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Innovation Team – Approved Course Resources P111 – Introduction to Pneumatics Solutions

PM - Training and Consulting

Description: Edition: Editors: Resources:

Innovation Team – Approved Course Resources – P111 – Solutions v1.0 (10/03) Martin Williams, David Hoey Festo Companies, Product Management – Training and Consulting

© Festo Didactic GmbH & Co. KG, 73770 Denkendorf/Germany, 2003 Internet: www.festo.com/didactic E-mail: did@festo.com

The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design registration.

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© Festo Didactic GmbH & Co. KG • Innovation Team – Approved Course Resources P111 – Sol.

Contents

P111 – Introduction to Pneumatics – Exercises & Solutions Exercise 1 ___________________________________________________________ 4 Exercise 2 ___________________________________________________________ 8 Exercise 3 __________________________________________________________ 11 Exercise 4 __________________________________________________________ 14 Exercise 5 __________________________________________________________ 17 Exercise 6 __________________________________________________________ 20 Exercise 7 __________________________________________________________ 24 Exercise 8 __________________________________________________________ 28 Exercise 9 __________________________________________________________ 31 Exercise 10__________________________________________________________ 35 Exercise 11__________________________________________________________ 39 Exercise 12__________________________________________________________ 42 Exercise 13__________________________________________________________ 46 Exercise 14__________________________________________________________ 50 Exercise 15__________________________________________________________ 54 Exercise 16__________________________________________________________ 58

© Festo Didactic GmbH & Co. KG • Innovation Team – Approved Course Resources P111 – Sol.

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Exercise 1

Exercise 1

Direct Control of a Single-Acting Cylinder

Problem Description

The allocating device supplies aluminium valve blanks to a machining station. By operating a push button, the piston rod of the single-acting cylinder (1.0) is made to advance. After releasing the actuating button, the piston rod returns.

Equipment list

Quantity 1

Description Single acting cylinder

Symbol

1

Push button actuated, spring return, normally closed, 3/2 directional control valve
1

2

3

4

© Festo Didactic GmbH & Co. KG • Innovation Team – Approved Course Resources P111 – Sol.

Exercise 1 Solution: Exercise 1 2 1 3 © Festo Didactic GmbH & Co. 5 . KG • Innovation Team – Approved Course Resources P111 – Sol.

The destination of the swivelling slide (upper or lower) is decided by means of a valve with selector switch. KG • Innovation Team – Approved Course Resources P111 – Sol. Equipment list Quantity 1 Description Double acting cylinder Symbol 1 Selector switch actuated. 5/2 directional control valve 4 2 5 1 3 6 © Festo Didactic GmbH & Co. according to the selection.Exercise 2 Exercise 2 Direct Control of a Double-Acting Cylinder Problem Description With the help of the vertical switching point. . spring return. soft cool (ignite) briquettes are to be fed to an upper or lower conveyor. detented.

Exercise 2 Solution: Exercise 2 4 2 5 1 3 © Festo Didactic GmbH & Co. 7 . KG • Innovation Team – Approved Course Resources P111 – Sol.

5/2 directional control valve 4 2 5 1 2 3 1 Push button actuated. spring return. KG • Innovation Team – Approved Course Resources P111 – Sol. The cylinder diameter is 160mm and the stroke is 100mm. when the push button is released. the cylinder returns to its initial position. Equipment list Quantity 1 Description Double acting cylinder Symbol 1 Selector switch actuated. detented.Exercise 3 Exercise 3 Indirect Control of a Double-Acting Cylinder Problem Description Press fit bushings are to be removed from steel blocks using a double acting cylinder. normally closed. 3/2 directional control valve 1 3 8 © Festo Didactic GmbH & Co. The start signal is to be given using a push button. spring return. .

9 . KG • Innovation Team – Approved Course Resources P111 – Sol.Exercise 3 Solution: Exercise 3 4 2 5 2 1 3 1 3 © Festo Didactic GmbH & Co.

