EE061 Pneumatic Controls PR Inst

SRI LANKA INSTITUTE of ADVANCED TECHNOLOGICAL EDUCATION
ELECTRICAL and ELECTRONIC

ENGINEERING
Instructor Manual
Training Unit
Pneumatic Controls
Practice
No: EE 061
Training Unit
Pneumatic Controls
Practical Part
No.: EE 061
Edition:
2009
All Rights Reserved
Editor:
MCE Industrietechnik Linz GmbH & Co

Education and Training Systems, DM-1
Lunzerstrasse 64 P.O.Box 36, A 4031 Linz / Austria
Tel. (+ 43 / 732) 6987 3475
Fax (+ 43 / 732) 6980 4271
Website: www.mcelinz.com
1
PNEUMATIC CONTROLS
LIST OF CONTENT
CONTENTS
Page
Introduction ...........................................................................................................................4
General Information...........................................................................................................4
Safety ................................................................................................................................6
Performing Exercises ........................................................................................................6
Commissioning ..................................................................................................................7
Exercise 1
Direct control of a single-acting cylinder, extending ......................................9
Exercise 2
Direct control of a single-acting cylinder, retracting.....................................11
Exercise 3
Indirect control of a single-acting cylinder ...................................................14
Exercise 4
Regulating the speed of a single-acting cylinder .........................................17
Exercise 5
Slow-speed extension, rapid retraction of a single-acting cylinder..............20
Exercise 6
Direct control of a double-acting cylinder with push-button .........................23
Exercise 7
Indirect control of a double-acting cylinder ..................................................26
Exercise 8
Speed regulation of a double-acting cylinder ..............................................28
Exercise 9
Controlling a double-acting cylinder, impulse valve, 2 push-buttons...........31
Exercise 10
Displacement-dependent control of a double-acting cylinder, impulse valve ..

.....................................................................................................................34
Exercise 11
Controlling a double-acting cylinder, impulse valve, 2 reflex nozzles..........37
Exercise 12
Stop control, double-acting cylinder with 5/3 directional control valve, tensile
load
.....................................................................................................................41
Exercise 13
Pressure-dependent control of 1 double-acting cylinder .............................45
Exercise 14
Time-dependent control of 1 double-acting cylinder....................................49
Exercise 15
Logical control with shuttle and twin-pressure valves..................................53
Exercise 16
Sequential control of 2 double-acting cylinders without overlapping signals...

.....................................................................................................................57
Exercise 17 Sequential control of 2 double-acting cylinders with signal overlapping, rollers

with idle return.....................................................................................................................61
Exercise 18
Sequential control of 2 double-acting cylinders with signal overlapping,
change-over valve...............................................................................................................65
Introduction
General Information
The exercises to be found in this brochure "Rexroth Practice for Professionals Pneumatics" correspond to the exercises of "bungsreihe Pneumatik" [Training series
"Pneumatics"] published by the Bundesinstitut fr Berufsbildung (Federal Institute for
Vocational Training) in Berlin.
The exercises were extended in respect to the technological further developments in

pneumatic control technology and new exercises were added to the practice series.
For practical exercises, a practice System and the basic kit for pneumatics under the BIBB
order number 0827 003 365 are available.
In order to achieve the best practical results, the basic kits include only industrial
components. The components are equipped with a patented "Snap-in" system and can be
easily and quickly attached to the base plate by the user in the exercises.
The following features characterize the practice system:

-
The base plate is a grooved plate. lt provides the advantage of being able to position
the components infinitely and allows a variable arrangement on the plate.
The grooved plate can be used horizontally on a lab table to do practical exercises.
The air service unit can be tilted to a 45 degree angle and thus can be optimally
mounted on the horizontal plate.
The mobile "DS3 synergy" system uses various table and accessory modules to create
various set-ups.
The grooved plate can also be used in a vertical or tilted position.
The "Snap-in" system allows all components to be easily attached and in some cases
be turned at a 90 degree angle. In this manner the space on the plate can be used
more effectively.
Valves of various nominal sizes with quick-release coupling attached are used. The
elements are connected by plastic tubes of the same diameter.
All cylinders used have a piston diameter of 25 mm. Single-acting cylinders have a
stroke length of 50 mm, the double-acting cylinders of 100 mm and are spring
cushioned.
For exercises in connection with electro-pneumatic components, the double-acting

cylinders are equipped with proximity switching through an annular magnet
encapsulated in the piston.
Base plate and basic kit for the practical exercises

Description
Order No.
Grooved plate LT
0 827 003 702
Basic kit Pneumatics BIBB
0 827 003 365
Optional Equipment and Accessories
Description
Order No.
DS3 Basic frame
0 827 003 701
Grooved plate ERGO
0 827 003 717
Mobile file
0 827 003 707
Writing support
0 827 003 705
Information board (A4-sheet holder)
0 827 003 721
Safety
In general there are no real dangers when doing exercises with pneumatic components.
Nevertheless, all piping work should principally be executed with the air pressure turned off
(ball valve an the air-service unit should be closed).
Please regard the following measures in any case:

-
The locking plugs on the quick-release couplings of distributor and components should
be properly secured!
Plastic tubes that come loose from quick-release couplings when pressure is applied
have a "lashing effect" (protect eyes!).
When detaching tubes under pressure, use one hand to press the release ring and the
other to pull out the end of the tube, holding it tightly.
lt is possible that cylinders will independently start to move when turning on the air
pressure.
Do not try and touch any moving parts (piston rod, switching cam). This could cause
painful injuries by pinching your finger between the limit switch and switching cam.
Performing Exercises
For optimum, synergetic and successful learning within a reasonable exercise time, two
students should work together at a practice unit at a time.
The equipment to be used is listed in the equipment list in the instructions.
The arrangement of the equipment on the base plate should be executed according to
the arrangement sketch that goes with each exercise.
The components are attached by snapping them properly onto the grooves in the
grooved plate.
The exercise is to be circuited according to the circuit diagram with plastic tubes and Tdistributors.
The plastic tubes are to be stuck into the quick-release coupling with light pressure. To
detach the tubes, briefly press the release ring with one hand and remove the tube with
the other.
Note: to avoid the plastic tubes from getting stuck, frequently cut off the end of the tube
with the tube cutter.
Pay attention to optimum error detection: when an error occurs, do not pipe the
exercise again, even in the most complicated circuits that are already mounted, but
rather use the systematic error analysis to find the error and eliminate it.
Further notes an executing the exercises, as well as written and graphic evaluation can
be found in the instructions in each description.
Commissioning
For each exercise unit, a pressure supply of 6 to 8 bar, without lubrication, should be
available, with a suction capacity of 50 to 100 NI/min.
The system pressure at the work-place should be set an the air regulator as a standard
of pe = 5 bar.
All piping work should be carried out without pressure (ball valve an the air service unit
should be closed).
Any air escaping through open quick-release couplings or from plastic tubes causes a
drop in pressure, especially when several workplaces with relatively low supply
capacity and insufficient storage volume are in operation.
Basic Kit Pneumatics BIBB Order No. 1 827003 365, List of Components
Qty.
1
1
1
3
1
2
1
1
1
1
3
1
4
2
2
1
1
2
5
1
3
1
1
1
2
2
1
25
5
5
25m
2m
1
Description
Order No.
Air service unit with 3/2 directional control ball valve, G1/8, 0.5
- 10 bar
Distributor, 6-fold, self-closing couplings
Cylinder, single-acting with return spring, = 25 mm, stroke =
50 mm
Cylinder, double-acting, with adjustable spring cushioning and
for proximity switching, = 25 mm, stroke = 100 mm
Cylinder, double-acting with adjustable spring cushioning and
for proximity switching, = 25 mm, stroke = 100 mm, with an
attachment for tensile load 3.4 kg
3/2 directional control valve M5, manually operated with pushbutton, closed neutral position
3/2 directional control valve G1/8, manually operated with
push-button, flow in both directions
5/2 directional control valve G1/8, manually operated with
push-button
3/2 direct. control valve G1/8 with restoring spring, pneum.
operated, flow in both directions
5/2 directional control valve G 1/8 with restoring spring,
pneumatically operated
5/2 directional control impulse valve G1/8, pneumatically
operated
5/3 directional control valve G1/8, pneumatically operated,
mid-position closed
3/2 directional control valve M5, mechanically operated, roller,
closed neutral position
3/2 direct. control valve M5, mech. operated, idle return roller,
Flow control valve with non-return G1/8, hose version
Quick-exhaust valve G1/4
3/2 directional control time delay valve, G1/8, flow in both
directions, 0.15 - 55 s
Shuttle valve (OR) G 1/8, 1-fold
Twin-pressure valve (AND) G 1/8, 1-fold
Pressure display, pneumatic, red, minimum pressure 1.2 bar
Pressure gauge 0 - 10 bar
Pressure switch with 3/2 directional control valve function,
adjustable 2-8 bar
Pressure control valve with pressure gauge, G1/8, 0.5 - 10 bar
Pressure control valve for low pressure, with pressure gauge,
G1/8, 0 - 1 bar
Reflex nozzle, min. pressure, 0.4 bar
3/2 amplifier for reflex nozzle, 2-stage, G 1/8, X=12 - 500 mbar
Step sequence for 4 steps and check step, M5
Blanking plug, tube diameter 4 mm
Two-way plug, tube diameter 4 mm
T-connection for plastic tubing 4 mm
Plastic tubing 4 x 1; calibrated on the outside, PU black
Plastic tubing 6 x 1; calibrated on the outside, PU black
Tube cutter for plastic tubes
1 827 003 410
Comp
. No.
1
1 827 003 411

