensor must function in a non-contacting fashion.
• The proximity sensor should be insensitive to dust and vibration.
• A permanent magnet must be attached to the cylinder’s piston.
c) Select a suitable proximity sensor and explain why it fulfils the specified requirements.
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b) Complete the electrical circuit diagram for the diverter. Add any missing circuit symbols. Identify the
individual components and enter the missing port designations.
– Complete the equipment list. Enter the quantity, identification and designation of the required
components to the tables below.
Pneumatic components
1 – 24 V DC power pack
Electrical components
Initial position
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Step 1-2
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Step 2-n
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Step n-(n+1)
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Learning objectives
After completing this exercise:
• You’ll be familiar with the setup and function of pressure sensors.
• You’ll be able to set up pressure-dependent control systems.
• You’ll be able to describe a controller sequence in GRAFCET.
Layout
Stamping fixture
General conditions
• Working pressure should be 550 kPa (5.5 bar).
Work assignments
1. Describe the function of a pressure sensor.
2. Describe the stamping fixture’s sequence in GRAFCET
3. Complete the pneumatic and electrical circuit diagrams.
4. Complete the equipment list.
5. Set up the controller’s pneumatic and electrical sections.
6. Double check the controller configuration.
7. Describe the controller’s work sequence.
Work aids
• Books of tables
• Textbook: Fundamentals of pneumatics and electropneumatics
• Component data sheets
• FluidSIM® P design and simulation software
• WBT: Electropneumatics
Information
Pressure-sensitive sensors, so-called pressure switches, are used in order to measure and monitor
pressure within the system.
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Information
Pressure sensors can be subdivided into two groups. Differentiation is made between:
• Pressure sensors with mechanical contact (mechanical mode of operation)
• Pressure sensors with electronic switching (electronic mode of operation)
b) Describe the task and the function of the pressure switch depicted below.
Electrical
Pneumatic
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Requirements:
• The pressure sensor is electronically adjustable,
• has an adjustable switching output,
• an analogue voltage output and
• it has a digital display for the measured pressure value.
2. GRAFCET
a) Create the GRAFCET for the stamping fixture. Add the step enabling conditions and actions to this end.
Add comments to the steps and step enabling conditions.
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b) Complete the electric circuit diagram for the stamping fixture. Add any missing circuit symbols. Label
the individual components and enter the port designations.
– Complete the equipment list. Enter the quantity, identification and designation of the required
components to the table below.
Double-acting cylinder
Pneumatic components
2 -MB1, -MB2 Solenoid coils for 5/2-way double solenoid valve -QM1
1 – 24 V DC power pack
Electrical components
Initial position
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Step 1-2
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Step 2-3
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Learning objectives
After completing this exercise:
• You’ll be able to make use of an optical proximity sensor.
• You’ll be familiar with sequence descriptions and will be able to prepare them for specified sequences.
• You’ll be able to implement controllers with two cylinders.
Layout
General conditions
• Adjust the one-way flow control valves such that both cylinders are retracted at the same speed.
• The front end position of the single-acting ejectorcylinder must be detected by an optical proximity
sensor.
Work assignments
1. Describe the function of the optical proximity sensor.
2. Prepare the specified sequence descriptions for the process.
3. Complete the pneumatic and electrical circuit diagrams.
4. Complete the equipment list.
5. Set up the controller’s pneumatic and electrical sections.
6. Double check the controller configuration.
7. Describe the controller’s work sequence.
Work aids
• Books of tables
• Textbook: Fundamentals of pneumatics and electropneumatics
• Component data sheets
• FluidSIM® P design and simulation software
• WBT: Electropneumatics
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b) Enter the technical data to the table included below. Use the respective data sheet to this end.
Technical data
Switching voltage
Residual ripple
Switching frequency
Output function
c) Explain in writing what needs to be observed when setting up the circuit with regard to the position of
the proximity sensor.
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d) Sketch supply power into the drawing shown below, and connect the terminals at the optical proximity
sensor to supply power. Enter the connections to the table.
Red (1) 24 V
Blue (3) 0V
Displacement-step diagram
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– Complete the pneumatic and electrical circuit diagrams for the pallet loading station Supplement any
incomplete circuit symbols. Label the individual components and enter the missing port designations.
– Complete the equipment list. Enter the quantity, identification and designation of the required
components to the table below.
Pneumatic components
1 – 24 V DC power pack
Electrical components
Initial position
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Step 1-2
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Step 2-3
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Step 3-4
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Learning objectives
After completing this exercise:
• You’ll e able to detect and eliminate faults in simple electropneumatic controllers.
Layout
General conditions
• A fault has occurred.
Work assignments
1. Familiarize yourself with the circuit and the control sequence.
2. Describe the essential steps required for systematic troubleshooting
3. Apply systematic troubleshooting to the fault in the sequence for the pallet loading station.
4. Describe the consequences of a broken wire in the electrical circuit
5. Pinpoint and describe the fault. Restart the controller.
Work aids
• Books of tables
• Textbook: Fundamentals of pneumatics and electropneumatics
• Component data sheets
• FluidSIM® P design and simulation software
• WBT: Electropneumatics
– Familiarize yourself with the controller’s function and its control sequence. Make use of the following
documentation and circuit diagrams to this end.
Displacement-step diagram
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3. Applying the troubleshooting procedure to a fault in the sequence for the pallet loading station
Information
The following fault occurs during the sequence for the pallet loading station:
• The piston rods in cylinders -MM1 -MM2 advance.
The controller fails during this step.
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– A wire is interrupted at the points identified in the electrical circuit shown below.
Explain which effects a broken wire would have on the circuit’s function at each of the identified points.
Broken wire in the earth cable from relay -KF1, current path 2
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Broken wire in the supply line, solenoid coil -MB1, current path 7
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Broken wire in supply line, relay contact 14 (relay -KF3), current path 8
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a) Set up the controller for the container handling unit and assure that the control sequence runs correctly.
b) Ask your trainer to create a fault in the control sequence. Pinpoint and eliminate the fault by means of
systematic troubleshooting.
c) Process this work assignment in the order of the worksheets. Pinpoint the fault at the controller and
eliminate it. Restart the controller.