2.

0 MATERIALS AND METHODS

2.1 EQUIPMENT

1. Air regulator and filter

- Control air flow into the circuit and
filter foreign particle from entering
the circuit.

2. Pneumatic manifold
-

3. Double acting cylinder

- Allow two way-controlled cylinder
movement.

4. Sensor
- Detect motion and convert it into
electrical signal.

5. Limit switch
- Uses mechanical switch, activated
by physical contact and convert it
into electrical signal.

6. Lamps
- Indicator for when cylinder extend
or return

7. Power supply 24VDC 4.5A

- Provide electrical power for electro
pneumatic components.

8. Reed switch
- Magnetically operated switch
 (Woodford, 2020) mounted on
double acting cylinder.
9. Switch box
- Control component on and off
state.

10. Pushbuttons
- Pushed to operate an electrical
device.

11. Cables
- Connect power source to
component.

12. 5/2-way double solenoid DCV

double solenoid
- Receive electrical signal and
convert it into mechanical action
with the help of pressurized air.
2.2 SAFETY PRECAUTIONS

General

1. Work with the controllers only under the supervision of a trainer.

2. Observe specifications included in the data sheets for the individual components.

Mechanical system

1. Secure all of the components onto the slotted profile plate.

2. Avoid actuating limit switches frontally.
3. Use a tool to actuate the limit switches, for example a screwdriver.
4. Only reach into the setup when it is at a complete standstill.

Electrical specifications

1. Electrical contacts can only be made and broken when there is no voltage present!
2. For electrical connections, only use adapter cables with safety connectors.
3. Only use low voltage (max. 24 V DC).

Pneumatics

1. Do not exceed the 600 kPa maximum allowable pressure (6 bar).

2. Do not turn on compressed air until all tubing links are finished and sealed.
3. When the tubing is under pressure, do not disconnect it.
4. By using compressed air, there is a risk of injuries! Cylinders will automatically advance
and retract.
5. There is a risk of an injury if the tubing comes off!
 Use the shortest tubing links possible.
 Put on your safety glasses.
 In the case that the tubing comes off. Switch off the compressed air source right away.
6. Configuration of a pneumatic circuit. Plastic tubing with an outside diameter of 4 or 6
mm is used to connect the devices.
7. Switch compressed air supply off before dismantling the circuit.
8. Dismantling of a pneumatic circuit. By pressing down the blue release button, the tubing
can be taken out (Didactic, n.d.).
2.3 PROCEDURE

2.3.1 Task 1

Objective:

To read electrical wiring circuit diagram and assemble few electro-pneumatics components
Based on the wiring circuit.

Figure 1: Electrical Wiring Circuit Diagram Figure 2: Electrical wiring using limit switch

Procedure:

1. A pneumatic equipment and electrical wiring diagram were constructed using the
FLUIDSIM 4.2
2. Assemble double acting cylinder, 5/2-way directional control valve, air regulator and
manifold were assembled on the trainer as in Figure 1. All electrical component boxes
were mounted on the trainer.
3. Compressor pressure as well as air regulator pressure was checked.
4. All pneumatic components were connected with pneumatic tubes.
5. All the electrical components were connected using plug cables as shown in the wiring
circuit in Figure 2
6. Trainer air pressure was set to 0.2 MPa or 2.0 bar (according to trainer).
7. The main valve at the air regulator was switched on.
8. The main switch at the DC power supply box was switched on.
9. Pushbutton A was pressed and followed by pushbutton B. What happen to the cylinder
was observed. Findings was recorded.
10. Pushbutton B was substituted with limit switch as shown in Figure 2.2.3. Pushbutton A
was pressed and what happen was observed. Findings was recorded.
11. The observation between simulation (FluidSIM 4.2) and Actual system was compared.
12. The main valve at the air regulator and the DC power supply was switched off once the
task completed.

2.3.2 Task 2

Objective:

To assemble and verify an electro-pneumatic system with AND function and comparing the
application of limit switch and reed switch. Lamp is used as output.

Figure 3: Electrical wiring with AND function. Figure 4: Electrical wiring using reed switch
and lamp as output.

Procedure:

1. The same pneumatic components final setup as in Task 1 was used. Pneumatic cylinder
with reed switch was used. The limit switch was kept in its position.
2. A pneumatic equipment and electrical wiring diagram were constructed using the
FLUIDSIM 4.2
3. All the cables were removed and the components was rewired as depicted in Figure 3.
4. The main valve at the air regulator was switched on.
5. The power switch at the DC power supply was switched on.
6. Pushbutton A was pressed and released, followed by pushbutton B. What happen to the
cylinder was observed. Findings was recorded.
7. Then pushbutton A and B was pressed together. What happen to the cylinder was
observed. Findings was recorded.
8. The DC power supply was switch off. Limit switch cables were removed and the limit
switch was also removed.
9. The reed switch was wired at the cylinder as shown in Figure 4. The DC power supply
was switch on. Pushbutton A and B was pressed together. Findings was discussed.
10. The components were rewired where once the cylinder reaches maximum extend, the
lamp was switched on Figure 4.
11. The observation between simulation (FluidSIM 4.2) and Actual system was compared.
12. The main valve and the DC power supply was switched off once the task completed.

2.3.3 Task 3

Objective:

To assemble and verify an electro-pneumatic system with AND function and using sensor.

Figure 5: Electrical wiring with sensor.

Procedure:

1. The same pneumatic components final setup as in Task 2 was used. Sensor was installed
in the position as depicted in Figure 5.
2. A pneumatic equipment and electrical wiring diagram were constructed using the
FLUIDSIM 4.2
3. All the cables were removed and the components was rewired as depicted in Figure 5.
4. The main valve at the air regulator was switched on.
5. The power switch at the DC power supply was switched on.
6. Then pushbutton A and B was pressed together. What happen to the cylinder was
observed. Findings was recorded.
7. The DC power supply was switch off.
8. The components were rewired where once the cylinder reaches maximum extend, the
lamp was switched on.
9. The observation between simulation (FluidSIM 4.2) and Actual system was compared.
10. The main valve and the DC power supply was switched off once the task completed.

2.3.4 Task 4

Objective:

To design electro-pneumatic system where a sensor detects an object, a sensor lamp is

activated and a double acting cylinder starts to extend. When the cylinder reaches maximum
extend, another lamp will be activated and the cylinder retracts automatically.

Procedure:

1. Electro-pneumatic system was designed according to the task aim

2. A pneumatic equipment and electrical wiring diagram were constructed using the
FLUIDSIM 4.2.
3. Based on the task aim, the required pneumatic components were installed on the training
panel.
4. All the wire was connected to the electrical components.
5. The main valve and DC power supply were switched on.
6. the system was verified by putting hand to the sensor.
7. The observation between simulation (FluidSIM 4.2) and Actual system was compared.
8. The main valve and the DC power supply was switched off once the task completed.
REFERENCE

1. Didactic, F. (n.d.). Safety in pneumatic systems.

2. Woodford, C. (2020). How reed switches work (magnetically operated switches).
EXPLAINTHATSTUFF! https://www.explainthatstuff.com/howreedswitcheswork.html