Handling Solutions 1

Handling Station
Solution to exercise 1: Learning about components and their

function
Learning objective
Upon completing this exercise, you should
• be familiar with the key components in the handling station
Problem description
All automated systems use a range of components such as sensors, valves, motors, etc. It is
important to be familiar with the function of the components within a system.
Task
1. Match the components with their correct designation and describe their purpose within the station.
Aids
• Theory book
• FluidSIM® online help
• Data sheets
®
© 2007 Festo Didactic GmbH & Co. KG • MecLab U 1
Handling Station Exercise Solutions
Name: Class: Date:
1. Match the components with their correct designation and describe their purpose within the station.
No. Designation Function within the station
1 Magnetic proximity sensor Outputs a signal when a piston passes the sensor
2 Double-acting cylinder Drive for movement in the z direction
(guided)
3 Gripper Grips the workpiece
4 Storage plate Stores workpieces
5 Multi-pin plug distributor Provides the electrical connection for the sensors and actuators
6 One-way flow control valve Regulates the speed of the cylinders
7 Double-acting cylinder Drive for movement in the x direction

(guided)
8 Magnetic proximity sensor Outputs a signal when a piston passes the sensor
9 Solenoid valves Control the movement of the cylinders
10 3/2-way hand valve Shuts off the compressed air supply
11 Cable duct Routes the cables
2 U ®
© 2007 Festo Didactic GmbH & Co. KG • MecLab
Handling Station
Solution to exercise 2: Learning about components, symbols and
designations
Learning objective
• be familiar with the symbols and designations of key pneumatic components
Problem description
important to describe the function of the system clearly and simply. This is done using, among other
things electrical, pneumatic and hydraulic circuit diagrams.
To understand these circuit diagrams, you must be familiar with the symbols used.
Task
1. Match the components with the correct symbols and designations. Do this by entering the number
assigned to the component in the correct fields in the "Symbol" and "Designation" columns.
Aids
• Theory book
• Data sheets
®
Name: Class: Date:
2. Match the components with the correct symbols and designations. Do this by entering the number
assigned to the component in the correct fields in the "Symbol" and "Designation" columns.
Component Symbol Designation
1 [ 2 ] [ 2 ]
One-way flow control valve
2 [ 3 ] [ 6 ]
4 2 Double-acting cylinder
1 3
3 [ 1 ] [ 3 ]
4/2-way single solenoid valve
4 [ 5 ] [ 1 ]
4 2 Gripper
1 3
5 [ 6 ] [ 4 ]
Inductive proximity sensor
6 [ 4 ] [ 5 ]
4/2-way double solenoid valve
4 U ®
Handling Station
Solution to exercise 3: Learning about the structure of symbols
Learning objective
• be familiar with the symbol and designation of key pneumatic components
• be familiar with the structure of the symbols
Problem description
important to describe the function of the system clearly and simply. This is done using, among other
things, circuit diagrams. There are electrical, pneumatic and hydraulic circuits.
To understand these circuit diagrams, you must be familiar with the symbols used. This exercise is
designed to teach you about the symbols.
Task
3. The circuit diagram for the handling station is shown below. Describe the function of the numbered
components.
Aids
• Theory book
• Data sheets
®
Name: Class: Date:
4. The circuit diagram for the handling station is shown below. Describe the function of the numbered
components.
6 U ®
Name: Class: Date:
Number Function
a Pneumatic circuit
b Electrical circuit
1 Double-acting cylinder
Converts pneumatic energy into mechanical energy.
2 4/2-way double solenoid valve

Switches to the opposite switching position by means of a current pulse.
3 4/2-way single solenoid valve

Switches to the open switching position as long as there is current flowing through the solenoid coil. Resetting
is performed by a pneumatic spring.
4 One-way flow control valve

Regulates the speed of the double-acting cylinder.
5 Magnetic sensor (proximity sensor)

Outputs a signal when the cylinder piston approaches it (piston contains a permanent magnet).
6 Programmable logic controller (logic module)

Processes the sensor signals and controls the solenoid coils.
7 Solenoid coils
These actuate the solenoid coils of the solenoid valves in the electrical circuit.
8 On/off switch
9 Magnetic sensors (proximity sensors)

These provide position feedback in the pneumatic circuit.