Equipment list Quantity 1 Description Double acting cylinder Symbol 1 Double air actuated. normally closed. .Exercise 4 Exercise 4 Memory Control of a Double-Acting Cylinder Problem Description The roller track is to be swivelled by means of a double acting cylinder. spring return. 5/2 directional control valve 14 4 2 12 5 1 2 3 2 Push button actuated. The signals to extend and to retract are given from separate push buttons. KG • Innovation Team – Approved Course Resources P111 – Sol. 3/2 directional control valve 1 3 10 © Festo Didactic GmbH & Co. The cylinder is to remain in the in the position indicated by the last signal until an opposing signal is given.

Exercise 4 Solution: Exercise 4 4 14 5 2 2 12 3 2 1 1 3 1 3 © Festo Didactic GmbH & Co. KG • Innovation Team – Approved Course Resources P111 – Sol. 11 .

normally closed. An acknowledgement signal is required when the piston is fully extended to ensure that the part has been transfered. a part is to be moved from one roller track to another.Exercise 5 Exercise 5 Automatic Return using Limit Switch Problem Description Using a double acting cylinder. The return stroke is to be automatic. The operation is to be started using a push button. 5/2 directional control valve 14 4 2 12 5 1 2 3 1 Push button actuated. KG • Innovation Team – Approved Course Resources P111 – Sol. spring return. spring return. 3/2 directional controlvalve 1 3 12 © Festo Didactic GmbH & Co. normally closed. . 3/2 directional control valve 1 3 2 1 Roller lever actuated. 1A Equipment list Quantity 1 Description Double acting cylinder Symbol 1 Double air actuated.

Exercise 5 Solution: Exercise 5 1.2 1 2 1.3 2 1 3 1 3 © Festo Didactic GmbH & Co. 13 .3 1. KG • Innovation Team – Approved Course Resources P111 – Sol.0 1.1 4 14 5 2 12 3 1.

spring return. Equipment list Quantity 1 Description Double acting cylinder Symbol 1 Double air actuated. 3/2 directional control valve 1 3 2 1 Roller lever actuated. parts are to be fed. 3/2 directional control valve 1 3 14 © Festo Didactic GmbH & Co. The return stroke is initiated by the actuator after it reaches the end of the forward rotation.Exercise 6 Exercise 6 “OR” Function Problem Description Production parts are moved by an actuator towards a measuring machine. . When either of these is actuated. 5/2 directional control valve 14 4 2 12 5 1 2 3 2 Push button actuated. normally closed. Two push buttons are to be incorporated in the circuit. spring return. KG • Innovation Team – Approved Course Resources P111 – Sol. normally closed.

KG • Innovation Team – Approved Course Resources P111 – Sol. 15 .Exercise 6 1 “OR” gate (Shuttle valve) X A Y © Festo Didactic GmbH & Co.

2 2 1.3 1.Exercise 6 Solution: Exercise 6 1.3 2 1 3 1 3 1 3 16 © Festo Didactic GmbH & Co.0 1.1 4 14 5 2 12 3 1 1. .4 2 1.6 12 2 10 1. KG • Innovation Team – Approved Course Resources P111 – Sol.

parts are to be put together. KG • Innovation Team – Approved Course Resources P111 – Sol. spring return. 17 .Exercise 7 Exercise 7 “AND” Function Problem Description In an assembly station. The process can only start when a push button is pressed and a workpiece is present. 1A Equipment list Quantity 1 Description Double acting cylinder Symbol 1 Double air actuated. normally closed. The cylinder will remain in the forward position and only return if a second push button is pressed and a limit switch indicates that the cylinder is in the forward position. 5/2 directional control valve 14 4 2 12 5 1 2 3 2 Push button actuated. 3/2 directional control valve 1 3 © Festo Didactic GmbH & Co.

spring return. normally closed. KG • Innovation Team – Approved Course Resources P111 – Sol. . 3/2 directional control valve 1 2 3 1 “AND” gate (Two-pressure valve) X A Y 18 © Festo Didactic GmbH & Co.Exercise 7 2 Roller lever actuated.