1 827 003 371
2
3
1 827 003 372
1 827 003 373
1 827 003 392
1 827 003 393
1 827 003 396
1 827 003 374
1 827 003 376
10
1 827 003 377
11
1 827 003 378
12
1 827 003 399
13
1 827 003 401
14
1 827 003 379

1 827 003 381
1 827 003 385
15
16
17
1 827 003 382

1 827 003 383
1 827 003 409
1 827 003 406
1 827 003 388
18
19
20
21
22
1 827 003 386

1 827 003 387
23
24
1 827 003 403

1 827 003 389
1 827 003 390
1 823 105 006
1 823 391 629
1 823 381 043
1 820 712 010
1 820 712 012
1 827 391 390
25
26
27
-------------
Exercise 1 Direct control of a single-acting cylinder, extending
Aim
This exercise provides basic know-how and skills on the set-up and operation of pneumatic
controls using the control of a single-acting cylinder as an example.
Suggestion for the positioning of equipment on the working plate
Pneumatic circuit diagram
List of equipment
Pos.
01
02
03
06
21
Qty. Description
1 Air service unit
(filter with water
separator, pressure
regulator and
pressure gauge)
with 3/2 directional
control ball valve
1 Distributor, 6-fold
1 Single-acting
cylinder
1 3/2 directional
control valve with
manually operated
push-button
1 Pressure gauge
Accessories
Task
-
The piston rod of the single-acting cylinder (Z1) should extend after the button (S1) has
been actuated and remain extended as long as the button is pushed.
The active pressure that is placed on the cylinder piston should appear on the pressure
gauge.
The pressurized air is supplied by an air service unit (filter with water separator,
pressure regulator and shut-off valve) and by the compressed-air distributor.
The circuit diagram is to be drawn or additions made using symbols and port symbols
according to ISO 1219 and RP68P.

-
The piston rod of the single-acting cylinder Z1 extends after pushing the button S1 and
remains in that position as long as the button is pushed.
A pressure gauge registers the active pressure on the cylinder piston.
Didactic notes
-
This simple exercise helps get the student acquainted with the practical use of the
practice unit and components.
The student performs the proper setting of the working pressure on the air service unit
and practices the use of plastic tubes and quick-release couplings.
Before starting the first exercise, the participant should be informed of the procedure as
well as the security measures involved.
Instructions
-
The arrangement of the equipment on the working plate should be as shown in the
arrangement sketch.
The working pressure of pe = 5 bar is to be set at the pressure regulator of the air
service unit.
The components are to be connected with plastic tubes and accessories according to
the circuit diagram.
The working pressure is switched on with the ball valve.
The exercise is started and the proper function is checked.
Conclusion
A single-acting cylinder can basically only be controlled with a 3/2 directional control valve.
Corresponding to the basic position of the single-acting cylinder (piston rod retracted) a 3/2
directional control valve in locked, neutral position (n.c. = normally closed) should be
mounted.
10
Exercise 2 Direct control of a single-acting cylinder, retracting
Aim
This exercise demonstrates the use of a 3/2 directional control valve with flow in both
directions functioning as an open neutral position valve of a single-acting cylinder extended
in neutral position.
Suggestion for the positioning of equipment an the working plate
List of equipment
Pos.
01
Qty.
1
02
03
1
1
07
Description
Air service unit
(filter with water
separator,
pressure
regulator and
pressure gauge)
with 3/2
directional control
ball valve
Distributor, 6-fold
Single-acting
cylinder
3/2 directional
control valve with
manually
operated pushbutton, flow in
both directions
Accessories
11
Task
-
The basic position of the piston rod of the single-acting cylinder (Z1) is extended after
switching on the compressed air supply.
After actuating the push-button (S1) the piston of the single-acting cylinder should
retract and remain retracted as long as the button S1 is pushed.
The pressurized air is supplied by an air service unit (filter with water separator,
pressure regulator and shut-off valve) and by the pressure distributor.
The circuit diagram is to be drawn or additions made using symbols and port symbols
according to ISO 1219 and RP68P.

-
After switching on the pressure by opening the 3/2 directional control ball valve, the
piston of the single-acting cylinder extends.
After pushing the button S1 (3/2 directional control valve), the piston rod of the singleacting cylinder Z1 retracts and remains retracted as long as the button S1 is pushed.
Didactic notes
-
In addition to the 2 types of seat constructions for 3/2 directional control valves, closed
neutral position or open neutral position, the spool valve design is also available.
One advantage of the spool valve is that the valve principally allows "flow" in both
directions.
This type of valve can therefore be applied in an open neutral position or also in the
closed neutral position.
Technical notice referring to the equipment: the designation of symbols for ports for
spool valves with flow in both directions is often found in different manners:
in some cases only the symbol indicates this design, but often the ports are marked
with 1/3 or 3/1 or 1 (3) or 3 (1).
In the case of servo valves, a mechanical alteration is often necessary (for example
twisting the servo head) in addition to exchanging the two ports 1 and 3.
In the circuit diagram the solution with a manually operated 3/2 directional control valve
in open neutral position is to be considered as correct.
Instructions
-
arrangement sketch.
service unit.
12
The components are to be piped according to the circuit diagram with plastic tubes and
accessories.
The exercise is started and the proper function is controlled.
Conclusion
In addition to the 3/2 directional control valves in closed neutral position (or n.c.) there are
also directional control valves with open neutral position, (n.o. normally open). When a
pneumatic circuit diagram is marked as "pressure-free" (3/2 directional control ball valve on
"off"), then the cylinder also must be pictured in the pressure-free condition, i.e. the piston
rod is retracted.
13
Exercise 3 Indirect control of a single-acting cylinder
Aim
This exercises conveys know-how on the indirect control of cylinders, using a single-acting
cylinder and a pneumatically operated 3/2 directional control valve as an example.
List of equipment
Pos.
01
Qty.
1
02
03
1
1
06
09
Description
Air service unit
(filter with water
separator, pressure
regulator and
pressure gauge)
control ball valve
Distributor, 6-fold
Single-acting
cylinder
3/2 directional
control valve with
push-button, closed
neutral position
Pneumatically
operated 3/2
directional control
valve, closed
neutral position
Accessories
14
Task
-
The piston rod of a single-acting cylinder (Z1), retracted in neutral position, should
advance after pushing an easily pressed button (S1).
Note: for the control of a large-volume cylinder (with a large piston diameter) an
accordingly dimensioned directional control valve is necessary.
The cylinder is mounted a slight distance from the button (S1).
After releasing the manual push-button, the piston of the cylinder should retract
automatically into its back position.
Additions to the circuit diagram.
All connections should be marked with the port symbols according to ISO 5599 or RP
68 P.