®
U 7
Handling Station
Solution to exercise 4: Creating schematic and circuit diagrams
Learning objective
• be able to create schematic diagrams, pneumatic circuit diagrams and allocation lists
Problem description
Engineers use schematic diagrams, technical drawings, part lists or circuit diagrams to represent
machines or machine parts efficiently and clearly.
Task
5. Create a schematic diagram for the handling station pictured, showing the function and position of
the key components.
6. Create an allocation list that specifies which sensor or actuator is plugged into which slot on the
multi-pin plug distributor.
7. Create a pneumatic circuit diagram of the station using FluidSIM®.
Aids
• Theory book
• FluidSIM®
• Handling station
Picture of the station
8 U © 2007 Festo Didactic GmbH & Co. KG • MecLab

®
Name: Class: Date:
8. Create a schematic diagram for the handling station pictured, showing the function and position of
the key components.
9. Create an allocation list that specifies which sensor or actuator is plugged into which slot on the
multi-pin plug distributor.
Slot Designation Description
0 1S1 Magnetic proximity sensor at cylinder 1A, rear
2 1S2 Magnetic proximity sensor at cylinder 1A, front
4 2S1 Magnetic proximity sensor at cylinder 2A, top
6 2S2 Magnetic proximity sensor at cylinder 2A, bottom
1 1M1 Advance cylinder 1
3 1M2 Retract cylinder 1
9 3M1 Close gripper
®
Name: Class: Date:
10. Create a pneumatic circuit diagram of the station using FluidSIM®.
10 U ®
Handling Station
Solution to exercise 5: Controlling a double-acting cylinder
Learning objective
• be able to select the components of an electropneumatic circuit
• be able to design electropneumatic circuits
• be able to actuate a double-acting cylinder using FluidSIM®
Problem description
Workpieces are to be lifted using a pneumatic cylinder. A control system is to be designed for this
purpose.
A vertically arranged double-acting cylinder equipped with one-way flow control valves is provided for
lifting. This cylinder is to be supplied with air by means of a solenoid valve and controlled via PC. The
cylinder should advance when a pushbutton is actuated and retract after a second pushbutton is
actuated.
Task
11. Select a suitable valve from the four available and explain the reasons for your choice.
12. Design a pneumatic circuit diagram for the components you selected and test its function via
simulation.
13. Complete the electrical circuit diagram with the suitable actuating elements and transfer the
solution to FluidSIM®. Test its function via simulation.
14. For safety reasons the cylinder should advance slowly, but retract quickly. How can this be
achieved? Test your solution via simulation.
15. Extend the circuit so that the vertically arranged cylinder of the handling station can be controlled
and test its operability. What do you have to do so that the actual cylinder also advances slowly
and retracts quickly?
16. How can you arrange it so that the cylinder automatically retracts upwards after reaching the
advanced (lower) end position? Modify the circuit and test the result.
Aids
• Theory book
• FluidSIM®
®
Name: Class: Date:
17. Select a suitable valve from the four available and explain the reasons for your choice.
a 4/2-way double solenoid valve
b 4/2-way single solenoid valve
c 3/2-way normally closed solenoid valve
d 3/2-way normally closed valve, manually actuated
The manually-actuated valve is not suitable for the task because it cannot be controlled via PC. The
3/2-way solenoid valve does not have enough ports (1) for the double-acting cylinder.
The 4/2-way single solenoid valve is reset by a pneumatic spring as soon as the control current is
switched off, i.e. the cylinder would retract immediately if the pushbutton were released.
Only the 4/2-way double solenoid valve is suitable. It stores the switching position until another
reversing pulse is received.
18. Entwerfe einen pneumatischen Schaltplan aus den gewählten Komponenten und teste die
Funktion in der Simulation.
Nutze dazu FluidSIM®. Die notwendigen Komponenten sind der doppeltwirkende Zylinder, das
gewählte Ventil, zwei Drosselrückschlagventile und eine Druckluftquelle. Teste die Schaltung im
Simulationsmodus, indem Du die Handhilfsbetätigung des Ventils mit der Maus anklickst.
12 U ®
Name: Class: Date:
19. Complete the electrical circuit diagram with a suitable actuating component. The actuating
components available are (see illustration):
a) pushbutton (N/O contact), b) detenting pushbutton (N/O contact),

c) pushbutton (N/C contact), d) detenting pushbutton (N/C contact).
The pushbutton is suitable since the double solenoid valve only needs one current pulse to reverse.
20. For safety reasons the cylinder should advance slowly, but retract quickly. How can this be
achieved? Test your solution via simulation.
To facilitate this, the opening of the one-way flow control valve 2V3 must be reduced (double-click on
the valve). This restricts the flow of air coming out of the front cylinder chamber and the cylinder
advances more slowly. The one-way flow control valve 2V2 remains fully open.

