Pnuematics Exercises

Exercise 1: Pressing of cheese wheels
Training aims • To familiarise yourself with the design and mode of operation of a single-acting
cylinder.
• To familiarise yourself with the design and mode of operation of a 3/2-way valve.
• To be able to identify and draw types of directional control valve actuation.
• To be able to explain and design an example of direct actuation.
Problem definition During cheese production, pneumatic cylinders are to be used to press cheese
wheels into moulds. Design the control system whereby this process can be carried
out.
Parameters • A single-acting cylinder is to be used .

• The pneumatic control of the cylinder is to be realised by mean of a manually
operated valve.
Project task 1. Describe the mode of operation of a single-acting cylinder.

2. Describe the mode of operation of a 3/2-way valve.
3. Complete the pneumatic circuit diagram for the pressing device.
4. Carry out the assembly.
5. Check the assembled circuit.
6. Describe the mode of operation of the circuit.
7. Compile an equipment list.
© Festo Didactic GmbH & Co. KG • 541088 A-3

Positional sketch
Cheese production
1. Cheese wheels are to be manually inserted into the device.

2. Actuation of the pushbutton is to cause the cylinder to advance and press the
cover onto the device.
3. The pushbutton is to be pressed until the pressing operation is completed.
4. If the pushbutton is released, the cylinder is to retract again and release the
device.
5. The wheel can then be removed.
Note
A single-acting cylinder with a strong reset spring must be used for this control
system.
Safety advice
Please limit the pressure at the service unit to a maximum of 3.5 bar (350 kPa) for
this exercise.
A-4 © Festo Didactic GmbH & Co. KG • 541088

Name: Date:
Design and mode of operation of a single-acting cylinder Sheet 1 of 2
– Compare the symbols shown with the schematic representation of the single-
acting cylinder. Check whether these match.
1A1
Symbol of a single-acting cylinder
1 2 3 4 5
8 7 6
Schematic representation of a single-acting cylinder
– Assign the designations to the individual components.
No. Description
Cylinder barrel
End cap
Bearing cap
Piston rod
Piston
Reset spring
Supply port
Exhaust port
Table of component designations

Name: Date:
Design and mode of operation of a single-acting cylinder Sheet 2 of 2
The theoretical piston force is calculated according to the following formula:
Fth = A•p
Fth = Theoretical piston force (N)
A = Effective piston surface (m2)
p = Working pressure (Pa)
The effective piston force is of significance in practice. Frictional resistance is to be

taken into account when you calculate this. Friction forces of approx. 10% of the
theoretical piston force can be assumed for standard operating conditions (pressure
range of 4 to 8 bar (400 to 800 kPa),.
The following applies for single-acting cylinders:
Feff = A • p – (FF + FR)
Feff = Effective piston force (N)

FF = Friction force (approx. 10% of Fth ) (N)
FR = Return spring force (N)
– Calculate the effective piston force in the advance stroke for the cylinder when
used at an operating pressure of 6 bar (600 kPa)!
Note
You will find information regarding the technical data in Chapter D and on the
CD-ROM provided.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Name: Date:
Mode of operation of a 3/2-way valve. Sheet 1 of 1
– Complete the symbol of a 3/2-way valve, manually operated, with spring return,
normally closed.
1 3
Symbol of a 3/2-way valve
3
1
Schematic representation of a 3/2-way valve
– Explain the mode of operation of the 3/2-way valve.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Name: Date:
Completing the pneumatic circuit diagram Sheet 1 of 1
– Complete the pneumatic circuit diagram for the device and enter the port
designations.
Pneumatic circuit diagram
Note
The Start-up valve with filter control valve and the manifold are not shown. These
components are required for the circuit assembly.

Name: Date:
Compiling the equipment list Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires
an equipment list.
– Compile the equipment list by entering the required equipment in the table
below.
Quantity Description
Equipment list


Exercise 2: Opening of an animal feed silo
cylinder.
• To be able to identify and draw directional control valves.
Problem definition The slide of an animal feed silo is to be opened by pressing a pushbutton. The slide
is closed again when the pushbutton is released.
Parameters • A single-acting cylinder is to be used.

• The pneumatic control of the cylinder is to be realised by means of a pushbutton
actuator.
Project task 1. Answer the questions regarding the 3/2-way valve.

2. Create the pneumatic circuit diagram for the slide control.
6. Compile the equipment list

Positional sketch
Animal feed silo
1. Operation of the pushbutton actuator is to cause the cylinder to retract until the
retracted end position is reached.
2. The pushbutton actuator is to be operated for as long as the slide is to remain
open.
3. If the pushbutton actuator is released again, the cylinder is to advance thus
causing the slide to close the silo opening.
Note
A single-acting cylinder with a strong reset spring is to be used for this control
system.
Safety advice
this exercise.