-
A manually operated 3/2 directional control valve in closed neutral position (start button
S1) applies pressure to a pneumatically operated 3/2 directional control valve.
A large volume single-acting cylinder is controlled via a pneumatically operated 3/2

directional control valve (pos. 9), the piston rod extends.
Didactic notes
-
Basic knowledge of the dimensioning of pneumatic components is a prerequisite for

understanding this exercise.
lt should be pointed out that in practice it is necessary to use plastic tubes of different
dimensions and colors.
Circuit diagram: control lines are the connecting lines between the output of signalling
elements (for example button S1) and the pneumatic actuation ports of the actuators
(for example pneumatically operated 3/2 directional control valve, port 12). These
connecting lines are to be drawn as dotted lines.
The air pressure line to the signalling elements is also often dotted.
Note: therefore it is especially important that the participants understand the topics
"servo valves" and "indirect control of cylinders" and do not confuse the two.
The main reason for using indirect control in pneumatics: large volume, single-acting
cylinders should be able to be controlled with a small dimensioned directional control
valve at acceptable working speed. In addition, the button can also be mounted
somewhat farther away from the cylinder (for example a button built into a control
panel).
15
Instructions
-
arrangement sketch.
service unit.
accessories.
The exercise is started and the proper function is controlled.
Conclusion
Large volume cylinders cannot be directly controlled with small-dimensioned directional
control valves. These cylinders are therefore indirectly controlled through the installation
of pneumatically operated 3/2 directional control valves in a size corresponding to the
cylinder size.
16
Exercise 4 Regulating the speed of a single-acting cylinder
Aim
This exercise demonstrates the application of a one-way flow control valve to infinitely
adjust the speed of a single-acting cylinder.
List of equipment
Pos. Qty. Description
01
1 Air service unit (filter
with water separator,
pressure regulator
and pressure gauge)
control ball valve
02
03
1 Single-acting cylinder
07
1 3/2 directional control
valve with pushbutton, closed neutral
position
15
1 Flow control valve
with non-return,
adjustable
21
2 Pressure gauge
Accessories
17
Task
-
The extension speed of the piston rod of a single-acting cylinder (Z1), retracted in its
neutral position, should be infinitely adjustable.
The retraction of the piston rod occurs at normal speed. The retraction speed is not
adjustable.
The cylinder is controlled with a manually operated button (S1). After releasing the
button, the piston of the cylinder should retract automatically into its back position.
All connections should be marked with the connection symbols according to ISO 5599
or RP 68 P.

-
A single-acting cylinder Z1 is directly controlled via a pneumatically operated 3/2

directional control valve (S1).
A flow control valve with non-return is built into the working line between the cylinder
and the control valve which enables the piston rod to extend with infinitely adjustable
speed and to retract with normal speed (through spring force).
The flow control valve with non-return is mounted in such a way that the air flowing into
the cylinder is restricted (supply air restriction).
Two pressure gauges indicate the pressure before and alter the flow control valve with
non-return.
Didactic notes
-
If there is no port symbol on the flow control valve with non-return, then the direction of
the symbol on the valve is considered that of the flow control valve with non-return.
That is the reference for the correct mounting of the element.
If the flow control valve with non-return is closed all the way or otherwise blocked
(particles in the throttle) then the cylinder can only retract but not extend.
Instructions
-
arrangement sketch.
service unit.
accessories.
18
The knurled-head screw on the flow control valve with non-return should be unscrewed
as far as possible (counter-clockwise).
Actuate S1, observe the retraction and extension speeds.
When frequently changing the setting of the flow control valve with non-return, observe
both speeds (when retracting and extending) as well as the pressure on both pressure
gauges.
Conclusion
Flow control valves with non-return are used to achieve infinitely adjustable speed
regulation of the piston rod movement. The flow control valves with non-return are
mounted in the working lines between the directional control valve and cylinder. For a
single-acting cylinder the supply air restriction is used for the extending movement.
19
Exercise 5 Slow-speed extension, rapid retraction of a single-acting cylinder
Aim
In addition to throttling the cylinder speed, this exercise shows how to achieve the highest
possible speed when retracting the piston rod by using a quick-exhaust valve.
List of equipment
01
pressure regulator
and pressure gauge)
control ball valve
02
03
1 Single-acting cylinder
07
valve with pushbutton, closed neutral
position
15
1 Flow control valves
with non-return,
adjustable
16
1 Quick-exhaust valve
Accessories
20
Task
-
The piston rod of a large volume, single-acting cylinder (Z1) is to extend with restricted,
adjustable speed.
The retraction of the piston rod should occur at the highest possible speed, also when
the directional control valve (S1) is mounted a distance away from the cylinder.
The cylinder is controlled by a manually operated button (S1). After releasing the
button, the piston rod should retract automatically into its back position.
or RP 68 P.

-
Via the flow control valve with non-return mounted in the working line the speed of the
piston rod when extending can be infinitely restricted.
Through the quick-exhaust valve, also mounted in the working line (as near to the
cylinder port as possible), the cylinder piston retracts with the maximum possible
speed.
Didactic notes
-
In practice, the valves are screwed directly on to the cylinder port with a double nipple
(with the exception of miniature quick-exhaust valves for tubes with a diameter less
than 3 mm).
Depending on the diameter of the cylinder and the piston rod speed, a loud exhaust
noise can be heard when pressure is released from the quick-exhaust valve. An
exhaust silencer should be available in such cases to protect those persons working
there.
Quick-exhaust valves are also used in cases where pressure needs to be quickly
released (for example they are installed in pneumatic two-hand safety controls).
Instructions
-
arrangement sketch.
accessories.
The knurled-head screw on the flow control valve with non-return should be unscrewed
as far as possible.

21
Actuate S1, observe the retraction and extension speeds.
When frequently changing the setting of the flow control valve with non-return, make
sure to observe both speeds.
Conclusion
The highest possible speed of the piston rod can be achieved by mounting a quickexhaust valve in the corresponding working line of a cylinder.
The pressure release of the cylinder volume then occurs directly via the exhaust vent port
3 of the quick-exhaust valve. The quick-exhaust valve is mounted directly at the cylinder
port.
22
Exercise 6 Direct control of a double-acting cylinder with push-button
Aim
This exercise provides know-how on the direct control of double-acting cylinders with
manually operated 5/2 directional control valves.
In addition, the effect of adjustable spring cushioning in double-acting cylinders can be
observed.
List of equipment
01
pressure regulator
and pressure gauge)
control ball valve
02
04
1 Double-acting
cylinder with
adjustable spring
cushioning
08
valve with pushbutton
Accessories
23
Task
-
The piston rod of a double-working cylinder (Z1) should extend after actuating a button.
After releasing the button (S1), the piston of the cylinder should retract automatically to
its back position.
or RP 68 P.