®
U 13
Name: Class: Date:
21. Extend the circuit so that the cylinder of the handling station can be controlled and test its
operability.
Do this by extending the circuit diagram to include the multi-pin plug symbol and assign the
designation for the solenoid coil to the slot where the solenoid coil is actually plugged in.
What do you have to do so that the actual cylinder also advances slowly and retracts quickly?
The actual one-way flow control valve must also be adjusted to get the actual cylinder to advance
more slowly.
22. How can you arrange it so that the cylinder automatically retracts upwards after reaching the
advanced (lower) end position? Modify the circuit and test the result.
The magnetic proximity sensor 2S2 switches when the cylinder reaches the advanced (= lower) end
position. This signal can be used instead of the UP pushbutton to reverse the valve 2V1.
14 U ®
Handling Station
Solution to exercise 6: Learning about logic operations
Learning objective
• be familiar with the most important logic operations
• be able to create logic programs in FluidSIM®
• be able to solve simple control tasks using logic operations
Problem description
Logic operations are an important basis of control technology. In the FluidSIM® logic module, inputs
and outputs are linked using logic operations. This exercise deals with the most important logic
operations.
Task
23. Transfer the following logic circuits to FluidSIM® and study the circuit's behaviour by setting the
input channels I1 through I3 to the status 'high' by clicking on them. Complete the truth table. In
each case specify an example of a control task that can be solved using this logic operation.
24. Create the logic circuit shown below in FluidSIM®, test its behaviour and describe it. What control
tasks can this so-called latching element be used for?
25. Create the circuit shown below in FluidSIM®.
Open the logic module and create a program with the following characteristics:
• Lamp P1 should light up when the two pushbuttons T1 and T2 are pressed (and stay on
after pushbuttons T1 and T2 have been released).
• The lamp should switch off when pushbuttons T3 or T4 are actuated.
26. Extend the circuit from Exercise 3 so that an electric motor is switched on and off instead of the
lamp.
Aids
• Theory book
• FluidSIM®
®
Name: Class: Date:
27. Transfer the following logic circuits to FluidSIM® and study the circuit's behaviour by setting the
input channels I1 through I3 to the status 'high' by clicking on them. Complete the truth table. In
each case specify an example of a control task that can be solved using this logic operation.
I1 I2 I3 Q1
0 0 0 0
0 0 1 0
0 1 0 0
0 1 1 0
1 1 1 1
1 1 0 0
1 0 1 0
1 0 0 0
Example of a control task:

Activate when all three inputs are 1 (AND).
I1 I2 I3 Q1
0 0 0 0
0 0 1 1
0 1 0 1
0 1 1 1
1 1 1 1
1 1 0 1
1 0 1 1
1 0 0 1

Activate when at least one input is 1 (OR).
16 U ®
Name: Class: Date:
I1 Q1
0 1
1 0

Activate when pushbutton (N/C contact) is pressed (NOT).
I1 I2 Q1
0 0 1
0 1 0
1 0 0
1 1 0

