10 12 Pneuma

Exercise 10: Designing a stamping device
Objectives
1. To be able to design a pressure-dependent reversal control.

2. To familiarise yourself with the design and mode of operation of magnetic proximity
sensors.
Problem definition
Small mounting blocks are to be stamped during the production of door frames. These blocks
are to be stamped by means of a stamping device.
Parameters
▪ The stamping pressure is to be 5.5 bar (550 kPa).
Project task
1. Answer the questions or carry out the exercises regarding the fundamentals of the
training contents listed.
2. Design the pneumatic and electrical circuit diagrams.
3. Simulate the electro-pneumatic circuit diagram and check its correct functioning.
4. Compile an equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.
80
MCE14-ME ELECTIVE 1 LAB
Positional sketch
Stamping device
1. The pressing of a pushbutton is to cause the stamping device to advance and the work
piece to be stamped.
2. The stamping tool is to return into the initial position once the stamping pressure is
obtained.
81
Worksheets
Fundamentals: Magnetic proximity sensor
In contrast with limit switches proximity sensors are switched contactless and without an
external mechanical actuating force.
- Describe the design and function of a magnetic proximity sensor (reed switch).
82
As regards polarity there are two different designs of electronic proximity sensors, i.e. PNP or
NPN.
- Describe the differences between these two types.
83
Fundamentals: Pressure switches
Pressure sensitive sensors, so-called PE converters, are used to monitor the pressure in a system.
- Describe the mode of operation of PE converter.
84
Fundamentals: Pressure sensors
Pressure sensors can be divided into two groups whereby differentiation is made between:
▪ Pressure sensors with mechanical contact (mechanical principle of action)

▪ Pressure sensors with electronic switching (electronic principle of action)
- Describe the purpose and function of the pressure sensor shown below.
85
Fundamentals: Choice of proximity sensors
The end positions of a drive cylinder are to be sensed by means of proximity sensors. The
following requirements apply regarding the proximity sensors:
▪ The end positions of the piston rod are to be sensed contactless
▪ The proximity sensors are to be insensitive to dust
▪ The piston rod and trip cam of the cylinder are made of metal
- Choose which proximity sensors meet the specified requirements and explain your
reasons for this.
86
Completing the pneumatic and electrical circuit diagrams
- Design the pneumatic and electrical circuit diagrams for the stamping device.
Pneumatic circuit diagram
87
E
Electrical circuit diagram
88
Compiling the equipment list
Apart from the circuit diagram, comprehensive project documentation also requires an
equipment list.
- Compile the equipment list by entering the required equipment in the table below.
Equipment list
89
- Describe the process.
Process description:
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90
ASSESSMENT RUBRIC (for Exercise No.10)
Criteria 1 2 3 Score
Laboratory Skills
Manipulative Skills Members do not demonstrate needed skills

Members occasionally demonstrate Members always demonstrate
needed skills needed skills
Experimental Set-up
Members are able to set-up the Members are able to set-up the
Members are unable to set-up the materials materials materials with minimum supervision
Process Skills
Members do not demonstrate targeted
process skills targeted process skills targeted process skills
Safety Precaution Members do not follow safety precaution Members follow safety precaution
Members follow safety precaution at
all times
Work Habits
Time management/Conduct of Experiment

Members do not finish on time with Members finish on time with incomplete Members finish ahead of time with
incomplete data data complete data
Cooperative and Teamwork

Members do not know their task and have
Members have defined responsibilities Members are on task and have
no defined responsibilities.
most of the time. Group conflicts are responsibilities at all-time. Group
Group conflicts have to be settled by the cooperatively managed most of the conflicts are cooperatively managed
teacher. time. at all times.
Neatness and Orderliness Messy workplace/paper during and after

the experiment Clean and orderly workplace/papers with Clean and orderly workplace/papers
occasional mess during and after the at all times during and after the
experiment. experiment.
Ability to do Independent Work