-
The cylinder is retracted in neutral position.
The double-acting cylinder is directly controlled by a manually operated 5/2 directional

control valve (pos. 8).
The spring cushioning mounted in the cylinder can be adjusted.
Didactic notes
-
At the end of the exercise, refer to the 4/2 directional control valve and explain the
difference between the two valve designs.
Explain the features of the various spool designs (soft-sealing spool, metal spool) of
5/2 directional control valves.
A watchmaker's screwdriver is necessary for adjusting the set screw of the spring
cushioning.
lnstructions
-
arrangement sketch.
accessories.
Check and see if the cylinder is retracted in neutral position and that pressure is
applied to it in this position.
Actuate S1.
Check the proper sequence.
Extra experiment:
-
Set the greatest possible working pressure on the pressure regulator.
Both set screws of the spring cushioning are to be unscrewed with a screwdriver as far
as possible (counter-clockwise).
24
Trigger the cylinder and observe how hard the piston hits the end positions.
Adjust spring cushioning to a higher level and observe the effect of the spring
cushioning.
Conclusion
The control of a double-acting cylinder occurs principally through a 5/2 directional control
valve as an actuator.
In the basic setting (spring position) of a 5/2 directional control valve supplied with
compressed air at port 1, port 2 is always "pressurized" and port 4 always "vented".
25
Exercise 7 Indirect control of a double-acting cylinder
Aim
This exercise demonstrates the indirect control of a double-acting cylinder with a
pneumatically operated 5/2 directional control valve.

List of equipment
01
pressure regulator and
pressure gauge) with 3/2
directional control ball
valve
02
04
1 Double-acting cylinder
with adjustable spring
cushioning
10
1 Pneumatically operated
5/2 directional control
valve
06
valve with push-button,
Accessories
Task
-
The piston rod of a double-acting cylinder (drive element Z1), retracted in neutral
position, should extend after actuating a button (controlling element S1).
26
Control of the cylinder (Z1) should occur indirectly.
After releasing the push-button (S1), the piston of the cylinder should retract
automatically to its back position.
Additions to the circuit plan.
or RP 68 P.

-
A pneumatically operated 5/2 directional control valve (actuator) is controlled with a

manually operated 3/2 directional control valve (signalling element S1).
The piston rod of the double-acting cylinder (actuating drive Z1) extends.
Didactic notes
-
Point out how the control sequence is broken up into different components:
signalling elements (signal input) control elements (signal processing) actuators (signal
output) drive elements (execution of the movement)
Point out the signal flow direction of the signalling elements up to the drive element.
This breakdown into components and the signal flow direction should also be depicted
in the pneumatic circuit diagram.
lnstructions
-
The arrangement of the equipment an the working plate should be as shown in the
arrangement sketch.
accessories.
The working pressure is switched an with the ball valve.
Check and see if the cylinder is retracted in neutral position and that pressure is
applied to it in this position.
Actuate S1.
Control the proper sequence.
Conclusion
Air-actuated 5/2 directional control valves are, as all other pneumatically operated
directional control valves, controlled with a 3/2 directional control valve as a signalling
element. The function of the signalling elements (model of the 3/2 directional control valve)
is principally always the closed neutral position (n.c.).
27
Exercise 8 Speed regulation of a double-acting cylinder
Aim
In this exercise, the various types of speed regulation (throttling) of the piston rod
movements of double-acting cylinders with one-way flow control valves are looked at and
the effects are observed.
List of equipment
04
cushioning
08
valve with push-button
15
with non-return,
adjustable
Air service unit,
pressure distributor
and accessories (not
included in the circuit
diagram)
28
Task
-
The extension speed and the retraction speed of the piston rod of a double-acting
cylinder (drive element Z1), retracted in neutral position, should be infinitely adjustable.
The movement of the piston rod is not allowed to be a jerky movement, neither when
extending nor when retracting.
lt is assumed that the drive element (Z1) and the actuator (S1) are mounted at least 2 3 meters apart.
The cylinder is controlled with a manually operated button (actuator S1). After releasing
the button (S1), the piston of the cylinder should retract automatically to its back
position.
or RP 68 P.
Circuit 1: the speed of the cylinder piston is restricted when extending (restricting the
exhaust) by mounting one flow control valve with non-return in the working line port 2 of
the 5/2 directional control valve.
Circuit 2: the speed of the cylinder piston is restricted when retracting (restricting the
exhaust) by mounting one flow control valve with non-return in the working line port 4 of
the 5/2 directional control valve .
Circuit 3: both speeds of the cylinder piston are restricted (both restricting the exhaust)
by mounting two flow control valves with non-return in both working lines of the 5/2
directional control valve.
Circuit 4: the speed of the cylinder piston is restricted when extending (air supply
restriction) by mounting one flow control valve with non-return in the working line port 4
of the 5/2 directional control valve.
Pneumatic circuit diagrams
Didactic notes
-
Explain the difference between the models "hose version" and "screw-in version" of
flow control valves with non-return.
Discuss advantages and disadvantages of speed regulation with flow control valves
directly mounted in the exhaust ports of the valve. Refer to the differences in the use of
this restriction of 4/2 or 5/2 directional control valves in this context.
Also refer to the function of flow control valves in silencers or directly mounted in
valves.
29
Instructions
-
The 4 exercises are to be arranged and piped alter each other an the working plate.
The working pressure is switched an with the ball valve.
In all 4 exercises, the adjustment of the flow control valve with non-return is to be
changed.
Then observe and judge the movements of the piston and the effect an speed and jerkfree movement.
Conclusion
In the case of double-acting cylinders, the speed regulation in both directions is usually
achieved by mounting two flow control valves with non-return in the working lines
between cylinder (actuating drive) and 512 directional control valve (actuator). Both flow
control valves with non-return are applied as a standard to restrict exhaust air flow.
30
Exercise 9 Controlling a double-acting cylinder, impulse valve, 2 pushbuttons
Aim
In this exercise we examine how a pneumatically operated impulse valve functions when
controlling a double-acting cylinder.
List of equipment
04
cushioning
11
valve, impulse valve
15
with non-return,
adjustable
06
valve, with manually
operated push-button
07
operated push-button,
flow in both directions
Air service unit,
diagram)
31
Task
-
The piston rod of a double-acting cylinder (drive element Z1), retracted in neutral
position, should extend after actuating a button (signalling element S1) and remain
extended alter releasing the button (S1).
After actuating a second button (signalling element S2), the piston rod of the cylinder
should again retract and also remain in this position, even when the button (S2) is no
longer actuated.
The working speed of the cylinder should be able to be infinitely adjusted in both
directions.
or RP 68 P.

-
By briefly actuating the button S1, the piston rod of the double-acting cylinder extends
to its front end position and remains in this position.
Only when the button S2 is also briefly actuated does the piston rod retract back into its
initial position. The speed of both cylinder movements can be infinitely adjusted with
the flow control valves with non-return.
Didactic notes
-
Discuss basic properties and cases of application of pneumatic impulse valves.
Explain the cause and effect when both control ports of the impulse valve receive a
signal simultaneously.
Concerning service and error detection in the case of pneumatic controls it should be
pointed out that an impulse valve has no defined basic setting.
Instructions
-
arrangement plan.
accessories.
The working pressure is switched on with the ball valve. Observe whether the piston of
the cylinder remains in the back end position.
Actuate S1 briefly and release, the piston of the cylinder extends.
Actuate S2 briefly and release, the piston of the cylinder retracts.
32
When the piston of the cylinder is in the back end position, actuate S1 and continue to
press. Then additionally actuate button S2 and continue to press. Determine effects.
Repeat the same experiment, but this time with an extended cylinder piston and first
continue to press button S2, then actuate button S1.
Conclusion
Impulse valves (e.g. 5/2 directional control impulse valves) store pneumatic signals and
are always controlled with 2 pneumatic signals (3/2 directional control valves). An impulse
valve remains in the actual switch position until it receives the opposite signal (without the
aid of pressurized air). An impulse valve therefore has no defined basic setting (= bistable).
33
Exercise 10 Displacement-dependent control of a double-acting cylinder,

impulse valve
Aim
The displacement-dependent control of a double-acting cylinder by using limit switches is
demonstrated in this exercise.
Example of application
Functional diagram
34
List of equipment
Pneumatic circuit diagrams

04
cushioning
11
valve, impulse valve
15
with non-return,
adjustable
06
operated push-button
13
valves, with roller
Air service unit,
diagram)
Task
"Sheet-bending machine"
-
A double-acting cylinder is used in a bending machine to form a metal sheet.
The piston of the cylinder (Z1) extends when the button (S0) is actuated until it reaches
its front end position and forms the workpiece.
Then the piston of the cylinder automatically retracts to its back end position.
The working speed should be infinitely adjustable in both directions.
Additionally: the button (S0) is normally only actuated briefly. If the button remains
actuated the cylinder nevertheless must retract to its back end position.
Develop the functional diagram with actuator and drive element.
Drawing up the circuit diagram with symbols and port symbols according to ISO 5599
or RP 68 P.