Deactivate as soon as a pushbutton is pressed.
®
Name: Class: Date:
28. Create the logic circuit shown below in FluidSIM®, test its behaviour and describe it. What control
tasks can this so-called latching element be used for?
Input I1 sets the output Q1. This remains 1 until input I2 is set (latching element).
18 U ®
Name: Class: Date:
29. Create the circuit shown below in FluidSIM®.
– Open the logic module and create a program with the following characteristics:
• Lamp P1 should light up when the two pushbuttons T1 and T2 are pressed (and stay on
after pushbuttons T1 and T2 have been released).
• The lamp should switch off when pushbuttons T3 or T4 are actuated.
®
Name: Class: Date:
30. Extend the circuit so that a double-acting cylinder retracts and advances instead of the lamp
lighting up.
20 U ®
Handling Station
Solution to exercise 7: Creating control systems via sequencing
programs
Learning objective
• be familiar with the mode of operation and fields of application of sequencing
• be able to create simple control systems via sequencing programs
Problem description
Many sequences in automation technology are characterised by one process step having to take
place after another. Sensors check whether one step has been successfully completed before the next
step starts. This is referred to as sequencing. There is a special programming technique available for
user-friendly sequencing.
A simple sequence is to be programmed that lifts a workpiece in the handling station from the holder
using the vertically arranged cylinder. The workpiece should then be released again when a
pushbutton is actuated.
Task
31. Read up about the programming technique for sequencing in the theory section. Describe the
basic idea in your own words.
32. Create a schematic diagram of the setup as well as an allocation list that shows which electrical
components are plugged into which slots on the multi-pin plug distributor. Also create the
pneumatic and electrical circuit diagrams in FluidSIM® (using the logic module, still without a
program).
33. Describe in detail the sequence outlined in the problem description. Use the prepared form on the
worksheet.
34. Open the logic module in FluidSIM® by clicking on it with the mouse and create the program to
accomplish the sequence described in Exercise 3. Test the program via simulation.
35. Test the program using the handling station. Ensure that the wiring and the tubing correspond to
the circuit diagram and allocation list.
Aids
• Theory book
• FluidSIM®
®
Name: Class: Date:
36. Read up about the sequencing programming technique in the theory section. Describe the basic
idea in your own words.
With sequencing, the execution of a step is a condition for the next step. The current step is stored by
a latching element assuming the status 1. The next step only begins when the preceding step is
complete (indicated by the output on the latching element). The next step then deletes the preceding
step.
37. Create a schematic diagram of the setup as well as an allocation list that shows which electrical
components are plugged into which slots on the multi-pin plug distributor. Also create the
pneumatic and electrical circuit diagrams in FluidSIM® (using the logic module, still without a
program).
Schematic diagram
Note
Your schematic diagram may vary slightly, however the arrangement of the components must be
clear and the designations must match the allocation list.
22 U © 2007 Festo Didactic GmbH & Co. KG • MecLab

®
Name: Class: Date:
Slot Designation Explanation
4 2S1 Magnetic proximity sensor, upper
6 2S2 Magnetic proximity sensor, lower
5 2M1 Solenoid coil 1 at valve 2 (advance)
7 2M2 Solenoid coil 2 at valve 2 (retract)
Assignment list
Pneumatic and electrical circuit diagrams

®
U 23
Name: Class: Date:
38. Describe in detail the sequence outlined in the problem description. Use the prepared form on the
worksheet.
Step Action Output Condition
0 Cylinder at top, pushbutton not 2M1 = 0

pressed 2M2 = 0
1 Cylinder advances 2M1 = 1 2S1 = 1, pushbutton pressed
2 Cylinder reaches lower end position 2M1 = 0 2S2 = 1, step 1

2M2 = 1
3 Cylinder reaches upper end position 2M1 = 1 2S1 = 1, step 2

2M2 = 0
The program consists of three steps:

Step 1: Set Q3 (= 2M1), reset step 3
Step 2: Set Q4 (= 2M2), reset step 2
Step 3: Reset step 2
The hi-element only serves to suppress error messages.
24 U ®
Name: Class: Date:
®
Handling Station
Solution to exercise 8: Handling workpieces
Learning objective
• be familiar with the mode of operation and fields of application of sequencing
• be able to create complex control systems via sequencing programs.
Problem description
Handling tasks are frequently encountered in production. Not all of these tasks require industrial
robots;
so-called 2-axis handling systems are used for simple motion sequences. Handling scenarios where a
workpiece is moved from one location to another are frequently called pick and place tasks. Examples
of these include
• retrieving a workpiece from a conveyor
• placing one workpiece in another (assembly)
• placing a workpiece in packaging
This exercise deals with a pick and place task using the handling station.
Task
41. Create a schematic diagram, an allocation list and an electropneumatic circuit diagram for the
handling station. The logic module is to serve as the controller.
42. The handling system is to move a workpiece from the rear tray to the front tray. Describe this
sequence in detail. Use the prepared worksheet. Specify which input and output signals have to
be received and transmitted. The program should start when a pushbutton is pressed.
the circuit diagram and allocation list. Adjust the holders so the gripper can securely grip the
workpiece.
Aids
• Theory book
• FluidSIM®
26 U ®
Name: Class: Date:
45. Create a schematic diagram, an allocation list and an electropneumatic circuit diagram for the
handling station. The logic module is to serve as the controller.
Schematic diagram
Note
Your schematic diagram may vary slightly; however, the arrangement of the components must be
clear and the designations must match the allocation list.
®
Name: Class: Date:
Slot Designation Explanation
0 1S1 Magnetic proximity sensor at cylinder 1, rear
2 1S2 Magnetic proximity sensor at cylinder 1, front
4 2S1 Magnetic proximity sensor at cylinder 2, rear
6 2S2 Magnetic proximity sensor at cylinder 2, front
9 3M1 Close gripper
Allocation list
Electropneumatic circuit diagram
28 U ®
Name: Class: Date:
46. The handling system is to move a workpiece from the rear tray to the front tray. Describe this
sequence in detail. Use the prepared worksheet. Specify which input and output signals have to
be received and transmitted. The program should start when a pushbutton is pressed.
Step Action Output Condition
1 Advance cylinder 2 2M1 = 1 1S1 = 1