Members require occasional supervision Members do not need to be
Members require supervision by the teacher by the teacher supervised by the teacher
Report Presentation
Describing the design and function of Wrong description of the design and
Incomplete description of the design and
magnetic proximity sensors function magnetic proximity sensors
function magnetic proximity
Correct description of the design and
sensors function magnetic proximity sensors
Describing the difference between PNP and Wrong description for the difference of
Correct description for the difference
these magnetic proximity sensors Incomplete description for the
NPN electronic proximity sensors
of these magnetic
difference of these magnetic proximity
sensors proximity sensors
Wrong description for the mode of

Describing the mode of operation of a PE Incomplete description for the mode of Correct description for the mode of
converter operation of a PE converter operation of a PE converter operation of a PE converter
Describing the purpose and function of the Wrong description of the purpose and Incomplete description of the purpose Correct description of the purpose
pressure sensor function of the pressure sensor and function of the pressure sensor and function of the pressure sensor
Requirement and reasons for the selection Incorrect requirement and reasons for the Incomplete requirement or reasons for Correct requirement and reasons for
of proximity sensors selection of proximity sensors the selection of proximity sensors the selection of proximity sensors
Completing the pneumatic circuit diagram Minimal error in the design and parts Correct and complete design of
Incorrect design of circuit diagram and placement in the circuit diagram pneumatic circuit diagram
incomplete placement of parts in the
symbol
Completing the electrical circuit diagram Minimal error in the design and parts Correct and complete design of
symbol
Wrong description of the process Incomplete description of the process

Process description
Correct and complete description of
the process
Compiling the equipment list Wrong placement of equipment in the list Incomplete compilation of equipment
Correct and complete compilation of
equipment
Other Comments/Observation: Total Score
Total Number of Item

51
91
Exercise 11: Realising a pallet loading station
Objectives
1. To familiarise yourself with displacement-step diagrams and to be able to design these

for specified problem definitions.
2. To be able to realise a sequence control using two cylinders.
Problem definition
Stacks of roof tiles are to be strapped with a band and then transported to a pallet loading
station, where they are to be transferred onto Euro pallets.
Parameters
▪ Adjust the one-way flow control valve so that both cylinders retract at identical speed.
Project task
1. Design the displacement-step diagram.

2. Draw up the corresponding function diagram and function chart.
3. Design the pneumatic and electrical circuit diagrams.
4. Simulate the electro-pneumatic circuit diagram and check its correct functioning.
5. Compile an equipment list.
6. Carry out the pneumatic and electrical circuit assembly.
7. Check the circuit operation.
92
Positional sketch
Pallet loading station
1. Cylinder 1A1 is to advance when pushbutton S1 is pressed, whereby a single package

arrives at the loading point and sensor 1B2 is actuated.
2. Cylinder 2A1 advances, actuates sensor 2B2, and pushes the package onto the pallet.
3. If 2B2 is actuated and S1 is un-actuated, cylinder 1A1 retracts. 1B2 is therefore no longer
actuated and cylinder 2A1 retracts. Consequently, the overall sequence is:
1A1+ 2A1+ 1A1–

2A1–
93
Worksheets
Fundamentals: Designing the displacement-step diagram
If pushbutton S1 is actuated, cylinder 1A1 advances whereby the package reaches its loading
point and sensor 1B2 is actuated. Cylinder 2A1 advances, actuates sensor 2B2 and pushes the
package onto the pallet. If 2B2 is actuated and S1 unactuated, cylinder 1A1 retracts. 1B2 is no
longer actuated and cylinder 2A1 retracts. Consequently, the overall sequence is:
1A1+ 2A1+ 1A1–
2A1–
- Design the displacement-step diagram for the problem definition described.
Displacement-step diagram
94
Completing the pneumatic and electrical circuit diagrams
- Design the pneumatic and electrical circuit diagrams for the pallet loading station.
95
96
Compiling the equipment list
Apart from the circuit diagram, comprehensive project documentation also requires an
equipment list.
- Compile the equipment list by entering the required equipment in the table below.
Equipment list
97
- Describe the process
Process description:
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98
Laboratory Skills

needed skills needed skills
Experimental Set-up
Members are unable to set-up the Members are able to set-up the Members are able to set-up the
materials materials materials with minimum supervision
Process Skills
process skills targeted process skills targeted process skills
Members follow safety precaution at
all times
Work Habits


Members do not know their task and have
Members have defined responsibilities Members are on task and have
no defined responsibilities.
most of the time. Group conflicts are responsibilities at all-time. Group
Group conflicts have to be settled by the cooperatively managed most of the conflicts are cooperatively managed
teacher. time. at all times.
Neatness and Orderliness Messy workplace/paper during and after

the experiment Clean and orderly workplace/papers Clean and orderly workplace/papers
with occasional mess during and after at all times during and after the
the experiment. experiment.