6 12 2 1. 19 .Exercise 7 Solution: Exercise 7 1.5 10 1 2 3 2 1.3 1 3 W/P 1 3 1 3 © Festo Didactic GmbH & Co.1 4 14 5 2 12 3 1 1.4 2 1.2 2 1.0 1. KG • Innovation Team – Approved Course Resources P111 – Sol.

3/2 directional control valve 1 3 2 One-way adjustable flow control valve 20 © Festo Didactic GmbH & Co. Equipment list Quantity 1 Description Double acting cylinder Symbol 1 Double air actuated. The cylinder diameter is 50mm and it has a 160mm. normally closed. spring return. KG • Innovation Team – Approved Course Resources P111 – Sol. 5/2 directional control valve 14 4 2 12 5 1 2 3 2 Push button actuated. The speed of forward and return strokes is to be slow and separately adjustable.Exercise 8 Exercise 8 Speed Regulation Problem Description The forward and return strokes of the cylinder are to be controlled by separate push buttons. .

21 . KG • Innovation Team – Approved Course Resources P111 – Sol.3 2 1 3 1 3 © Festo Didactic GmbH & Co.03 1.1 4 14 5 2 12 3 1.2 1 2 1.0 1.Exercise 8 Solution: Exercise 8 1.02 1.

Equipment list Quantity 1 Description Double acting cylinder Symbol 1 Double air actuated. Additional Conditions : • The clamp can be released only when the drill is fully up. normally closed. normally closed. A third push button is to release the clamp.Exercise 9 Exercise 9 “OR” / “AND” / Speed Control Problem Description The clamping of a workpiece is to be controlled by either of two push buttons. 3/2 directional control valve 1 3 2 1 Roller lever actuated. spring return. spring return. • The clamping speed is to be slow and adjustable. . • Unclamping is to be very fast. KG • Innovation Team – Approved Course Resources P111 – Sol. 3/2 directional control valve 1 3 1 “AND” gate (Two-pressure valve) X A Y 22 © Festo Didactic GmbH & Co. 5/2 directional control valve 14 4 2 12 5 1 2 3 3 Push button actuated.

Exercise 9 1 One-way adjustable flow control valve 1 Quick exhaust valve A P R 1 “OR” gate (Shuttle valve) X A Y © Festo Didactic GmbH & Co. KG • Innovation Team – Approved Course Resources P111 – Sol. 23 .

1 4 14 2 12 5 1 3 1.0 A P R 1. KG • Innovation Team – Approved Course Resources P111 – Sol.Exercise 9 Solution: Exercise 9 1. .4 2 1.5 Drill 2 1 3 1 3 1 3 1 3 24 © Festo Didactic GmbH & Co.3 2 1.7 Y X A Y 1.6 X A 1.2 2 1.

Equipment list Quantity 1 Description Double acting cylinder Symbol 1 Double air actuated.Exercise 10 Exercise 10 Adjustable Force Problem Description A double acting cylinder is to used to emboss a part. The return stroke of the cylinder is to occur automatically after the forward end position and the preset pressure have been reached. 3/2 directional control valve 1 3 © Festo Didactic GmbH & Co. 5/2 directional control valve 14 4 2 12 5 1 2 3 2 Push button actuated. The extend stroke is to be slow and adjustable. KG • Innovation Team – Approved Course Resources P111 – Sol. Note : The position of the one-way flow control valve in the circuit will affect the operation of the sequence valve. The cylinder may be extended only when the part is present and either one of two push buttons is actuated. spring return. 25 . normally closed.

spring return. normally closed. KG • Innovation Team – Approved Course Resources P111 – Sol.Exercise 10 2 Roller lever actuated. 3/2 directional control valve 1 2 3 1 “AND” gate (Two-pressure valve) X A Y 1 One-way adjustable flow control valve 1 “OR” gate (Shuttle valve) X 1 Pressure sequence valve A Y 26 © Festo Didactic GmbH & Co. .