Name: Date:
Mode of operation of a 3/2-way valve Sheet 1 of 1
– Complete the symbol of a 3/2-way valve, manually operated, with spring return,
normally open.
1 3
1
3
– Explain the mode of operation of the 3/2-way valve.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Name: Date:
– Amend the pneumatic circuit diagram for the device and enter the port
designations.
Note
Please note that circuits must be shown in their initial position.
1A1
1S1 2
1 3
Note
The On-Off valve with filter regulating valve and the manifold are not shown. These

Name: Date:
Amending the equipment list Sheet 1 of 1
– Amend the equipment list.
1 Compressed air supply
Tubing material
1 Single-acting cylinder
1 3/2-way valve, manually operated, normally closed
Equipment list
Amended equipment list


Exercise 3: Testing of key blanks
cylinder.
• To be able to identify and draw types of directional control valve actuation.
• To be able to to analyse and evaluate circuits.
Problem definition Key blanks are to be tested at a manual workstation. The insertion of the key blanks
requires a certain amount of time. It must therefore be possible for the clamping
cylinders to be retained in both end positions.
Parameters • Use one of the circuits from the previous exercises and adapt this for the purpose
of this problem.
Project task 1. Complete the pneumatic circuit diagram for the clamping device
5. Amend the equipment list

Positional sketch
Test station for key blanks
1. Key blanks are to be inserted manually into the test device.

2. Actuation of the selector switch is to cause the cylinder to advance and secure
the key blanks.
3. The cylinder is to remain in this position even after the selector switch is
released.
4. Resetting of the selector switch is to cause the cylinder to return into the
retracted end position and to remain there until the selector switch is actuated
again.
Safety note
this exercise.
Additional exercises • What errors can occur during the assembly and tubing up of the circuit?
• What is the effect of such errors. Describe these.

Name: Date:
– Complete the circuit diagrams below.

– Select the optimal circuit and complete this by adding the required type of
actuation. Explain the reasons for your choice.
a) b)
Pneumatic circuit diagrams
Note
The On/Off valve with the filter regulating valve and the manifold are not shown.
These components are required for the circuit assembly.

Name: Date:
Amending the equipment list Sheet 1 of 1
– Amend the equipment list.
1 Cylinder, single-acting
1 3/2-way valve with pushbutton, normally open
1 Manifold
1 Start-up valve with filter control valve
1 Compressed air supply
Equipment list
Amended equipment list

Name: Date:
Completing additional exercises Sheet 1 of 1
– What errors can occur during the assembly and tubing up of the circuit?
– What is the effect of such errors? Describe these.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________


Exercise 4: Sorting of packages
Training aims • To familiarise yourself with the design and mode of operation of a double-acting
cylinder.
Problem definition Packages are sorted manually from a conveyor into large containers at a sorting
station. When the containers are filled, these are transferred and a new container is
made available. During this time material flow is to be stopped whilst the conveyor
continues to run. The stopping action is realised by means of a mechanical blocking
device (slide). This blocking device is to be operated from the sorting position.
Parameters • A double-acting cylinder is to be used for cost reasons.
Project task 1. Describe the mode of operation of a double-acting cylinder.

2. Describe the mode of operation of a 5/2-way valve.
3. Draw a pneumatic circuit diagram for the package blocking device.

Positional sketch
Package conveyor
1. Actuation of the selector switch is to cause the cylinder to advance and push the
slide into the material flow.
2. The cylinder is to remain in this position even after the selector switch is released
and the material flow is to remain interrupted.
retracted end position and release the material flow again.
4. The cylinder is to remain in this position until the selector switch is actuated
again.
Safety note
this exercise.

• What is the effect of such errors? Describe these.
• What are your observations with regard to the advance and return movement of
the cylinder? Explain these.
• Why is a double-acting cylinder more cost effective than a single-acting cylinder?
• Determine the requirements placed on the directional control valve.
• Give the reasons why a selector switch has been chosen to realise the actuating
function.


Name: Date:
Design and mode of operation of a double-acting cylinder Sheet 1 of 4
– Compare the symbol shown with the schematic representation of the double-
acting cylinder. Check whether these match.
1A1
Symbol of a double-acting cylinder

Name: Date:
1 2 3 4 5
9 8 7 6
Schematic representation of a double cylinder
– Assign the designations to the individual components.
No. Designation
Cylinder barrel
End cap
Bearing cap
Piston rod
Piston
Supply port of piston chamber
Supply port of piston rod chamber
Adjusting screw of end position cushioning
Table of component designations

Name: Date:
The piston force generated by a working element is dependent on the air pressure,
cylinder diameter and frictional resistance of the sealing elements. The theoretical
piston force is calculated according to the following formula:
Fth = A•p
Fth = Theoretical piston force (N)
The effective piston force is of significance in practice. Frictional resistance is to be

taken in account when you calculate this. Under normal operating conditions,
friction forces of approx. 10% of the theoretical piston force can be assumed.
The following applies for double-acting cylinders:
Advance stroke Feff = (A • p) – FF