-
If the start button (S0) is actuated and the feeler roll (S1) mounted in the back end
position of the cylinder (Z1) is also actuated, then the signal reaches port 14 of the
impulse valve and switches it over, extending the piston rod.
If limit switch S2 is contacted by the piston rod plunger, the signal arrives at port 12 of
the impulse valve, the impulse valve switches back to the right switch position, the
piston retracts.
35
The limit switch S1 is actuated in the back end position of the piston; now the control is
ready for a new start.
The speed of both cylinder movements is infinitely adjusted with the flow control valves
with non-return.
Didactic notes
-
lt is standard to use 3/2 directional control valves in closed, neutral position with
mechanical feeler roll actuation as limit switches for displacement-dependent
pneumatic controls.
The limit switches are depicted in the lower level of the pneumatic circuit diagram like
all other signalling and connecting elements and not at their location of actuation!
At the location of actuation only the symbol of the signalling element with a mark (short
line) is entered.
In addition, a triangle is drawn at the front of the piston rod. This represents the
mechanical actuation by various parts such as cams, plungers, disks, etc.
Instructions
-
arrangement sketch.
accessories.
When S0 is actuated and the limit switch S1 is mounted properly in the back end
position of the cylinder, the piston rod of the cylinder extends.
Conclusion
Mechanically actuated signalling elements are used as "limit switches" for displacementdependent controls.
A limit switch in neutral position can be actuated or not actuated. If a limit switch is
actuated in neutral position, then it will be depicted as actuated.
36
Exercise 11 Controlling a double-acting cylinder, impulse valve, 2 reflex

nozzles
Aim
Introducing the pneumatic, proximity switching signalling technology with the example of
reflex nozzles and pneumatic amplifiers.
Functional diagram
37
List of equipment
04
cushioning
23
1 Pressure regulating
valve with filter and
pressure gauge, pe =
0 - 1 bar
11
impulse valve
15
with non-return,
adjustable
06
valves with pushbutton, closed neutral
position
25
2 Reflex nozzles
26
2 3/2 amplifiers
Air service unit,
included in circuit
diagram)
38
Task
"Conveying parts from a drop magazine"
-
After actuating the start button (S0), the piston of a double-acting cylinder pushes parts
from a drop magazine on to a conveyer belt.
When the piston has pushed the part out of the drop magazine, it automatically
retracts.
Additionally: a new start may only be possible if the piston of the cylinder is actually in
its back end position.
Additionally: mechanically operated signallers cannot be used for scanning cylinder

plungers and parts. The signallers must operate "without contact".
The working speed of the cylinder should be infinitely adjustable in both directions.
Design the functional diagram with actuator and drive element.
or RP 68 P.

-
If the start button (S0) is actuated and the reflex nozzle (B1) mounted in the back end
position of the cylinder (Z1) scans the plunger and switches the pneumatic amplifier
assigned to it, then the piston rod extends.
The piston rod then retracts when the reflex nozzle (B2) mounted in the front end
position of the cylinder switches the assigned pneumatic amplifier and a signal reaches
the control port 12 of the impulse valve.
The speed of both cylinder movements can be infinitely adjusted with the flow control
valves with non-return.
Didactic notes
-
Discuss applications with proximity switching pneumatic signalling technology in

pneumatics such as areas where there is a danger of explosion, situations where there
is a danger of dust and contamination.
Explain the function of reflex nozzles.
Explain the operation principle of pneumatic amplifiers (flapper-nozzle principle).
State the proper working pressure of nozzles and amplifiers.
39
Instructions
-
arrangement sketch.
Check and see if there is a distance of 2-3 mm set between the cylinder plunger and
the two reflex nozzles.
accessories.
Attention: check whether the standard pressure and the low pressure lines on both
pressure amplifiers are properly connected.
The pressure on the low pressure regulator should be set at pe = 0.4 bar
The circuit is to be tested.
Conclusion
Reflex nozzles are used in pneumatic controls for proximity switching. These signallers
work out of physical reasons in the low pressure range at approx. 0.3 - 0.5 bar. Therefore
the output signal X of a reflex nozzle is also a low pressure signal and must be amplified
before using in a standard pressure range.
40
Exercise 12 Stop control, double-acting cylinder with 5/3 directional control

valve, tensile load
Aim
This exercise demonstrates the use of a 5/3 directional control valve with closed midposition for stopping a double-acting cylinder.
The exercise also shows the effects of leaks in the connecting lines and in the 5/3
directional control valve when holding a load.
Functional diagram
41
List of equipment

05
1 Double-acting cylinder,
with a device for
tensile load
12
valve, closed midposition
15
with non-return,
adjustable
21
2 Pressure gauges
06
valve, with push
button, closed neutral
position
07
valve, with push
button, flow in both
directions (closed
neutral position)
Air service unit,
diagram)
Task
"Controlling the door of a hardening plant"
-
The piston of the double-acting cylinder (Z1) opens and closes the doors of a
hardening plant. The push-button (S1) is to be used to open the door, and the pushbuttons (S2) to dose it again.
As soon as one of the push-buttons is no longer actuated, the cylinder stops. The door
then remains in this position.
In jog mode, the door can be brought into any position and locked (stopped) there.
The active pressure is controlled by means of 2 pressure gauges at the cylinder ports.
Design the functional diagram with actuator and drive element.
or RP 68 P.
42

-
The actuator, a pneumatically operated 5/3 directional control valve with closed midposition, is used to control a double-acting cylinder.
The two signalling elements, S1 and S2 (two 3/2 directional control valves, manually
operated) are used to direct the piston of the cylinder upwards or downwards.
As soon as one of the two signalling elements is actuated, the 5/3 directional control
valve moves into the closed mid-position, stopping the cylinder (locked).
The weight of the door and with it the special stopping behavior of the cylinder is
replaced by the tensile load.
Didactic notes
-
All tube connections from the actuator to the drive element must be checked for leaks.
Refer to the result of tubes coming loose in the working lines of the cylinder.
Point out the locking of the piston, even when there is no working pressure.
Demonstrate what happens when both signalling elements are actuated.
How precise is the stopping with this control?
Does the speed regulation have an effect on the precision of the stopping?
When observing the pressure of the lower cylinder port, pull the piston down lower with
your hand.
Clearly define the difference between stopping (locking) and positioning.
Discuss other possible circuits for stop control (application of non-return valves in the
working lines of the cylinder).
At the end of the exercise refer to the two other 5/3 directional control valves, (5/3
vented mid-position and 5/3 directional control valves, pressurized, mid-position).
lnstructions
-
arrangement sketch.
The cylinder must be securely mounted with the tensile load (only possible with a
vertically mounted working plate).
accessories.
After turning on the working pressure, the position of the cylinder, extended in neutral
position, with the tensile load is not allowed to change.
Actuating the signalling element S2 causes the piston rod of the cylinder to move
upwards with the weight.
43
After releasing the signalling element S2, the cylinder piston stops but is still "pulled
down" a short distance by the weight.
At this moment (working pressure of pe = 5 bar) the pressure in the upper cylinder
chamber is below patm, the pressure in the lower cylinder chamber is briefly at approx. 4
bar, but it will surely sink lower.
Any leaks in the piping and in the elements cause the pressure to sink lower and at a
pressure of about pe = 1 bar at the piston rod side the cylinder piston continues to
move downward step by step.
Conclusion
5/3 directional control valves with closed mid-position are used for simple pneumatic
stop control circuits. These valves are mainly pneumatically operated, if there is no
control pressure at 14 or 12, then the valve is automatically set in the mid-position by a
spring balancing.
44
Exercise 13 Pressure-dependent control of 1 double-acting cylinder
Aim
By using a 3/2 directional control valve with adjustable minimum pressure of response, a
pressure-dependent (and in addition displacement-dependent) control of a double-acting
cylinder is put into effect.
Functional diagram
45
List of equipment