Members require occasional supervision Members do not need to be
Members require supervision by the teacher by the teacher supervised by the teacher
Report Presentation
Designing the displacement-step diagram

Wrong design of the displacement-step
for the problem definition described Complete design of the
Incomplete design of the
diagram for the problem definition
displacementstep diagram for the displacement-step diagram for the
described problem definition described problem definition described
Completing the pneumatic circuit diagram Minimal error in the design and parts Correct and complete design of
symbol
Completing the electrical circuit diagram Minimal error in the design and parts Correct and complete design of
symbol
Process description Wrong description of the process Incomplete description of the process
Correct and complete description of
the process
Compiling the equipment list Wrong placement of equipment in the list Incomplete compilation of equipment
Correct and complete compilation of
equipment

39
99
Exercise 12: Eliminating a fault on the pallet loading station
Objective
1. To be able to identify and eliminate faults in simple electro-pneumatic control systems.
Problem definition
The pallet loading station stops during continuous operation. A fault has occurred and must be
eliminated. Thereafter the pallet loading station is to be re-started.
Parameters
▪ Only one fault has occurred.
Project task
1. Describe the behaviour of the control system. Compare this with the correct control
system behaviour. Use the displacement-step diagram to assist you.
2. Localise potential causes of the fault with the help of the pneumatic and electrical circuit
diagrams.
3. Find the fault in the control system and eliminate it.
4. Re-start the control system.
100
Positional sketch
Pallet loading station
1. Cylinder 1A1 is to advance if pushbutton S1 is pressed. This causes a single package to

reach its loading point thereby actuating sensor 1B2.
2. Cylinder 2A1 advances, actuates sensor 2B2 and pushes the package onto the pallet.
3. If 2B2 is actuated and S1 unactuated, cylinder 1A1 retracts, 1B2 is no longer actuated and
cylinder 2A1 retracts. Consequently the overall sequence is:
1A1+ 2A1+ 1A1–

2A1–
101
Fault finding in simple electro-pneumatic circuits
The following fault occurs in the circuit shown below:
The piston rod of cylinder 1A1 and the piston rod of cylinder 2A1 advance and remain in the
forward end position.
- Describe what the potential causes of the fault could be.
102
103
A cable break occurs at the areas marked in the circuit shown below.
- Describe what the effects of a cable break at these respective points are on the
functioning of the circuit.
104
Fault finding: Determining the required status
- Create the displacement-step diagram with the help of the documentation given out.
105
Fault finding: Set-point/actual comparison
Determine the ACTUAL status of the system with the help of the following documentation:
▪ Positional sketch with problem description ▪
Graphic representation
- If the correct function is not given (REFERENCE/ACTUAL comparison), clearly mark
the area in the diagram where the fault occurs.
106
Fault finding: Description of faults
You have marked the area where a fault occurs in the diagram of the worksheet
‘REFERENCE/ACTUAL comparison.
- Describe the process up the point where the station or system stops.
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107
Fault finding: Definition of faults – pneumatics
Once you have established the ACTUAL status of the system, consider what the causes of the
faults could be.
In which pneumatic tubing connections could the fault occur?
- Enter all the possibilities and indicate components at the start and end of the tubing
connection in order to ensure clear identification.
Potential faults
108
Fault finding: Definition of faults – electrics
Once you have established the ACTUAL status of the system, consider what the causes of the
faults could be.
▪ In which current paths could the fault be located?