Return stroke Feff = (A' • p) – FF
Feff = Effective piston force (N)
D2 • π
= ( )
4
A' = Effective annular surface (m2)
π
= (D 2 − d 2 )
4
FF = Friction force (approx. 10% of Fth ) (N)
D = Cylinder diameter (m)
d = Piston rod diameter (m)

Name: Date:
– Calculate the effective piston force of the advance stroke and return stroke for
the cylinder in question using at a working pressure of 6 bar (600 kPa).
Note
You will find information regarding the technical data in Chapter D and on the
CD-ROM provided.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Name: Date:
Mode of operation of a 5/2-way valve Sheet 1 of 1
– Complete the symbol of a 5/2-way valve, manually operated, with spring return.
14 5 4 1 2 3
– Explain the mode of operation of a 5/2-way valve.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Name: Date:
Designing the pneumatic circuit diagram Sheet 1 of 1
– Complete the circuit diagram below and also enter the required type of actuation.
Explain the reasons for your choice.
Note
The Start-up valve with filter control valve is not shown. These components are
required for the circuit assembly.

Name: Date:
an equipment list.
below.
Equipment list

Name: Date:
Completing aditional exercises Sheet 1 of 1
– Describe the mode of operation of a double-acting cylinder.
– What are your observations with regard to the advance and return movement of
the cylinder? Explain these.
– Why is a double-acting cylinder more cost effective than a single-acting cylinder?
– Determine the requirements placed on the directional control valve.
– Explain your reasons why the selector switch is the form of actuation selected for
the directional control valve.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Exercise 5: Stopping crates of drinks
Training aims • To be able to explain and design an example of indirect actuation.

• To familiarise yourself with the mode of operation of a 5/2-way valve with
pneumatic actuation.
• To be able to differentiate between a signal element and a control element.
Problem definition Crates of drinks are to be provided with new labels. This process is to be checked via
a test set-up. The crates of drinks are supplied on a conveyor and must be
individually transported past a labelling device. The crates are to be stopped by
means of a mechanical stop (slide). The slide is to operated from the system control
console.
Parameters • Stopping of the material flow is to be effected from a second control console,
where compressed air is available and a pneumatic solution is therefore to be
used.
Project task 1. Determine the circuit requirements with regard to the actuating components and
control element.
2. Complete the pneumatic circuit diagram for the stopping of material flow.
6. Compile an equipment list

Positional sketch
Labelling crates of drinks
1. Actuation of a selector switch is to cause the cylinder to advance and push the
slide into the material flow; the crates are thus stopped.
retracted end position and once again release the flow of material.
3. It is to remain in this position until the selector switch is actuated again.
Safety note
this exercise.
Additional exercises • What errors can occur during the design and tubing up of the circuit?
• Explain the terms „pilot control“ and „remote control“.

Name: Date:
– Complete the circuit diagram below.
4 2
5 3
1
Note

Name: Date:
an equipment list.
below.
Equipment list

Exercise 5: Stopping of crates of drinks
Name: Date:
– Explain the terms „pilot control“ and „remote control“.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________


Exercise 6: Opening and closing of a pipe
Training aims • To be able to measure pressure in pneumatic control systems.

• To be able to differentiate between and utilise types of flow control in
accordance with specifications.
Problem definition The slide in a pipe is to be opened and closed. Actuation is to be triggered by means
of a valve with selector switch. A double-acting cylinder is to be used as the drive.
Parameters • The slide is to open/close only gradually since the load on the pipe would
otherwise be to great (the formation of surges is to be avoided).
Project task 1. Design the pneumatic circuit diagram.

6. Observe the pressure ratios upstream and downstream of the flow control valve
and document these.

Positional sketch
Waste water treatment
1. If the selector switch is actuated, the cylinder is to advance and open up flow.
2. If the selector switch is reset, the cylinder is to return into the initial position and
the slide is to close.
Safety note
this exercise.
• At what pressure do you notice juddering operation?
• Describe what causes juddering operation.

Name: Date:
Function of a one-way flow control valve Sheet 1 of 1
Symbol of a one-way flow control valve
1 2
Schematic representation of a one-way flow control valve
– Describe the function of a one-way flow control valve.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Name: Date:
– Complete the circuit diagram below. Enter the symbols of the one-way flow
control valves.
1A1
1V1 1 1 1V2
2 2
1S1 4 2
5 3
1
Note

Name: Date:
an equipment list.
– Create the equipment list by entering the required equipment in the table below.
Equipment list

Name: Date:
– At what pressure do you notice juddering operation?
– Describe what causes juddering operation.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Exercise 7: Shutting off using a quick shut-off function
Training aims • To be able to set cylinder advancing and retracting speeds.

• To be able to differentiate between and utilise types of flow control in
Problem definition A filling plant fills pots of paint with wall and ceiling paint. The pipes through which
the paint flows are to close quickly. The opening of the pipe is to be effected
gradually.
Parameters • A double-acting cylinder is to be used
Project task 1. Create the pneumatic circuit diagram for the shut-off device.
5. Compile the equipment list.