Exercise 10 Solution: Exercise 10 1.5 2 3 3 12 1 1 3 1 1 3 © Festo Didactic GmbH & Co. KG • Innovation Team – Approved Course Resources P111 – Sol.1 4 14 5 2 12 3 1 W/P 1.3 1. 27 .8 2 1 3 1.4 2 2 1.2 2 1.7 1.02 1.6 1 2 1 1 2 1 1.0 1.5 1.

Exercise 11 Exercise 11 Adjustable Force with Pressure Regulator Problem Description A clamp is to hold assorted parts of different materials. Equipment list Quantity 1 Description Double acting cylinder Symbol 1 Double air actuated. The clamping force must be adjustable and rapid declamping is also required. 5/2 directional control valve 14 4 2 12 5 1 2 3 2 Push button actuated. Clamping and declamping will be initiated by separate push buttons. spring return. normally closed. . 3/2 directional control valve 1 3 1 Quick exhaust valve A P R 1 Pressure regulator 28 © Festo Didactic GmbH & Co. KG • Innovation Team – Approved Course Resources P111 – Sol.

2 1 2 1.Exercise 11 Solution: Exercise 11 1.02 1.03 1.3 2 1 3 1 3 © Festo Didactic GmbH & Co. 29 .1 4 14 5 2 12 3 1.0 1. KG • Innovation Team – Approved Course Resources P111 – Sol.

After the piston has reached the forward end position. spring return. 3/2 directional control valve 1 3 30 © Festo Didactic GmbH & Co. 5/2 directional control valve 4 14 5 1 2 2 12 3 1 Push button actuated. KG • Innovation Team – Approved Course Resources P111 – Sol. spring return. The piston rod is to return automatically to the initial position. the components are to be pressed together for twenty seconds. 3/2 directional control valve 1 3 2 1 Roller lever actuated. 1A Equipment list Quantity 1 Description Double acting cylinder Symbol 1 Double air actuated. normally closed.Exercise 12 Exercise 12 Timer Functions Problem Description A push button is to control the forward stroke. normally closed. .

KG • Innovation Team – Approved Course Resources P111 – Sol.Exercise 12 1 Delay On Timer © Festo Didactic GmbH & Co. 31 .

5 Z A P 1.2 2 1.1 4 14 5 2 12 3 1 1.Exercise 12 Solution: Exercise 12 1.3 2 1 3 1 3 32 © Festo Didactic GmbH & Co. KG • Innovation Team – Approved Course Resources P111 – Sol. .3 1.0 1.

Clamping and declamping are to be controlled by separate push buttons. The riveting cylinder must extend rapidly. riveting the parts. Note : It is important that the signal to the sequence valve is taken from the correct location. The extension and retraction speed of the clamping cylinder is to be separately adjustable.Exercise 13 Exercise 13 Two Cylinders Motion with Sequence Valve Problem Description After two parts have been inserted in a fixture. KG • Innovation Team – Approved Course Resources P111 – Sol. The riveting cylinder and the clamping cylinder should react at the same time. Equipment list Quantity 2 Description Double acting cylinder Symbol © Festo Didactic GmbH & Co. Then a second cylinder is to extend. 33 . the clamping cylinder is to reach a given clamping pressure. otherwise the system will not operate properly.

3/2 directional control valve 1 2 3 2 One-way adjustable flow control valve 1 Quick exhaust valve A P R 1 Pressure sequence valve 34 © Festo Didactic GmbH & Co.Exercise 13 1 Double air actuated. . spring return. 5/2 directional control valve 14 4 2 12 5 1 3 1 Single air actuated. 5/2 directional control valve 2 Push button actuated. KG • Innovation Team – Approved Course Resources P111 – Sol. normally closed.

KG • Innovation Team – Approved Course Resources P111 – Sol. 35 .Exercise 13 Solution: Exercise 13 4 14 5 2 12 3 4 14 5 2 1 3 2 2 1 3 1 3 © Festo Didactic GmbH & Co.