▪ What is the function of the current path?
- Enter all the possibilities.
Potential faults
109
Fault finding: Localisation of faults – pneumatics
Investigate the potential causes of errors you have found in the pneumatics.
▪ Use the same fault numbering that you have used for the worksheet ‘Definition of faults
– pneumatic.
▪ Document the procedure used to investigate the tubing connections.
- Enter the results of your investigation.
Measuring and test protocol
110
Fault finding: Localisation of faults
Investigate the potential error causes you have found.

▪ Use the same fault numbering that you have used in the worksheet ‘Definition of faults -
electrics’.
▪ Document the procedure you have used to check the line connection.
- Enter the result of the investigation.
Measuring and test protocol
111
Fault finding: Elimination of fault
Once you have localised the failure location, your procedure for the elimination of the fault must
be documented on this worksheet.
- Describe each of the steps carried out in detail.

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Note
In the event of the system not fulfilling the intended function, return to the first worksheet and
repeat the fault finding.
Ask for new worksheet s to do so.
112
Fault finding: Re-starting
Once you have identified, localised and eliminated the fault, re-start the system in accordance
with the required status.
Reset the specified required times.
- Briefly document the procedure followed in note form.

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113
Laboratory Skills

Members occasionally demonstrate needed Members always demonstrate needed
skills skills
Experimental Set-up
Members are able to set-up the
Members are unable to set-up the materials Members are able to set-up the materials materials with minimum supervision
Process Skills
Members occasionally demonstrate Members always demonstrate targeted
process skills targeted process skills process skills
Members follow safety precaution at all
times
Work Habits


Members do not know their task and have no
Members are on task and have
defined responsibilities.
Members have defined responsibilities most responsibilities at all-time. Group
Group conflicts have to be settled by the of the time. Group conflicts are conflicts are cooperatively managed at
teacher. cooperatively managed most of the time. all times.
Neatness and Orderliness Messy workplace/paper during and after the

experiment Clean and orderly workplace/papers with Clean and orderly workplace/papers at
occasional mess during and after the all times during and after the
experiment. experiment.

Members require occasional supervision by Members do not need to be supervised
Members require supervision by the teacher the teacher by the teacher
Report Presentation
Describing what are the potential cause of the Wrong descriptions of the potential cause of the Incomplete descriptions of the potential
Correct descriptions of the potential
fault could be in pneumatic circuit fault in pneumatic circuit cause of the fault in pneumatic circuit
cause of the fault in pneumatic
circuit
Wrong descriptions of the potential cause

Describing what are the potential cause of the Incomplete descriptions of the potential Correct descriptions of the potential
fault could be in electrical circuit of the fault in electrical circuit cause of the fault in electrical circuit cause of the fault in electrical circuit
Describing the effect of cable break in

Incomplete description for the effect of Correct description for the effect of cable
earthing wire of relay K1 (current path 2)
cable break in earthing wire of relay K1 break in earthing wire of relay
Wrong description for the effect of cable break
in earthing wire of relay K1 (current path 2) (current path 2) K1 (current path 2)
Describing the effect of cable break in signal

line of sensor 2B2 (current path 4) Wrong description for the effect of cable
cable break in signal line of sensor 2B2 break in signal line of sensor
break in signal line of sensor 2B2 (current path
4) (current path 4) 2B2 (current path 4)
Describing the effect of cable break in supply

line of relay K3 (current path 5)
cable break in supply line of relay K3 break in supply line of relay K3
Wrong description for the effect of cable break
in supply line of relay K3 (current path 5) (current path 5) (current path 5)
Describing the effect of cable break in supply Wrong description for the effect of cable
Incomplete description for the effect of Wrong description for the effect of
line of relay contact 14 at K2 break in supply line of relay contact 14 at
cable break in supply line of relay contact 14 cable break in supply line of relay
(current path 7) K2 (current path 7) at K2 (current path 7) contact 14 at K2 (current path 7)
Describing the effect of cable break in Wrong description for the effect of cable
earthing wire 2M1 (current path 8) break in earthing wire 2M1 (current path 8)
cable break in earthing wire 2M1 break in earthing wire 2M1
(current path 8) (current path 8)
Incorrect displacement-step diagram Incomplete presentation of Correct and complete presentation of

displacement-step diagram
displacement- step diagram
Creating the displacement-step diagram with
the help of the documentation given out.
Incorrect displacement-step diagram, no clear Incomplete displacement-step diagram, no