04
11
5/2 impulse valve
15
21
06
1
1
14
22
Flow control valves

with non-return,
adjustable
Pressure gauge
valve, with push
position
valves, with feeler roll
valve, with adjustable
operating pressure
Air service unit,
diagram)
Task
"Knuckle-joint embossing press"
-
The piston of a double-acting cylinder (Z1) extends and embosses a piece of metal
with the aid of a knuckle-joint embossing die.
The piston of the cylinder retracts automatically when the embossing die has reached
the workpiece and the piece of metal has been embossed with a certain adjustable
force (pressure an the cylinder, bottom side).
Additionally: a new start should only then be possible when the cylinder is actually in its
back end position.
The working speed of the cylinder should be able to be infinitely adjusted in both
directions.
Design of the functional diagram with actuator and drive element.
or RP 68 P.
46

-
After actuating the signalling element S0 and under the prerequisite that the limit switch
S1 has been actuated, a signal reaches the control port 14 of the 5/2 impulse valve.
The piston of the cylinder Z1 extends.
In its front end position the piston actuates the limit switch S2.
When the pressure exceeds the value of 4.5 bar in the back cylinder chamber of Z1
and thus in the control line 12 of the pressure-dependent 3/2 directional control valve
S5, the signalling element S5 switches.
The output signal of S5 applies pressure to the control port 12 of the impulse valve.
The piston of the cylinder retracts, actuates S1 in the back end position and now the
control is ready for a new start.
Didactic notes
-
The adjustable pressure-dependent 3/2 directional control valve is also called a

(pressure) delivery valve.
The adjustable pressure-dependent 3/2 directional control valve can also be mounted
in a screw joint, which is directly screwed into the cylinder thread (similar to a flow
control valve with non-return).
In order to avoid mix-ups, the topic of proportional pressure regulators should be

discussed in this context during this exercise.
The pressure characterization on the pressure gauge should be observed at different

speeds of the piston.
Instructions
-
arrangement sketch.
accessories.
The set screw on the pressure-dependent 3/2 directional control valve is to be set
counter-clockwise all the way to the left (this should result in an operating pressure of
approx. 2 bar).
The working pressure is to be turned on.
The signalling element S0 is to be actuated.
47
The pressure on the pressure gauge should be observed and adjusted through several
attempts with the set screw at the pressure-dependent 3/2 directional control valve so
that the piston of the cylinder first retracts when the pressure has reached approx. 4.5
bar.
The piston of the cylinder may only retract when the limit switch S2 has been actuated.
Conclusion
Pressure-dependent signalling elements in pneumatic controls are 3/2 directional control
valves with adjustable response pressure. Pressure-dependent signalling elements
(directional control valves) can be recognized by the adjusting arrow in the symbol that is
drawn through the middle of the restoring spring.
48
Exercise 14 Time-dependent control of 1 double-acting cylinder
Aim
This exercise provides information on time elements used in pneumatic control technology,
their function and application.
Functional diagram (stroke-time diagram)
49
List of equipment

04
11
5/2 impulse valve
15
06
13
17
Flow control valves

with non-return,
adjustable
valve, with push
position
valves, with roller
valve, pneumatically
operated
time-delay valve,
adjustable from 0.15 55 s
Air service unit,
diagram)
Task
"Press-in and bonding device"
-
A loudspeaker membrane and a casing brushed with glue are placed into a heated
device by hand.
After pressing the start button (S0), the piston of a double-acting cylinder (Z1) extends
and presses the membrane into the casing for a certain adjustable period of time.
After the delay time has elapsed, the piston of the cylinder retracts automatically into its
back end position.
Note: the time can be set between 2 and 5 seconds and has to correspond to the
period that the parts are actually being pressed together.
Additionally: The delay time should not be influenced by the continuous actuation of the
start button (S0).
Additionally: Even if the start button (S0) is continuously actuated, the piston of the
cylinder (Z1) should still only extend once.
The working speed of the cylinder should be infinitely adjustable when extending.
Design the functional diagram (stroke-time diagram) with actuator and drive element.
or RP 68 P.
50

-
When the signalling element S0 is actuated, the pneumatic signal is sent via the (not
yet switched) pneumatically operated 3/2 directional control valve in open neutral
position, via the limit switch S1 to the control line 14 of the 5/2 impulse valve.
The piston of the cylinder Z1 extends and in its front end position actuates the limit
switch S2.
When S2 is actuated, control air reaches inlet X (Z) of the 3/2 directional control delay
valve unit.
The pressure reaches the control inlet of the air-actuated 3/2 directional control valve
via the built-in flow control valve and to the volume.
The air coming in through the flow control valve requires some time to fill the volume.
If the pressure at the control inlet 12 of the directional control valve in the unit reaches
the control pressure of the valve, the 3/2 directional control valve opens. The outlet 2 of
the 3/2 directional control delay valve applies pressure to the control line 12 of the 5/2
impulse valve.
The piston of the cylinder is delayed in retracting.
Additionally: if the button S0 is actuated for a longer period, the pneumatically operated
3/2 directional control valve, pos. 9, switches after a short delay (filling the volume via
the flow control valve).
The directional control valve interrupts the signal to S1 and the control inlet 14 of the
impulse valve.
The control system can only be started again if the button S0 is released and then
actuated again.
Didactic notes
-
In this exercise the two time functions existing in pneumatic control technology are
applied.
The module pos. 17 is connected in closed neutral position, and the function "time
element with operating lag" results. Signal pressure results at port 2 only after the time
delay has elapsed.
The second time element is made up of a pneumatically operated 3/2 directional

control valve pos. 9, a one-way flow control valve and a plastic tube with a length of
approx. 500 mm.
This directional control valve is connected in open neutral position. This time element is
also switched in the function "with operating lag", but in this case the signal at port 2 of
the directional control valve is switched off after the time has elapsed.
51
The piping between the flow control valve with non-return and the control port of the 3/2
directional control valve pos. 9 must be absolutely leak-proof.
Instructions
-
arrangement sketch.
accessories.
Instead of the volume between the one-way flow control valve pos. 15 and port 12 of
the 3/2 directional control valve pos. 9, a tube of approx. 500 mm length is used.
The throttle of the one-way flow control valve pos. 15 is to be screwed in nearly all the
way.
The working pressure is to be switched on.
The signalling element S0 is to be actuated. Check whether an impulse of approx. 0.5 s

at port 14 of the impulse valve (open tube) is present.
The time delay between actuating the limit switch S2 and the beginning of retraction of
the piston should be set at approx. 4 s.
The signalling element S0 should be actuated for a longer period of time and held: the
piston of the cylinder extends to the front end position, retracts after the time delay of
the time element pos. 17 has elapsed. The piston may not extend again despite the
actuated signaller S0.
Conclusion
Time elements in pneumatics are modules and always consist of: 3/2 directional control
valves, flow control valves with non-return and volumes (reservoirs). By adjusting the
throttle, the time delay (operating or release lag) is set. The length and precision of the
time delay depends on the volume size and on the response pressure and the type of
switching of the directional control valve used.
52
Exercise 15 Logical control with shuttle and twin-pressure valves
Aim
This exercise uses a logical control to demonstrate the use of the logic basic functions OR
(shuttle valve) or AND (two-pressure valve) in pneumatics. In this exercise, a proximity
switching signalling element (reflex nozzle) is also used.
List of equipment
Pos.
04
Qty. Description
11
5/2 impulse valve
15
06
13
08
07
18
19
24
1
2
1
25
26
20
1
1
1
2 Flow control valves with nonreturn, adjustable