5/2 directional control valve 14 4 2 12 5 1 3 36 © Festo Didactic GmbH & Co. cylinder 1.0 extends. . The speeds of both cylinders are to be adjustable. Confirmation of all extended and retracted positions is required.0 onto the outfeed chute. Once the part is transferred. pushing the part from the magazine and positions it in preparation for transfer by cylinder 2. KG • Innovation Team – Approved Course Resources P111 – Sol. 1A 2A Equipment list Quantity 2 Description Double acting cylinder Symbol 2 Double air actuated. When a push button is pressed. the first cylinder retracts followed by the second.Exercise 14 Exercise 14 Co-ordinated Motion Control Problem Description Two cylinders are used to transfer parts from a magazine onto a chute.

3/2 directional control valve 1 3 4 One-way adjustable flow control valve © Festo Didactic GmbH & Co. 37 . normally closed. normally closed. KG • Innovation Team – Approved Course Resources P111 – Sol. spring return.Exercise 14 4 Roller actuated. spring return. 3/2 directional control valve 1 2 3 2 1 Push button actuated.

KG • Innovation Team – Approved Course Resources P111 – Sol.Exercise 14 Solution: Exercise 14 A0 A1 B0 B1 4 14 5 2 12 3 14 4 2 12 5 3 B0 2 B0 1 3 2 B1 2 A1 2 A0 A0 2 1 3 1 3 1 3 1 3 38 © Festo Didactic GmbH & Co. .

Equipment list Quantity 2 Description Double acting cylinder Symbol 3 Double air actuated. i. KG • Innovation Team – Approved Course Resources P111 – Sol. both pilot signals on the 5/2 way valve are active.Exercise 15 Exercise 15 Signal Overlap Problem Description In co-ordinated motion control. The parts are moved into position by a pneumatic cylinder. If two signals are operated simultaneously. Parts are manually placed in an embossing machine. the 5/2 way memory valve can only switch positions when a single point signal is present. 39 .e. 5/2 directional control valve 14 4 2 12 5 1 3 © Festo Didactic GmbH & Co. A second cylinder embosses the part and returns. After the embossing cylinder retracts. a signal overlap problem occurs. Design the circuit using the Cascade method. the feed cylinder returns.

normally closed.Exercise 15 1 Push button actuated. . KG • Innovation Team – Approved Course Resources P111 – Sol. spring return. 3/2 directional control valve 1 3 2 One-way adjustable flow control valve 40 © Festo Didactic GmbH & Co. normally closed. 3/2 directional control valve 1 2 3 2 4 Roller lever actuated. spring return.

4 2.3 1.3 2. 41 .2 1. KG • Innovation Team – Approved Course Resources P111 – Sol.Exercise 15 Solution: Exercise 15 1.3 2.3 © Festo Didactic GmbH & Co.2 1.4 2.

The cycle is to start when a Start button is pressed.Exercise 16 Exercise 16 Using Reversing Valves Problem Description Using a transfer station. 42 © Festo Didactic GmbH & Co. KG • Innovation Team – Approved Course Resources P111 – Sol.0 and then transferred onto a chute by Cylinder 2. . parts are to be transferred from a vertical magazine to a processing station.0 is only to retract after confirmation that Cylinder 1. Limit switches are used to confirm cylinder positions. The piston rod of Cylinder 2. The parts are pushed by Cylinder 1.0 for transfer to the processing station.0 has fully retracted.

The diagram is to be used to construct the circuit on the training board. KG • Innovation Team – Approved Course Resources P111 – Sol. draw a pneumatic circuit diagram for the problem in this exercise using ISO symbols and connecting the ports with solid lines. © Festo Didactic GmbH & Co.Exercise 16 Workspace In the space provided below. 43 .

Exercise 16 Solution: Exercise 16 44 © Festo Didactic GmbH & Co. . KG • Innovation Team – Approved Course Resources P111 – Sol.