Creating the displacement-step diagram: Set- comparison clear comparison
point/ mark the area in the diagram where the Correct and complete displacementstep
fault occurs.-actual comparison diagram, and with clear comparison
114
Wrong description of the process Incomplete description of the process Correct and complete description of the
Description of faults: Describing the process process
up to the point where the station or system
stops.
Incorrect definition of faults Incomplete definition of faults Correct and complete definition of
Definition of faults – pneumatics In which faults
pneumatic tubing connections could the
fault occur?
Incorrect definition of faults Incomplete definition of faults Correct and complete definition of
Definition of faults – electrics faults
In which current paths could the fault be
located? What is the function of the current
path?
Wrong data found for the potential causes of Incomplete data found for the potential Correct and complete data found for the
Localisation of faults – pneumatics Investigate errors causes of errors potential causes of errors
the potential causes of errors you have found
in the pneumatics.
Wrong data found for the potential causes of Incomplete data found for the potential Correct and complete data found for the
Localisation of faults – electrics errors causes of errors potential causes of errors
Investigate the potential causes of errors you
have found in the electrics
Elimination of fault: Listing the detailed Incorrect listing procedure for elimination of Incomplete listing procedure for
Detailed and correct listing procedure
procedure for the elimination of the faults the faults
elimination of the faults
for elimination of the
faults
Incorrect procedure for re-starting Incomplete procedure for re-starting

Re-starting: Briefly document the Correct and complete procedure for
procedure followed in note form. re-starting

72
115

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Exercise 10: Designing a stamping device

1. To be able to design a pressure-dependent reversal control.

▪ The stamping pressure is to be 5.5 bar (550 kPa).

Fundamentals: Magnetic proximity sensor

- Describe the differences between these two types.

- Describe the mode of operation of PE converter.

▪ Pressure sensors with mechanical contact (mechanical principle of action)

Pneumatic circuit diagram

Electrical circuit diagram

Manipulative Skills Members do not demonstrate needed skills

Time management/Conduct of Experiment

Cooperative and Teamwork

Neatness and Orderliness Messy workplace/paper during and after

Ability to do Independent Work

Wrong description for the mode of

Wrong description of the process Incomplete description of the process

Other Comments/Observation: Total Score

Total Number of Item

1. To familiarise yourself with displacement-step diagrams and to be able to design these

1. Design the displacement-step diagram.

Pallet loading station

1. Cylinder 1A1 is to advance when pushbutton S1 is pressed, whereby a single package

1A1+ 2A1+ 1A1–

Fundamentals: Designing the displacement-step diagram

Pneumatic circuit diagram

Manipulative Skills Members do not demonstrate needed skills

Time management/Conduct of Experiment

Cooperative and Teamwork

Neatness and Orderliness Messy workplace/paper during and after

Ability to do Independent Work

Designing the displacement-step diagram

Other Comments/Observation: Total Score

Total Number of Item

1. To be able to identify and eliminate faults in simple electro-pneumatic control systems.

▪ Only one fault has occurred.

Pallet loading station

1. Cylinder 1A1 is to advance if pushbutton S1 is pressed. This causes a single package to

1A1+ 2A1+ 1A1–

The following fault occurs in the circuit shown below:

- Describe what the potential causes of the fault could be.

Pneumatic circuit diagram

Electrical circuit diagram

In which pneumatic tubing connections could the fault occur?

▪ In which current paths could the fault be located?

- Enter all the possibilities.

Measuring and test protocol

Investigate the potential error causes you have found.

Measuring and test protocol

- Describe each of the steps carried out in detail.

Ask for new worksheet s to do so.

Reset the specified required times.

- Briefly document the procedure followed in note form.

Manipulative Skills Members do not demonstrate needed skills

Time management/Conduct of Experiment

Cooperative and Teamwork

Neatness and Orderliness Messy workplace/paper during and after the

Ability to do Independent Work

Wrong descriptions of the potential cause