3/2
directional
control
valve, with push button, closed
neutral position
3/2 directional control valves,
with roller
5/2 directional control valve,
manually operated
3/2 directional control valve, with
push button, flow in both
directions
(closed
neutral
position)
Shuttle valve, OR
Twin-pressure valves, AND
Pressure control valve with filter
and pressure gauge, 0 - 1 bar
Reflex nozzle
Amplifier, pneumatic
Pressure
display,
pneum.
Air service unit, pressure
distributor and accessories (not
included in the circuit diagram)
53
Single and multiple OR or AND circuits with shuttle and twin pressure valves
54
Task
"Logical control"
-
The piston of the double-acting cylinder (Z1) of a supply station supplies workpieces
under the following logical conditions:
The start button (S0) or an auxiliary button (S1) is actuated and parts are available in
the workpiece magazine (B2).
An optical display shows whether there are still enough parts available in the workpiece
magazine.
The cylinder should only retract into its back end position if it has actually reached the
front end position and an acknowledgement button (S4) is actuated.
A 5/2 impulse valve is used as an actuator.
Additionally: for scanning work-pieces in the magazine (B2) it is not possible to use a
mechanically operated signaller.
The scanning should therefore occur in a "non-contact" manner through a reflex
nozzle.
For economic reasons (for example there are several manually operated 5/2 directional
control valves) a 5/2 directional control valve is used as a signalling element instead of
the auxiliary button (S1).
or RP 68 P.

-
Signal pressure then reaches the control line 14 of the actuating drive (piston extends)
if the following conditions prove true:
the button S0 OR the button S1 is actuated, AND the reflex nozzle B2 (amplifier pos.
26) has switched.
Signal pressure then reaches the control line 12 (piston retracts) of the actuating drive
if the limit switch S3 AND the button S4 are actuated.
The reflex nozzle is supplied with low pressure of 0.4 bar via the pressure regulating
valve with filter pos. 24.
The pneumatic pressure display indicates whether the reflex nozzle or the amplifier is
supplying a signal.
55
Didactic notes
-
Demonstrate how the pressure stream of the reflex nozzle can "disturb" any object at 2
to 3 mm distance (for example a workpiece).
The use of 5/2 directional control valves in the function of a 3/2 directional control valve
(mounting a blanking plug in port 12) is a frequent occurrence in practice dealing with
valve carrier systems. Also if it is best to use as few types of valves as possible out of
logistic and service reasons.
Introduce the various AND cases of use of serial connection of signalling elements or
twin pressure valves.
Compare the AND circuit with an air-operated 3/2 directional control valve and the
technical solution twin pressure valve.
To fully cover the topic "Logic in Pneumatics" you should also talk about the equivalent
circuit for the NOT function (air-operated 3/2 directional control valve, open neutral
position).
Instructions
-
arrangement sketch.
accessories.
The low pressure regulator is to be adjusted.
The working pressure is to be turned on.
The logic functions are to be tested.
Conclusion
The shuttle valve is available for the logical OR operation in the pneumatic system
control technology.
A twin pressure valve is used for the logical AND operation. A "serial connection" of
pneumatic signallers also results in an AND function.
56
Exercise 16 Sequential
control
of
double-acting
cylinders
without
overlapping signals
Aim
This exercise helps to understand sequential controls and provides practical knowledge of
setting up and commissioning a control system with two pneumatic drives.
Practice in developing sequential diagram and pneumatic circuit diagram is exercised.
Functional diagram
57
List of equipment

04
2 Double-acting cylinders
11
5/2 impulse valves
15
06
13
Flow control valves with

non-return, adjustable
valve, with push button,
valves, with roller
distributor and
accessories (not included
in the circuit diagram)
58
Task
"Transport of Workpiece"
-
The workpieces coming in on the right roller conveyor should be elevated and sent in a
new direction.
After actuating the start button (S0) the piston of cylinder 1 (Z1) raises the workpieces
to the height of the second roller conveyor with its elevating platform.
Cylinder 1 (Z1) remains in this position until cylinder 2 (Z2) has pushed the workpieces
from the elevating platform onto the upper roller conveyor.
When cylinder 2 (Z2) has securely pushed all the workpieces onto the upper roller
conveyor, cylinder 1 (Z1) moves down again.
Only when cylinder 1 (Z1) has retracted into its lower end position does cylinder 2 (Z2)
also retract.
Additionally: a new start is only possible when cylinder 2 (Z2) is actually in its back end
position.
The working speed of both cylinders should be infinitely adjustable in both directions.
The functional diagram is to be developed with actuator and drive element.
or RP 68 P.

-
Two double-acting cylinders, retracted in neutral position, are displacementdependently controlled by impulse valves.
After actuating the start button S0, a control signal arrives at port 14 of the impulse
valve for cylinder Z1 via the actuated limit switch S3.
The piston rod of cylinder Z1 extends and in its front end position actuates the limit
switch S2.
The limit switch S2 sends a signal to the control port 14 of the impulse valve for
cylinder 2.
The piston rod of cylinder 2 extends into the front end position and actuates the limit
switch S4.
The limit switch S4 delivers the control signal to port 12 from the impulse valve for
cylinder Z1.
The piston of cylinder Z1 retracts and in its back end position actuates limit switch S1.
The limit switch S1 delivers a signal to port 12 from the impulse valve for cylinder Z2,
the piston retracts to the back end position.
The system control is in its initial position.
59
Didactic notes
-
Again point out that impulse valves have no defined basic position.
If system controls do not operate right away it is advisable to shut off the limit switches
in order to check for errors systematically.
Instructions
-
arrangement sketch.
accessories.
All flow control valves with non-return are to be set at approx. the mid-restriction of
piston rod speed.
Button S0 should be actuated. Check if the sequence is correct.
Conclusion
The forced, step by step sequence of a sequential control is realized by an actuating
sequence of 3/2 directional control valves with fester rolls as limit switches. If no
signals ever simultaneously reach ports 14 and 12 of an actuator, then the control takes
place without signal overlapping and without additional use of material.
60
Exercise 17 Sequential control of 2 double-acting cylinders with signal

overlapping, rollers with idle return
Aim
This exercise demonstrates a sequential control with two pneumatic drives. The signal
overlapping occurring during this exercise is constructively solved by use of rollers with idle
return. Practice is obtained in developing sequential diagrams and pneumatic circuit
diagrams.
Functional diagram
61
List of equipment

04
11
5/2 impulse valves
15
06
13
14

valves, with rollers
valves, with rollers with
idle return
distributor and
62
Task
"Drilling and boring jig"
-
The workpiece that is to be drilled is placed into a jig by hand.
After actuating the start button (S0), the piston of a double-acting cylinder (Z1) clamps
the workpiece.
When the workpiece has been clamped, the piston rod of the drilling cylinder (Z2)
extends, drills the workpiece and retracts (after completing the drilling procedure)
automatically back into its end position.
When the piston of cylinder 2 (Z2) has returned to its upper end position, the piston of
cylinder 1 (Z1) also retracts and unclamps the workpiece.
Note: If you detect one or more signal overlaps when developing the circuit diagram,
the solution can be found by using rollers with idle return.
Additionally: a new start should only be possible when the cylinder actually is in its
back end position.
The functional diagram is to be developed with actuators and drive elements.
or RP 68 P.