Positional sketch
Filling paint pots
1. Actuation of a selector switch is to cause a shut-off valve to open gradually.

2. Resetting of the selector switch is to cause the shut-off valve to close quickly.
Safety note
this exercise.
Additional exercises • What errors can occur during the tubing up?
• What is the effect of such tubing errors? Describe these.

Exercise 7: Shutting-off using a quick shut-off function
Name: Date:
– Complete the circuit diagram below and add the symbols of the one-way flow
control valves.
1A1
1Z2
1V1 1 1 1V2
1Z1 2 2
1S1 4 2
5 3
1
Note

Name: Date:
an equipment list.
below.
Equipment list

Name: Date:
– What errors can occur during tubing?

– What are the effects of such tubing errors. Describe these.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________


Exercise 8: Actuation of a shut-off device
Training aims • To familiarise yourself with one type of signal storage in pneumatic control
systems.
• To be able to set cylinder advancing and retracting speeds.
Problem definition The slide of a plastic granulate filling system is to close quickly. The opening of the
slide is to be effected gradually.
Parameters • A double-acting cylinder is to be used.
Project task 1. Describe the mode of operation of a quick exhaust valve.

2. Describe the mode of operation of a 5/2-way double pilot valve.
3. Design the pneumatic circuit diagram for the shut-off device.

Positional sketch
Granulate filling system
1. Actuation of a pushbutton is to cause a shut-off device (ball valve) to open

gradually.
2. Actuation of a second pushbutton is to cause the shut-off device to close quickly.
Safety note
this exercise..

Name: Date:
Function of a quick exhaust valve Sheet 1 of 1
1
1/3
Symbol of a quick exhaust valve
Schematic representation of a quick exhaust valve
– Describe how a quick exhaust valve functions.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Name: Date:
Mode of operation of a 5/2-way double pilot Sheet 1 of 1
14 5 4 1 2 3 12
Schematic representation of a 5/2-way double pilot valve
– Explain the mode of operation of the 5/2-way double pilot valve.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Name: Date:
2 2
4 2
5 3
1
Note

Name: Date:
an equipment list.
below.
Equipment list

Name: Date:
– What errors can occur during the assembly and tubing up of a circuit?
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________


Exercise 9: Brushing of cheese wheels
Training aims • To be able to explain and configure an indirect actuation.

• To be able to explain and realise logic AND/OR/NOT operations.
• To be able to explain and configure.
Problem definition Cheese wheels are to be brushed during production. Loading of the brushing device
is to be controlled manually. The cheese wheels are to be supplied via a conveyor.
Material flow is to be stopped by means of a slide if the device is filled .
Parameters • Material flow is to be controlled via two valves and the use of pushbuttons, i.e.
one pushbutton actuator to block and one to release material flow.
• Since the signal of the pushbutton actuators is only briefly applied, a circuit that
stores the signal status needs to be designed.
Project task 1. Describe the function of a shuttle valve.

2. Describe the construction of a self-latching loop.
3. Complete the pneumatic circuit diagram.

Positional sketch
Cheese production
1. Actuation of the pushbutton is to cause the cylinder to advance and push the
slide into the material flow.
2. The cylinder retains this position even after the pushbutton is released and
material flow is to remain interrupted.
3. Actuation of the second pushbutton is to cause the cylinder to return into the
retracted end position and release material flow again.
4. It is to remain there until the first pushbutton is actuated again.
Additional exercises • What errors can occur during tubing up?

• What are the effects of such tubing errors? Describe these.
• Describe the mode of operation of the self-latching loop on the basis of the
circuit.

Name: Date:
Function of a shuttle valve Sheet 1 of 1
1 1/3
Symbol of a shuttle valve
1 1/3
Schematic representation of a shuttle valve
– Describe the function of a shuttle valve.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Name: Date:
– Design the required self-latching circuit and complete the circuit diagram below.
1A1
1 1
2 2
4 2
14
5 3
1
1S1 2
1 3

Name: Date:
an equipment list.
Equipment list

Name: Date:
– What errors can occur during tubing up?

– What are the effects of such tubing errors? Describe these.
– Describe the mode of operation of the self-latching loop on the basis of the
circuit.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Exercise 10: Clamping of a workpiece
Training aims • To be able to explain and realise logic AND/OR/NOT operations.

• To familiarise yourself with one possibility of cylinder end position sensing.
Problem definition An automatic rotary indexing machine is used in production for the feeding of
workpieces. Workpieces to be processed are to be clamped in the individual
workpiece retainers. A clamping device is to be designed and checked by means of a
test setup.
Parameters • The clamping operation must not be started until the cylinder is in the retracted
end position.
• Actuation of a second pushbutton is to cause the cylinder to return into the
retracted end position and release the workpiece.
• A pressure gauge is to be installed at each of the working ports between the one-
way flow control valve and cylinder to display the pressure.
Project task 1. Describe the function of a dual pressure valve.