2S1 = 1
START = 1
2 Close gripper 3M1 = 1 2S2 = 1

1S1 = 1
Step 1
3 Retract cylinder 2 2M2 = 1 2S2 = 1

1S1 = 1
Step 2

2S1 = 1
Step 3

2S1 = 1
Step 4
6 Open gripper 3M1 = 0 1S2 = 1

2S2 = 1
Step 5

2S2 = 1
Step 6

2S1 = 1
Step 7
®
Name: Class: Date:
30 U ®
Name: Class: Date:
®

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Handling Station

Solution to exercise 1: Learning about components and their

Name: Class: Date:

No. Designation Function within the station

2 Double-acting cylinder Drive for movement in the z direction

3 Gripper Grips the workpiece

4 Storage plate Stores workpieces

6 One-way flow control valve Regulates the speed of the cylinders

7 Double-acting cylinder Drive for movement in the x direction

9 Solenoid valves Control the movement of the cylinders

10 3/2-way hand valve Shuts off the compressed air supply

11 Cable duct Routes the cables

Name: Class: Date:

Component Symbol Designation

One-way flow control valve

4/2-way single solenoid valve

Inductive proximity sensor

4/2-way double solenoid valve

Name: Class: Date:

Name: Class: Date:

2 4/2-way double solenoid valve

3 4/2-way single solenoid valve

4 One-way flow control valve

5 Magnetic sensor (proximity sensor)

6 Programmable logic controller (logic module)

9 Magnetic sensors (proximity sensors)

© 2007 Festo Didactic GmbH & Co. KG • MecLab

Picture of the station

8 U © 2007 Festo Didactic GmbH & Co. KG • MecLab

Name: Class: Date:

Slot Designation Description

0 1S1 Magnetic proximity sensor at cylinder 1A, rear

2 1S2 Magnetic proximity sensor at cylinder 1A, front

4 2S1 Magnetic proximity sensor at cylinder 2A, top

6 2S2 Magnetic proximity sensor at cylinder 2A, bottom

1 1M1 Advance cylinder 1

3 1M2 Retract cylinder 1

5 2M1 Advance cylinder 2

7 2M2 Retract cylinder 2

9 3M1 Close gripper

Name: Class: Date:

10. Create a pneumatic circuit diagram of the station using FluidSIM®.

Name: Class: Date:

Name: Class: Date:

a) pushbutton (N/O contact), b) detenting pushbutton (N/O contact),

© 2007 Festo Didactic GmbH & Co. KG • MecLab

Name: Class: Date:

Name: Class: Date:

Example of a control task:

Example of a control task:

Name: Class: Date:

Example of a control task:

Example of a control task:

Name: Class: Date:

Name: Class: Date:

29. Create the circuit shown below in FluidSIM®.

Name: Class: Date:

Name: Class: Date:

22 U © 2007 Festo Didactic GmbH & Co. KG • MecLab

Name: Class: Date:

Slot Designation Explanation

4 2S1 Magnetic proximity sensor, upper

6 2S2 Magnetic proximity sensor, lower

5 2M1 Solenoid coil 1 at valve 2 (advance)