-
Both double-acting cylinders are retracted in neutral position.
After actuating the start button S0, a control signal arrives at port 14 of the impulse
valve for cylinder 1 via the actuated limit switch S1.
The piston rod of cylinder 1 extends, before reaching the front end position it actuates
valve S2 (with rollers with idle return) briefly, and then continues to extend to the end
position. (The valve S2 with rollers with idle return is thus not actuated in the end
position!)
The short impulse from signal S2 applies pressure to the control port 14 of the impulse
valve for cylinder 2.
The piston rod of cylinder extends to the front end position and actuates the limit switch
S4.
The limit switch S4 transmits the control signal from the impulse valve to port 12 for
cylinder Z2.
The piston of cylinder Z2 retracts and before reaching the front end position it actuates
the valve S3 with idle return roller briefly and then continues to extend to the end
position. (The valve S3 with idle return roller is thus not actuated in the end position!)
63
The short impulse from signal S3 applies pressure to the control port 12 of the impulse
valve for cylinder Z1, the piston retracts to its back end position.
The control system is in its initial position.
Didactic notes
-
The direction of actuation of the idle return roller valves is marked by an arrow in the
circuit diagram.
Point out the following disadvantages of the solution with idle return roller valves:
At high piston rod Speeds the impulses of idle return roller valves are too short. The
impulse valves do not switch anymore when long signal lines are used.
The moment of cylinder movement is delayed because the impulse of the idle return
roller valve does not arrive in the end positions of the cylinder movements. This is
especially a problem with short strokes.
Instructions
-
arrangement sketch.
accessories.
The idle return roller valves should be mounted so that the plunger of the cylinder
piston just misses actuating the roller in the end position.
When mounting the parts, pay attention to the correct direction of actuation of the idle
return roller valves.
The correct sequence is to be checked.
Set the maximum piston rod speed with the flow control valves with non-return and
again check the correct sequence.
Conclusion
If signal overlapping occurs through the actuating sequence of the limit switches in a
sequential control, it is necessary to use other or additional components (functions) in
order to eliminate these signal overlaps.
Signallers with idle return rollers are only briefly actuated, send only short impulses in
one direction. Idle return rollers are thus used to neutralize signal overlapping instead of
standard rollers.
64
Exercise 18 Sequential control of 2 double-acting cylinders with signal

overlapping, change-over valve
Aim
This exercise demonstrates a sequential control with 2 pneumatic drives, with signal
overlapping.
A constructive solution with the use of a change-over valve is found.
Practical experience in developing sequential diagrams and recognizing signal overlaps is
gained, as well as in the methodical development of a pneumatic circuit diagram.
List of equipment

04
11
5/2 impulse valves
15
06
13

valves, with rollers
distributor and
65
Functional diagram (complete)
66
Task
"Press-in device"
-
A bolt is to be pressed in to a work-piece. The workpiece is placed in by hand, the bolt

is laid on by hand.
After actuating the start button (S0), the piston of a double-acting cylinder (Z1) pushes
the workpiece into a clamping fixture and clamps the workpiece.
When the workpiece is clamped, the piston rod of the press-in cylinder (Z2) extends,
presses the bolt into the workpiece and automatically retracts to its end position.
When the piston of cylinder 2 (Z2) returns to its upper end position, the piston of
cylinder 1 (Z1) also retracts to its end position.
The sequence of the control is displacement-dependent. Limit switches can be

mounted on both cylinders.
Additionally: a new start should only be possible if the cylinder is actually in its back
end position.
Note: If you detect one or more signal overlaps when developing the circuit diagram,
the solution can be found by using change-over valves.
67
A complete functional diagram with signalling elements, controlling element, actuators

and drive elements is to be developed.
or RP 68 P.

-
Both cylinders are retracted in neutral position.
Outlet 2 of the change-over valve, or line 2 is vented.
If the start button S0 supplied by line 2 is actuated, a control signal arrives at port 14 of
the change-over valve via the actuated limit switch S1, line 2 is vented and line 1 is
pressurized.
Pressure is applied directly to the impulse valve at port 14 from line 1, the piston rod of
cylinder 1 extends and in its front end position actuates the limit switch S2.
The limit switch S2 supplied by line 1 transmits a signal to control port 14 of the
impulse valve for cylinder 2.
The piston rod of cylinder 2 extends to its front end position and actuates the limit
switch S4.
The limit switch S4 supplied by line 1 transmits a control signal to port 12 of the
change-over valve, the valve switches the pressurized air from line 1 to line 2.
Cylinder 2 of the impulse valve directly applies pressure from line 2 to port 12, the
piston rod of cylinder 2 retracts and in its back end position actuates limit switch S3.
The limit switch S3, supplied by line 2, transmits a signal to the control port 12 of the
impulse valve for cylinder 1, the piston of cylinder 1 retracts to its back end position.
The control system is in its initial position.
The proper basic position of the change-over valve is reported by a pneumatic

pressure display.
Didactic notes
-
In this exercise the problems concerning an undefined basic position of an impulse

valve can be demonstrated using the example of the initial position of the change-over
valve:
If the impulse valve is mounted in the left switch position (pressure on outlet 4, or line
1), then the control system runs automatically in the case of correct piping without
actuating the start button.
Pay careful attention that the theoretical order of 2 supply lines is also to be clearly
seen in the actual piping.
68
Discuss the effect of a continuously activated start button S0 on the control sequence.
Instructions
-
arrangement sketch.
accessories.
The two supply lines are to be clearly identified through the special order of tubes,
distributors and pneumatic display (perhaps use a color classification).
The initial condition of the pneumatic display is to be checked.
The proper sequence of the control system is to be checked.
Conclusion
A simple solution to eliminate signal overlapping in sequential control systems is the use of
change-over valves. The task of a change-over valve is to switch off the signals of the
limit switches which are overlapping each other. This solution requires good knowledge
of control technology, or of systematic solution methods.
69

EE061 Pneumatic Controls PR Inst

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

EE061 Pneumatic Controls PR Inst

Uploaded by

Copyright:

Available Formats

SRI LANKA INSTITUTE of ADVANCED TECHNOLOGICAL EDUCATION

ELECTRICAL and ELECTRONIC

MCE Industrietechnik Linz GmbH & Co

Direct control of a single-acting cylinder, extending ......................................9

Direct control of a single-acting cylinder, retracting.....................................11

Indirect control of a single-acting cylinder ...................................................14

Regulating the speed of a single-acting cylinder .........................................17

Slow-speed extension, rapid retraction of a single-acting cylinder..............20

Direct control of a double-acting cylinder with push-button .........................23

Indirect control of a double-acting cylinder ..................................................26

Speed regulation of a double-acting cylinder ..............................................28

Controlling a double-acting cylinder, impulse valve, 2 push-buttons...........31

Displacement-dependent control of a double-acting cylinder, impulse valve ..

Controlling a double-acting cylinder, impulse valve, 2 reflex nozzles..........37

Pressure-dependent control of 1 double-acting cylinder .............................45

Time-dependent control of 1 double-acting cylinder....................................49

Logical control with shuttle and twin-pressure valves..................................53

Sequential control of 2 double-acting cylinders without overlapping signals...

Exercise 17 Sequential control of 2 double-acting cylinders with signal overlapping, rollers

Sequential control of 2 double-acting cylinders with signal overlapping,

The exercises were extended in respect to the technological further developments in

The following features characterize the practice system:

The grooved plate can also be used in a vertical or tilted position.

For exercises in connection with electro-pneumatic components, the double-acting

Base plate and basic kit for the practical exercises

0 827 003 702

Basic kit Pneumatics BIBB

0 827 003 365

Optional Equipment and Accessories

DS3 Basic frame

0 827 003 701

Grooved plate ERGO

0 827 003 717

0 827 003 707

0 827 003 705

Information board (A4-sheet holder)

0 827 003 721

Please regard the following measures in any case:

The equipment to be used is listed in the equipment list in the instructions.

1 827 003 410

1 827 003 411

1 827 003 372

1 827 003 373

1 827 003 392

1 827 003 393

1 827 003 396

1 827 003 374

1 827 003 376

1 827 003 377

1 827 003 378

1 827 003 399

1 827 003 401

1 827 003 379

1 827 003 382

1 827 003 386

1 827 003 403

Exercise 1 Direct control of a single-acting cylinder, extending

Suggestion for the positioning of equipment on the working plate

Pneumatic circuit diagram

Pneumatic circuit diagram

A pressure gauge registers the active pressure on the cylinder piston.

The working pressure is switched on with the ball valve.

The exercise is started and the proper function is checked.