2. Describe the function of a 3/2-way roller lever valve.
3. Complete the pneumatic circuit diagram.

Positional sketch
Automatic rotary indexing machine
1. A double-acting cylinder is to advance only if a pushbutton is actuated AND if the

cylinder is in the retracted end position at the same time, since it is otherwise not
possible to insert a workpiece for processing.
2. The clamping cylinder is to retain the forward end position until the workpiece is
processed. The duration of the processing time can vary.
3. Pressing of a second pushbutton is to cause the workpiece to be released.
Safety note
this exercise.
• What is the effect of adjusting the 3/2-way roller lever valve?

Name: Date:
Function of a dual pressure valve Sheet 1 of 1
1 1/3
Symbol of a dual pressure valve
1 1/3
Schematic representation of a dual pressure valve
– Describe the function of a dual pressure valve.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Name: Date:
Function of a 3/2-way roller lever valve Sheet 1 of 1
1 3
Symbols of a 3/2-way roller lever valve
– Describe the function of a 3/2-way roller lever valve.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Name: Date:
1A1
1B1
1 1
2 2
4 2
14 12
5 3
1
1B1 2
1 3

Name: Date:
Apart from a circuit diagram, comprehensive project documentation also requires an

equipment list.
below.
Equipment list

Name: Date:
– What errors can occur during the assembly and tubing up of the circuit diagram?
– What is the effect of adjusting the 3/2-way roller lever valve?
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________


Exercise 11: Actuation of a sliding door
Training aims • To be able to explain and realise logic AND/OR/NOT operations.

• To be able to combine logic operations.
• To familiarise yourself with the design and mode of operation of magnetic
proximity sensors.
• To be able to differentiate between and select and utilise 5/2-way valves in
Problem definition A sliding door is to be opened and closed from both sides by means of a pushbutton.
Only one pushbutton is to be located on each of the door in order to eliminate
incorrect operation in cases of emergency.
Parameters • Both functions must only be started if the door is in the forward end position.
• For reasons of safety, pressure must be limited to 3 bar (300 kPa) (risk of being
trapped).
Project task 1. Design a pneumatic circuit diagram for the control system of the sliding door.

Positional sketch
Sliding door
1. Provided that the sliding door is in a defined end position, it can be moved into
the opposite end position by means of pressing a button. The sliding door can
thus be opened or closed.
2. It is not possible to start the opening or closing function for as long as the door is
not in an end position.
Safety note
Please limit the pressure at the service unit to a maximum of 3 bar (300 kPa) for this
exercise.
• What happens if compressed air supply fails during the advancing and retracting
movement?
• How can the circuit be re-started; what needs to be done for this?

Name: Date:
Function of a pneumatic proximity sensor Sheet 1 of 1
1 3
Symbol of a pneumatic proximity sensor
1 3
S N
N S
Schematic representation of the pneumatic proximity sensor
– Describe the function of the pneumatic proximity sensor.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Name: Date:
1A1
1B1 1B2
1 1
2 2
4 2
14 12
5 3
1B1 2 1S1 2 1S2 2 1B2 2
1 3 1 3 1 3 1 3

Name: Date:
an equipment list.
Equipment list

Name: Date:
– What errors can occur during the assembly or tubing up of the circuit?
– What happens if the compressed air supply fails during the advancing and
retracting movement?
– How can the circuit be re-started and what needs to be done to this effect?
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Exercise 12: Feeding of workpieces
Training aims • To familiarise yourself with the logic NOT operation.

• To be able to combine logic operations.
• To be able to further develop existing circuits.
Problem definition Workpieces are to be fed from a magazine towards a machining process. The
ejecting of a workpieces must be prevented if the removal position is not clear.
Parameters • The checking function as to whether a workpiece is present in the removal

position is to be effected by means of a roller lever valve.
• The cylinder is to be throttled during advancing and retracting.
Project task 1. Complete the pneumatic circuit diagram.


Positional sketch
Automatic rotary indexing machine
1. The ejecting function is to be started by means of a pushbutton if the cylinder is

in the retracted end position. The ejecting cylinder is to push a workpiece from
the magazine only if a sensor in the removal area signals that the removal
position is NOT occupied.
2. If the removal position is clear, the cylinder is to move into the forward end
position with exhaust air restricted, eject the workpiece and immediately return
into the retracted end position.
• How would you need to change the circuit if the ejecting process were to start
only once a workpiece is present in the magazine AND the removal position is
clear?

Name: Date:
1A1
1 1
2 2
4 2
14 12
5 3
1
Note
Use a 3/2-way valve with pushbutton actuator or selector switch in the circuit
instead of a 3/2-way roller lever valve in order to simulate whether the removal
position is clear or occupied.

