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JOB Oke PDF
JOB Oke PDF
MECHANICAL ENGINEERING
NOVEMBER 2018
PNEUMATICS
JOB SHEETS
1
JOB SHEET
1. Pneumatic Trainer
2 Single-acting cylinder - 1
3 3/2-way valve, manual operated, unistable - 1
Instruction:
1 Study the pneumatic circuit.
2 Select the required components.
3 Connect the circuit.
4 Check to ensure that the air hoses are firmly secured on the valve connectors.
5 Turn on the main air supply and adjust to required pressure.
6 Actuate the start button.
7 Check for any air leakages and rectify them immediately.
8 Check for cylinder operation sequence.
9 Troubleshoot the circuit for correct operation if necessary.
Single-Acting Cylinder
3 /2 -W a y Va lv e , A ir-O pe ra te d,
2
2
1 3
1 3 3 /2 -W a y Va lv e , P us hbu tto n-O pera te d,
Norma lly -Clos e d, Unis t able (S pring Re turn).
2
JOB SHEET
1. Pneumatic Trainer
2 Double-acting cylinder - 1
3 3/2-way valve, manual operated, unistable – 2
4 5/2-way valve, pressure-operated, bistable - 1
Instruction:
14 12
5 3
E0 2 3 /2 W a y valve , Pushbutto n-o perated,
1
1 3
3
Assignment 1: Modify Circuit
Double-Acting Cylinder
A0 A1
14 12
5 3
4
JOB SHEET
1. Pneumatic Trainer
2 Double-acting cylinder
3 3/2-way valve, pushbutton operated, unistable
4 3/2-way valve, roller- perated, unistable
5 5/2-way valve, pressure-operated, bistable
6 Shuttle valve (OR element)
7 Two pressure valve (AND element)
Instruction:
1 Select the required components and connect up the circuit.
2 Check the circuit connection and ensure that the air hoses are firmly secured on the valve fittings.
3 Check the alignment of the 3/2-way roller operated valves.
4 Turn on the air supply and adjust to required pressure.
5 Actuate E1 or E2 and check for cylinder actuation.
6 Complete the truth table for ‘OR’ function.
7 Modify the circuit for ‘AND’ operation by replacing the shuttle valve with a two-pressure valve.
8 Draw the modify circuit and complete the truth table for ‘AND’ function.
E1 E2 A E1 E2 A
0 0 0 0
0 1 0 1
1 0 1 0
1 1 1 1
Table I Table II
5
Semi-Automatic Cycle Control with Two Switches
(Auto-Return)
Shuttle Valve A1
(OR Element)
2
1 1
4 2
A 14 12
5 3
Two-Pressure Valve 1
(AND Element) 2
1 1
2 2 2
A1
E1 1 3 E2 1 3 1 3
6
JOB SHEET
1. Pneumatic Trainer
2 Double-acting cylinder
3 5/2-way valve, pressure-operated, bistable
4 3/2-way valve, roller-operated, unistable
5 3/2-way valve, pushbutton-operated, unistable
6 5/2-way valve, pushbutton-operated, bistable
Instruction:
1 Study the given circuit sequence.
2 Select the required components and connect up the circuit.
3 Check the circuit connection and ensure that the air hoses are firmly secured on the valve fittings.
4 Check the alignment of all 3/2-way roller operated valves.
5 Turn on the air supply and adjust to required pressure.
6 Actuate pushbutton and check for cylinder actuation.
7 Check the cylinder operation sequence.
8 Troubleshoot the circuit to correct the sequence if necessary.
7
8
JOB SHEET
Job Title : Trace blocking signal in pneumatic circuit with sequence A+B+B-A-
1. Pneumatic Trainer
2 Double-acting cylinder
3 5/2-way valve, pressure-operated, bistable
4 3/2-way valve, roller-operated, unistable
5 3/2-way valve, pushbutton-operated, unistable
Instruction:
1 Study the given circuit sequence.
2 Select the required components and connect up the circuit.
3 Check the circuit connection and ensure that the air hoses are firmly secured on the valve fittings.
4 Check the alignment of all 3/2-way roller operated valves.
5 Turn on the air supply and adjust to required pressure.
6 Actuate pushbutton and check for cylinder actuation.
7 Check the cylinder operation sequence.
8 Trace circuit for any opposing signals.
9
10
JOB SHEET
Job Title : Removal of blocking signals from pneumatic circuit with A+B+B-A-
1. Pneumatic Trainer
2 Double-acting cylinder
3 5/2-way valve, pressure-operated, bistable
4 3/2-way valve, roller-operated, unistable
5 3/2-way valve, pushbutton-operated, unistable
Instruction:
1 Study the given circuit sequence.
2 Select the required components and connect up the circuit.
3 Check the circuit connection and ensure that the air hoses are firmly secured on the valve fittings.
4 Check the alignment of all 3/2-way roller operated valves.
5 Turn on the air supply and adjust to required pressure.
6 Actuate pushbutton ‘E’ and check for cylinder actuation.
7 Check the cylinder operation sequence.
8 Troubleshoot the circuit to correct the sequence of operation if necessary.
11
12
JOB SHEET
1. Pneumatic Trainer
2 Double-acting cylinder
3 5/2-way valve, pressure-operated, bistable
4 3/2-way valve, roller-operated, unistable
5 3/2-way valve, pushbutton-operated, unistable
6 5/2-way valve, pushbutton-operated, bistable
Instruction:
1 Study the given circuit sequence.
2 Select the required components and connect up the circuit.
3 Check the circuit connection and ensure that the air hoses are firmly secured on the valve fittings.
4 Check the alignment of all 3/2-way roller operated valves.
5 Turn on the air supply and adjust to required pressure.
6 Actuate pushbutton ‘E’ and check for cylinder actuation.
7 Check the cylinder operation sequence.
8 Troubleshoot the circuit to correct the sequence of operation if necessary.
13
14
JOB SHEET
1. Pneumatic Trainer
2 Double-acting cylinder
3 5/2-way valve, pressure-operated, bistable
4 3/2-way valve, roller-operated, unistable
5 3/2-way valve, pushbutton-operated, unistable
6 5/2-way valve, pushbutton-operated, bistable
Instruction:
1 Study the given circuit sequence.
2 Select the required components and connect up the circuit.
3 Check the circuit connection and ensure that the air hoses are firmly secured on the valve fittings.
4 Check the alignment of all 3/2-way roller operated valves.
5 Turn on the air supply and adjust to required pressure.
6 Actuate pushbutton ‘E’ and check for cylinder actuation.
7 Check the cylinder operation sequence.
8 Troubleshoot the circuit to correct the sequence of operation if necessary.
Conclusion:
15
16
JOB SHEET
1. Pneumatic Trainer
2 Double-acting cylinder
3 5/2-way valve, pressure-operated, bistable
4 3/2-way valve, roller-operated, unistable
5 3/2-way valve, pushbutton-operated, unistable
6 5/2-way valve, pushbutton-operated, bistable
Instruction:
1 Study the given circuit sequence.
2 Select the required components and connect up the circuit.
3 Check the circuit connection and ensure that the air hoses are firmly secured on the valve fittings.
4 Check the alignment of all 3/2-way roller operated valves.
5 Turn on the air supply and adjust to required pressure.
6 Actuate pushbutton ‘E’ and check for cylinder actuation.
7 Check the cylinder operation sequence.
8 Troubleshoot the circuit to correct the sequence of operation if necessary.
17
1 1
1
2 2
2 2
1 1 1
2 4
2
1
2 4
2
1
18
JOB SHEET (Coursework 1)
1. Pneumatic Trainer
2 Double-acting cylinder
3 5/2-way valve, pressure-operated, bistable
4 3/2-way valve, roller-operated, unistable
5 3/2-way valve, pushbutton-operated, unistable
Instruction:
1 Study the given circuit sequence.
2 Select the required components
3 Test the selected components for proper functioning.
4 Connect up the circuit in accordance with the given circuit diagram.
5 Check the circuit connection and ensure that the air hoses are firmly secured on the valve fittings.
6 Check the alignment of all 3/2-way roller operated valves.
7 Turn on the air supply and adjust to required pressure.
6 Actuate pushbutton ‘E’ and check for cylinder actuation.
7 Check the cylinder operation sequence.
8 Troubleshoot the circuit to correct the sequence of operation if necessary.
Conclusion:
19
A+B+B-C+C–
A-
A B C
a0 a1 b0 b1 c0 c1
A+ A- B+ B- C+ C-
a1 b0
S
S1
2
S
3
Z Y
b1
c0
Z Y
c1 a0
20
21
PROGRAMME DIPLOMA OF
MECHANICAL ENGINEERING
NOVEMBER 2018
ELECTRO-PNEUMATICS
JOB SHEETS
1
JOB SHEET
Module : Electro-Pneumatics
1. Profile board
2 Single-acting cylinder
3 3/2-way single-solenoid valve
4 Distribution block
5 Relay
6 Pushbutton switch
7 Wires & air tubes
Instruction:
1 Study the given circuit.
2 Adjust to required air pressure and off the air supply.
3 Switch off the 24V DC power supply.
4 Select the required components and connect up the circuit.
5 Check circuit connection, ensure that the air hoses are firmly secured on the valve fittings.
6 Turn on the air supply and DC 24 V supply.
7 Actuate the pushbutton switch and check for cylinder actuation.
8 Troubleshoot and rectify faults if necessary.
9 Modify, improve and test circuits as instructed.
2
J OB SHEET
+24V
Y1
1 3
Y1
0V
0V
+24V
H o ldi n g C o n t a ct
K1 K1 Lo a d C o n ta c t
Y1
1 3
0V
3
JOB SHEET 2
Module : Electro-Pneumatics
1. Profile board
2 Double-acting cylinder
3 5/2-way single-solenoid valve
4 Distribution block
5 Relay
6 Pushbutton switch
7 Roller-operated limit switch
8 Wires & air tubes
Instruction:
1 Study the given circuit.
2 Adjust to required air pressure and off the air supply.
3 Switch off the 24V DC power supply.
4 Select the required components and connect up the circuit.
5 Check circuit connection, ensure that the air hoses are firmly secured on the valve fittings.
6 Check the alignment of the roller operated limit switch.
7 Turn on the air supply and DC 24 V supply.
8 Actuate the pushbutton switch and check for cylinder actuation.
9 Troubleshoot and rectify faults if necessary.
10 Modify, improve and test circuits as instructed.
4
Auto Return of Double-Acting Cylinder
+24V
S2 14 24
START K1 K1
11 21
4 2
2
Y1
5 3 Normally-Closed S2
1 1
A1
K1 Y1
A2
0V
+2 4 V
4
S1 S2 K1 K1
S1
Norma lly-Ope n 1
Held-Close d
4 2
1
Y1 S2 Norma lly-Close d
5 3 2
1
A1
K1 Y1
A2
0V
A- A+
5
JOB SHEET 3
Module : Electro-Pneumatics
1. Profile board
2 Double-acting cylinder
3 5/2-way double-solenoid valve
4 Distribution block
5 Relay
6 Pushbutton switch
7 Roller-operated limit switch
8 Sensors
9 Wires & air tubes
Instruction:
1 Study the given circuit.
2 Adjust to required air pressure and off the air supply.
3 Switch off the 24V DC power supply.
4 Select the required components and connect up the circuit.
5 Check circuit connection, ensure that the air hoses are firmly secured on the valve fittings.
6 Check the alignment of the roller operated limit switch.
7 Turn on the air supply and DC 24 V supply.
8 Actuate the pushbutton switch and check for cylinder actuation.
9 Troubleshoot and rectify faults if necessary.
10 Modify, improve and test circuits as instructed.
+24V
4
S S2
4 2
1
1Y 1 1Y 2
4
5 3 S1
(A+) (A-)
1
1
1Y 1 1Y 2
1 2
(A+) (A-)
0V
3
6
(B) Indirect Control
A
S1 S2
+2 4 V
S K1 S2
Double-Solenoid 5/2-W ay Valve 4 2 K2
1 Y1 1 Y2
5 3 S1
(A+) (A-)
1
K1 1 Y1 1 Y2
K2
1 2 (A+) (A-)
0V
3
Air Servic e Unit
A
S1 S2
+2 4V
S K1
Dou ble-S oleno id 5/ 2-W ay Valve 4 2 K2
1 Y1 1 Y2 S2
5 3 (A-) S1
(A+)
1
K1 1 Y1 1 Y2
K2
1 2 (A+) (A-)
0V
3
Air Service Unit
7
JOB SHEET 4
Module : Electro-Pneumatics
1. Profile board
2 Double-acting cylinder
3 5/2-way double-solenoid valve
4 Distribution block
5 Relay
6 Pushbutton switch
7 Roller-operated limit switch
8 Timers
9 Wires & air tubes
Instruction:
1 Study the given circuit.
2 Adjust to required air pressure and off the air supply.
3 Switch off the 24V DC power supply.
4 Select the required components and connect up the circuit.
5 Check circuit connection, ensure that the air hoses are firmly secured on the valve fittings.
6 Check the alignment of the roller operated limit switch.
7 Turn on the air supply and DC 24 V supply.
8 Actuate the pushbutton switch and check for cylinder actuation.
9 Troubleshoot and rectify faults if necessary.
10 Modify, improve and test circuits as instructed.
A S1 S2
+24V
S S2
4 2 TIMER
1Y 1 1Y 2
5 3 S1
1
1Y 1 TIMER 1Y 2
1 2
0V
3
8
(B) De-energizing Delay (Delay-Off) Timer
+ 24
+24V V DC
S1 S2
4 2 K1
S2 K2 Timer C ontac t
1Y 1 1Y 2 NC NC
5 3
1 S1
K1 K2 1Y 1 1Y 2
0V
Timer Relay A+ A-
Delay De-ener gising
+24V
S1 S2
Delay-On
Timer Contact Delay-Off
K1 K2 Timer Contact
S2
K3
NC NC
4 2
1Y 1 1Y 2 N/O S1
5 3
1
Timer Relay
1Y 1 1Y 2
Relay K1 K2 K3
0V
Timer Relay A+ A-
Delay De-energising
9
Assignment:
(1) Add flow control valves to control speed of cylinder. Indicate whether it is meter-in or meter-out.
(2) Replace the start switch “S” from Detent Switch to Momentary Switch. Use relay to change
mechanical latching to electrical latching.
State why electrical latching circuit is safer as compared to the detent switch.
Solution
+24V
S1 S2
K3 K3
S2 K1 K2
Timer C ontac t
20%
20%
NO
NO
1(P) 1(P)
4 2 S1
1Y 1 1Y 2
5 3
1
K3 K1 K2 1Y 1 1Y 2
0V
Timer Relay A+ A-
Delay Energising
10
JOB SHEET 5
Module : Electro-Pneumatics
1. Profile board
2 Double-acting cylinder
3 5/2-way double-solenoid valve
4 Distribution block
5 Relay
6 Pushbutton switch
7 Roller operated limit switch
8 Counter
9 Wires & air tubes
Instruction:
1 Study the given circuit.
2 Adjust to required air pressure and off the air supply.
3 Switch off the 24V DC power supply.
4 Select the required components and connect up the circuit.
5 Check circuit connection, ensure that the air hoses are firmly secured on the valve fittings.
6 Turn on the air supply and DC 24 V supply.
7 Pre-set counter to 5 counts.
8 Actuate the pushbutton switch and check for cylinder actuation.
9 Troubleshoot and rectify faults if necessary.
10 Modify, improve and test circuits as instructed.
+24V
A S1 S2
S S2 K1 K2
R_SW ITCH
4 2
1
COUNTE R
1Y 1 1Y 2 NC C onta ct 2
5 3
1
S1
1 2
K1 K2 COUNTE R 5 1Y 1 1Y 2
3
0V
11
Assignment:
Use timer to reset the counter so that the circuit will restart automatically after 5 sec.
Solution:
+2 4V
A
S1 S2
S S2 K1 K2
1
4 2 TIM
CNT
1Y 1 1Y 2
2 4
5 3
1
S1
1 2
K1 TIM K2 CNT 5 1Y 1 1Y 2
3
0V
12
JOB SHEET 6
Module : Electro-Pneumatics
1. Profile board
2 Double-acting cylinders
3 5/2-way double-solenoid valves
4 Distribution block
5 Relays
6 Pushbutton switch
7 Roller operated limit switches
8 Sensors / Reed Switches
9 Timer
10 Counter
11 Wires & air tubes
Instruction:
1 Study the given circuit.
2 Adjust to required air pressure and off the air supply.
3 Switch off the 24V DC power supply.
4 Select the required components and connect up the circuit.
5 Check circuit connection, ensure that the air hoses are firmly secured on the valve fittings.
6 Check the alignment of the roller operated limit switches or sensors.
7 Turn on the air supply and DC 24 V supply.
8 Actuate the pushbutton switch and check for cylinder actuation.
9 Troubleshoot and rectify faults if necessary.
10 Modify, improve and test circuits as instructed.
13
A+ B+ A- B- Continuous Cycle
A
B
S3 S4
S1 S2
4 2
4 2
Y3 Y4
Y1 Y2 5 3
5 3 1
1
+24V
S1
S4
S2
S3
Y1
Y3 Y2 Y4
0V
A+ B+ A- B-
Assignment:
(1) Replace S2 & S4 with sensors or reed-switches. Connect & test the circuits.
(2) Add timer after “A+” to delay the start of “B+ “
(3) Add counter to stop the cycle after 5 counts.
(4) Re-design the above circuit when the sequence changed to A+B+B-A-.
Identify the problem of opposing or blocking signal.
14
NOTE: This circuit can’t work.
Identify the opposing or blocking signal in this circuit.
A
B
S3 S4
S1 S2
4 2
4 2
Y3 Y4
Y1 Y2 5 3
5 3
B+ 1 B-
A+ 1 A-
+24V
S1
S4
S2
S3
Y1
Y3 Y4 Y2
0V
A+ B+ B- A-
15
JOB SHEET 7
Module : Electro-Pneumatics
1. Profile board
2 Double-acting cylinders
3 5/2-way double-solenoid valves
4 Distribution block
5 Relays
6 Pushbutton switch
7 Roller operated limit switches
8 Sensors / Reed Switches
9 Timer
10 Wires & air tubes
Instruction:
1 Study the given circuit.
2 Adjust to required air pressure and off the air supply.
3 Switch off the 24V DC power supply.
4 Select the required components and connect up the circuit.
5 Check circuit connections to ensure that the air hoses are firmly secured on the valve fittings.
6 Check the alignment of the roller operated limit switches or sensors.
7 Turn on the air supply and DC 24 V supply.
8 Actuate the pushbutton switch and check for cylinder actuation and correct sequence.
9 Troubleshoot and rectify faults if necessary.
10 Modify, improve and test circuits as instructed.
16
A+B+B-A-
S1 S2 S3 S4
Y1 Y2 Y3 Y4
1 2 3 4
+ 24
v
K1 K1 K1
PB
1
S1 2
S2
S3
S4
A1
K1 Y1 Y3 Y4 Y2
A2
-0
v A+ B+ B- A-
Conclusion
1 Compare the removal of blocking signal by electro-
pneumatic pure pneumatic circuit.
2 Modify the circuit with time delay on after B-.
17
Modified circuit with Delay On after B-
A+B+B-A-
S1 S2 S3 S4
Y1 Y2 Y3 Y4
1 2 3 4
+ 24
v
K1 K1 K1
PB
1
S1 4
2
S2
S3 K2
S4
A1
K1 Y1 Y3 Y4 K2 Y2
A2
-0
v A+ B+ B- Timer A-
18
JOB SHEET 8
Module : Electro-Pneumatics
1. Profile board
2 Double-acting cylinders
3 5/2-way double-solenoid valves
4 Distribution block
5 Relays
6 Pushbutton switch
7 Roller operated limit switches
8 Sensors / Reed Switches
9 Timer & Counter.
10 Wires & air tubes
Instruction:
1 Study the electrical control circuit for the given sequence.
2 Adjust to required air pressure and off the air supply.
3 Switch off the 24V DC power supply.
4 Select the required components and connect up the circuit.
5 Check circuit connections to ensure that the air hoses are firmly secured on the valve fittings.
6 Check the alignment of the roller operated limit switches or sensors.
7 Turn on the air supply and DC 24 V supply.
8 Actuate the pushbutton switch and check for cylinder actuation and correct sequence.
9 Troubleshoot and rectify faults if necessary.
10 Modify, improve and test circuits as instructed.
19
A + B + B - C + C- A -
S1 S2 S3 S4 S5 S6
Y1 Y2 Y Y Y5 Y6
3 4
1 2 1 2 1 2 7 8 9
+ 24 v
PB K1 S4 K2 S6 K3 K1 K2 K3
1
S1 2
3
S2 S3 S
K2 K3 K1
5
K1 K2 K3 Y1 Y3 Y4 Y5 Y6 Y2
-0
v A B+ B- C+ C- A-
+
Conclusion
1 Draw the displacement step diagram.
2 Modify the circuit to include:
2.1 A time-delay of 3 sec after B+.
2.2 A counter to stop the cycle after 5 counts.
20
A B C
S3 S4 S5 S6
S1 S2
4 2 4 2 4 2
Y1 Y2 Y3 Y4 Y5 Y6
5 3 5 3 5 3
1 1 1
+24 V
K1 K2 K3
STA RT
K1 S4 K2 K3
S6
S1
K2 K3 K1
TIM S5
S2 S3
Y2
K1 K2 K3 Y1 Y3 TIM Y4 Y5 Y6
0V
A+ B+ TIME R B- C+ C- A-
+24V
K1 K2
STA RT K3
K1 S4 K2 K3
CNT S6
S1
K2 K3 K1
S2 TIM S5
S3
K1 K2 K3 Y1 Y3 Y2
CNT 5 TIM Y4 Y5 Y6
0V
A+ B+ COUNTER TIMER B- C+ C- A-
21
JOB SHEET 9
Module : Electro-Pneumatics
1. Profile board
2 Double-acting cylinders
3 5/2-way double-solenoid valves
4 Distribution block
5 Relays
6 Pushbutton switch
7 Roller operated limit switches
8 Wires & air tubes
Instruction:
1 Study the given circuit.
2 Adjust to required air pressure and off the air supply.
3 Switch off the 24V DC power supply.
4 Select the required components and connect up the circuit.
5 Check circuit connections to ensure that the air hoses are firmly secured on the valve fittings.
6 Check the alignment of the roller operated limit switches.
7 Turn on the air supply and DC 24 V supply.
8 Actuate the pushbutton switch and check for cylinder actuation.
9 Troubleshoot and rectify faults if necessary.
10 Modify, improve and test circuits as instructed.
22
A+ C+ / C- B+ / B- A-
A B C
S1 S2 S3 S4 S5 S6
4 2 4 2 4 2
Y1 Y2 Y3 Y4 Y5 Y6
5 3 5 3 5 3
1 1 1
+24V
K1
K1 K1
S TA RT
K2
K1 S6 K2
K2
S1
K2
S4 S2 S5
S3
K1 K2 Y1 Y5 Y6 Y3
Y4
Y2
0V
C- B+ B- A-
A+ C+
23
JOB SHEET 10
Module : Electro-Pneumatics
1. Profile board
2 Double-acting cylinders
3 5/2-way double-solenoid valves
4 Distribution block
5 Relays
6 Pushbutton switch
7 Roller operated limit switches
8 Wires & air tubes
Instruction:
1 Study the given circuit.
2 Adjust to required air pressure and off the air supply.
3 Switch off the 24V DC power supply.
4 Select the required components and connect up the circuit.
5 Check circuit connections to ensure that the air hoses are firmly secured on the valve fittings.
6 Check the alignment of the roller operated limit switches.
7 Turn on the air supply and DC 24 V supply.
8 Actuate the pushbutton switch and check for cylinder actuation.
9 Troubleshoot and rectify faults if necessary.
10 Modify, improve and test circuits as instructed.
24
A+ C- / C+ B+ A- / B-
A B C
S1 S2 S3 S4 S5 S6
4 2 4 2 4 2
Y1 Y2 Y3 Y4 Y5 Y6
5 3 5 3 5 3
1 1 1
+24V
K1
K1 K1
S TA RT
K2
K1 S5 K2
K2
S3
K2
S1 S2 S6 S4
K1 K2 Y1 Y6 Y5 Y3 Y2 Y4
0V
A+ C- C+ B+ A- B-
25
Extra Practical Assessments
1. Modify the circuit to the following sequence:
a) A+ B+ B- C+ A- C-
b) B- A+ A- C+ C- B+
c) A+ C- C+ B+ B- A-
d) C+ C- B+ A- A+ B-
e) A- B+ C- C+ B- A+
f) C+ A- A+ C-
B+ B-
3. Add a counter to stop the cycle after 5 counts with a reset switch to
restart the cycle.
26