Name: Date:
an equipment list.
below.
Equipment list

Name: Date:
Carying out additional exercises Sheet 1 of 1
– How would you need to change the circuit, if the ejecting process were to start
only once a workpiece is in the magazine AND the removal position is clear ?
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________


Exercise 13: Crushing of drinks cans
Training aims • To familiarise yourself with the design and mode of operation of a pressure
sequence valve.
• To be able to design pressure-dependent control systems.
Problem definition In a recycling plant drinks cans are to be crushed into a block for space-saving
storage. The pressing operation is to be triggered by means of a pushbutton. The
return stroke can be triggered by a pushbutton. The pressing operation is to start
only if sufficient pressure is available.
Parameters • The retracted end position is the initial position of the pressing cylinder.
• The pressing operation is to start only if the system pressure is above 6 bar
(600 kPa).
• The return stroke can be triggered manually since, depending on material load,
the pressing cylinder does not reach the forward end position.
Project task 1. Complete the pneumatic circuit diagram for the crushing of cans.

Positional sketch
Tin can press
1. A pressure sequence valve is to switch upon reaching the preset pressure and to
release compressed air for the circuit. The circuit must not function below a
pressure of 4.5 bar (450 kPa).
2. It should not be possible to commence the pressing operation via a start button
unless the pressing cylinder is in the upper end position. The pressing cylinder is
to move up to the forward end position or a stop predefined by the material.
3. The return stroke is to be triggered by means of a limit switch or pushbutton.
Note
The required protective grid is not shown.

Name: Date:
Function of a pressure sequence valve Sheet 1 of 1
12 1 3
Symbol of a pressure sequence valve
3 2 1 12
Schematic representation of a pressure sequence valve
– Describe the function of a pressure sequence valve.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Name: Date:
1A1
1B1 1B2
1V6 1 1 1V7
2 2
1V5 4 2
14 12
5 3
1
1V3 2 1V4 2
1 1/3 1 1/3
1B1 2 1S1 2 1S2 2 1B2 2
1 3 1 3 1 3 1 3
1V2 2
12 1 3
1V1
1 3

Name: Date:
an equipment list.
below.
Equipment list

Name: Date:
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Exercise 14: Packaging of brochures
Training aims • To familiarise yourself with the design and mode of operation of a pressure
regulating valve.
• To be able to design pressure-dependent control circuits.
Problem definition 10 brochures at a time are to be manually wrapped in plastic film. In order for the
film to be neatly bonded, the brochures will need to be clamped. To be able to
securely clamp the brochures a minimum pressure of 6 bar (600 kPa) must be
available. However at the clamping cylinder a maximum pressure of 8 bar (800 kPa)
is to be applied.
The advance and return stroke are to be triggered by means of a pushbutton. The
end positions of the clamping cylinder are to be sensed via pneumatic proximity
sensors.
Parameters • The process can only be started if the clamping cylinder is in the retracted end
position.
• It must only be possible to start the circuit if the operating pressure is above 6
bar (600 kPa.
• The return stroke is to be triggered intentionally since the duration of the
packaging process varies.
Project task 1. Complete the pneumatic circuit diagram for the packaging unit.

Positional sketch
Brochure production
1. A pressure sequence valve is to switch when the preset pressure is reached and
release the compressed air into the circuit.
2. The clamping operation is to start when the clamping cylinder is in the retracted
end position and a pushbutton is pressed. The cylinder is to advance and remain
in this position.
3. The process is to be completed via a second pushbutton and the cylinder to
return into the retracted end position.
• What is the function of the one-way flow control valve which is connected in
parallel to the pressure regulating valve?

Name: Date:
Function of a pressure regulating valve Sheet 1 of 1
1 3
Symbol of a pressure regulating valve
p1 p2
Schematic representation of a pressure regulating valve
– Describe the function of a pressure regulating valve.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Name: Date:
1A1
1B1
2 1 3
1V4 4 2
14 12
5 3
1
1V2 2
12 1 3
1V1
1 3

Name: Date:
an equipment list.
below.
Equipment list

Name: Date:
– What is the function of the one-way flow control valve, which is connected in
parallel to the pressure regulating valve?
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Exercise 15: Mounting of locking clips
Training aims • To be able to design pressure-dependent control systems.

• To be able to analyse circuits and optimise these in accordance with
specifications.
Problem definition Locking clips are to be fitted onto connector housings by means of an automatic
assembly system. Previously, pressure was set at the assembly system via a
pressure regulating valve, which repeatedly led to malfunctioning of the assembly
process.
The assembly process is to be tested using a test setup. Each assembly function is
to be triggered manually. The circuit is to be changed such that it only operates if the
pressure does not exceed a certain level.
Parameters • The pressure at the working port of the assembly cylinder must be a minimum of
3.5 bar (350 kPa), in order for the locking clips to be securely fitted.
• It must not be possible to start the process if the pressure is greater than 3.8 bar
(380 kPa).
• The return stroke of the assembly cylinder is to start automatically once the
forward end position is reached.
Project task 1. Complete the pneumatic circuit diagram for the automatic assembly system.
4. Describe the mode of operation of the circuit .
5. Compile the equipment list.

Positional sketch
Automatic assembly system of connector housings
1. The process is to be started via a pushbutton, when the assembly cylinder is in

the retracted end position.
2. The cylinder is to move into the forward end position using minimal force.
3. There it is to actuate a limit switch.
4. Then it is to return into the retracted end position.

Exercise 15: Fitting of locking clips
Name: Date:
Complete the pneumatic circuit diagram Sheet 1 of 1
1A1
1B1 1B2
1V7 1 1 1V8
2 2
1V6 4 2
14 12
5 3
1

Name: Date:
Analysing the pneumatic circuit diagram Sheet 1 of 2
– Analyse the circuit diagram below.
1A1
1B1
1 1V7
2
1V6
1V5 1
2 1 3
1V4 4 2
14 12
1V3 2 5 3
1
1 1/3
1B1 2 1S1 2 1S2 2
1 3 1 3 1 3
1V2 2
12 1 3
1V1
1 3

Name: Date:
Analysing the pneumatic circuit diagram Sheet 2 of 2
– Check whether the circuit of sheet 1 is also suitable for this problem definition?
– Where does the difference between these two circuits lie?
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Name: Date:
an equipment list.
below.
Equipment list

Exercise 16: Labelling of paint pots
Training aims • To be able to design pressure-dependent control systems.

• To familiarise yourself with the design and mode of operation of a time delay
valve.
Problem definition Pots of paint are to be labelled in a bonding fixture. The bonding process is to be
triggered via a pushbutton on the device.
A press-on time of 10 s is required in order for the adhesive to take effect. The
system is ready to start if the piston of the press-on cylinder is in the retracted end
position.
Parameters • The working pressure must be adjustable since the labels are to be bonded onto
the paint pots using minimal pressure.
• The cylinder is to retract as quickly as possible.
• The working pressure must be adjustable between 3 and 7 bar (300 and 700
kPa).
• The pressure is to be readable from a pressure gauge in front of the cylinder.
Project task 1. Complete the pneumatic circuit diagram


Positional sketch
Labelling device
1. The process is to be started using a pushbutton if the cylinder is in the retracted

end position.
2. The cylinder is to move into the forward end position using minimal force and to
remain in this position for a variable time period.
3. It is then to return into the retracted end position.
4. The pressure during advancing is to be displayed on a pressure gauge.

Name: Date:
Function of a time delay valve Sheet 1 of 1
12
1 3
Symbol of a time delay valve
12
Schematic representation of a time delay valve
– Describe the function of a time delay valve.
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Name: Date:
1A1
1B1 1B2
1
1/3
4 2
14 12
5 3
2 1
1 1/3
2
1B1 2 1S1 2 1B2 2
1 3
1 3 1 3 1 3

Name: Date:
an equipment list.
Equipment list


Exercise 17: Cleaning of workpieces
Training aims • To be able to design circuits with oscillating movements.

• To be able to use time delay valves dependent on parameters.
Problem definition A wire-mesh container with workpieces is to be moved in a cleaning bath. The
process is to be started via a pushbutton. The number of movements in the cleaning
bath is to be adjustable via a time delay valve.
Parameters • A roller lever valve is to be used to detect the retracted end position.
• 6 movements are to be carried out in the cleaning bath.
Project task 1. Convert a 5/2-way double pilot valve into a 3/2-way double pilot valve.
2. Complete the pneumatic circuit diagram for the automatic washing plant.

Positional sketch
Automatic washing plant
1. The process is to be started via a pushbutton if the lifting cylinder is in the

retracted end position.
2. The lifting device cylinder is to advance up to the forward end position and then
move up to the mid position and move back again to the forward end position.
This movement is to continue until the time delay valve interrupts the process.
3. The cylinder is then return into the retracted end position.
Additional exercises • Which components do you need to install in the circuit to ensure that the wire-
mesh container does not drop into the cleaning bath if the compressed air supply
is switched off?
• What is the effect of the one-way flow control valve on the operating behaviour of
the cylinder?

Name: Date:
Converting a 5/2-way double pilot valve Sheet 1 of 1
4 2
14 12
5 1 3
Symbol of a 5/2-way double pilot valve
– What functions can be realised as a result of the conversion of a 3/2-way valve?
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Name: Date:
1A1
1B3 1B2 1B1
1V4 4 2
14 12
5 3
1
1V3 2
1 1/3
1B1 2 1B3 2 1B2 2
1 3 1 3 1 3
1V2 2
10 12
1 3
1V1 2
1S1 2
1 3
1 3

Name: Date:
an equipment list.
Equipment list

Aufgabe 17: Cleaning of workpieces
Name: Date:
– Which component needs to be installed in the circuit to ensure that the wire-
mesh container does not drop into the cleaning bath if the compressed air supply
is switched off?
– What is the effect of the one-way flow control valves on the operating behaviour
of the cylinder?
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Exercise 18: Pressing in of lids
Training aims • To be able to analyse and design circuits using two cylinders.
Problem definition Lids are to be pressed into a fixture in a machining station. First, the lids are placed
onto the fixture. They are then to be pressed into the fixture by means of a press-in
cylinder.
Clamping of the lids is to be effected via a pushbutton. Once clamped, the pressing
process is to start. When the press-in cylinder reaches the forward end position,
both cylinders are to retract again.
Note
Any protective devices required are not taken into consideration.
Parameters • A single-acting cylinder is to be used for the clamping of workpieces.

• A roller lever valve is to be used to detect whether the clamping cylinder has
reached is forward end position.
• A double-acting cylinder is to be used as a press-in cylinder.
• The feed speed of the clamping and press-in cylinders is to be adjustbable.
Project task 1. Analyse the pneumatic circuit diagram for the press-in device.

Positional sketch
Press-in device
1. Plastic lids are to be placed into a fixture.

2. The pressing in process is to be started via a pushbutton.
3. A limit switch is to be used to detect whether the clamping cylinder has reached
its position.
4. The pressing-in cylinder is to advance only once the clamping cylinder has
reached its forward end position.
5. Both cylinders are to retract when the plastic lid is pressed in.
• What happens if the proximity sensor 1B2 on the cylinder is moved?

Exercise 18: Pressing-in of lids
Name: Date:
2A1
2B1 2B2
1A1
1B2
1V3 2 2V2 1
1 2
1V2 2 2V1 4 2
12 10 14 12
1 3 5 3
1

Name: Date:
an equipment list.
Equipment list

Name: Date:
– What happens if the pneumatic proximity switch 1B2 is moved?
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________


Pnuematics Exercises

Uploaded by

Document Information

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

Pnuematics Exercises

Uploaded by

Copyright:

Available Formats

Exercise 1: Pressing of cheese wheels

Parameters • A single-acting cylinder is to be used .

Project task 1. Describe the mode of operation of a single-acting cylinder.

© Festo Didactic GmbH & Co. KG • 541088 A-3

1. Cheese wheels are to be manually inserted into the device.

A-4 © Festo Didactic GmbH & Co. KG • 541088

Exercise 1: Pressing of cheese wheels

Design and mode of operation of a single-acting cylinder Sheet 1 of 2

Symbol of a single-acting cylinder

Schematic representation of a single-acting cylinder

– Assign the designations to the individual components.

Table of component designations

© Festo Didactic GmbH & Co. KG • 541088 A-5

Exercise 1: Pressing of cheese wheels

Design and mode of operation of a single-acting cylinder Sheet 2 of 2

The theoretical piston force is calculated according to the following formula:

The effective piston force is of significance in practice. Frictional resistance is to be

The following applies for single-acting cylinders:

Feff = A • p – (FF + FR)

Feff = Effective piston force (N)

A-6 © Festo Didactic GmbH & Co. KG • 541088

Exercise 1: Pressing of cheese wheels

Mode of operation of a 3/2-way valve. Sheet 1 of 1

Symbol of a 3/2-way valve

Schematic representation of a 3/2-way valve

– Explain the mode of operation of the 3/2-way valve.

© Festo Didactic GmbH & Co. KG • 541088 A-7

Exercise 1: Pressing of cheese wheels

Completing the pneumatic circuit diagram Sheet 1 of 1

Pneumatic circuit diagram

A-8 © Festo Didactic GmbH & Co. KG • 541088

Exercise 1: Pressing of cheese wheels

Compiling the equipment list Sheet 1 of 1

© Festo Didactic GmbH & Co. KG • 541088 A-9

A-10 © Festo Didactic GmbH & Co. KG • 541088

Parameters • A single-acting cylinder is to be used.

Project task 1. Answer the questions regarding the 3/2-way valve.

© Festo Didactic GmbH & Co. KG • 541088 A-11

Animal feed silo

A-12 © Festo Didactic GmbH & Co. KG • 541088

Exercise 2: Opening of an animal feed silo

Mode of operation of a 3/2-way valve Sheet 1 of 1

Symbol of a 3/2-way valve

Schematic representation of a 3/2-way valve

– Explain the mode of operation of the 3/2-way valve.

© Festo Didactic GmbH & Co. KG • 541088 A-13

Exercise 2: Opening of an animal feed silo

Completing the pneumatic circuit diagram Sheet 1 of 1

Pneumatic circuit diagram

A-14 © Festo Didactic GmbH & Co. KG • 541088

Exercise 2: Opening of an animal feed silo

Amending the equipment list Sheet 1 of 1

– Amend the equipment list.

1 Compressed air supply

1 3/2-way valve, manually operated, normally closed

Amended equipment list

© Festo Didactic GmbH & Co. KG • 541088 A-15

A-16 © Festo Didactic GmbH & Co. KG • 541088

© Festo Didactic GmbH & Co. KG • 541088 A-17

Test station for key blanks

1. Key blanks are to be inserted manually into the test device.

A-18 © Festo Didactic GmbH & Co. KG • 541088

Exercise 3: Testing of key blanks

Completing the pneumatic circuit diagram Sheet 1 of 1