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Learning System for Automation and Technology

Electropneumatics
Workbook Advanced level

094467

Authorised applications and liability


The Learning System for Automation and Technology has been developed and prepared exclusively for training in the field of automation and
technology. The training organization and / or trainee shall ensure that
the safety precautions described in the accompanying Technical documentation are fully observed.
Festo Didactic hereby excludes any liability for injury to trainees, to the
training organization and / or to third parties occurring as a result of the
use or application of the station outside of a pure training situation,
unless caused by premeditation or gross negligence on the part of Festo
Didactic.
Order no.:
Description:
Designation:
Edition:
Layout:
Graphics:
Authors:

094467
TEACHW.E-PNEUM.
D.S202-C-SIBU-GB
05/2002
06.05.2002, OCKER Ingenieurbro
OCKER Ingenieurbro
D. Waller, H. Werner, Th. Ocker

Copyright by Festo Didactic GmbH & Co., D-73770 Denkendorf 2002


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 registrations.
Parts of this training documentation may be duplicated, solely for training
purposes, by persons authorised in this sense.

Preface
The Festo Didactic Learning System for Automation and Technology has
been formulated according to various prerequisites and vocational
requirements. It has been divided into the following categories of training
packages:


Basic packages which convey basic knowledge spanning a wide


range of technologies

Technology packages which deal with important subjects of open and


closed-loop control technology

Function packages to explain the basic functions of automated systems

Application packages to facilitate practice-orientated vocational and


further training

The technology packages deal with the technologies of pneumatics,


electropneumatics, programmable logic controllers, hydraulics, electrohydraulics, proportional hydraulics and handling technology.
Mounting frame

Profile plate

U = 230V~

Storage tray

TP202 Festo Didactic

The modular design of the Learning System permits applications beyond


the scope of the individual packages. It is, for instance, possible to
design PLC controlled systems with pneumatic, hydraulic and electrical
actuators.
All training packages are based on an identical structure:


Hardware

Teachware

Software

Seminars

The hardware consists of industrial components and systems which


have been adapted for didactic purposes.
The courseware has been designed in line with didactic methods and
coordinated for use with the training hardware. The courseware comprises:


Textbooks (with exercises and examples)

Workbooks (with practical exercises, explanatory notes, solutions and


data sheets)

Transparencies and videos (to create a lively training environment)

The training and learning media is available in several languages, which


has been designed for use in the classroom as well as for self-tuition.
The software sector serves as a basis for providing computer training
program, simulation program and programming software for programmable logic controllers.
A comprehensive range of seminars on the subject of the various technology packages completes our program of vocational and further training.

TP202 Festo Didactic

Latest information about the technology package pneumaticTP 202


New in Pneumatic 2000:


Industrial components on the profile plate.

Fostering of key qualifications:


Technical competence, personal competence and social competence
form professional competence.

Training of team skills, willingness to co-operate, willingness to learn,


independence and organisational skills.

Aim Professional competence


Content
Part A

Course

Exercises

Part B

Fundamentals

Reference to the text book

Part C

Solutions

Function diagrams, circuits, descriptions of


solutions and quipment lists

Part D

Appendix

Storage tray, mounting technology


and datasheets

TP202 Festo Didactic

Table of contents
Introduction

Notes on safety and operation

11

Training contents of basic level and advanced level

13

Equipment set for the basic level (TP201)

15

Equipment set for the advanced level (TP202)

18

Component and exercise allocation (table)

20

Methodical structure of the exercises

21

Designation of components

22

TP202 Festo Didactic

Part A Course
Basic exercises
Exercise 1:

Bench drill

A-3

Exercise 2:

Feed unit for sheet metal strip

A-5

Exercise 3:

Filling device

A-7

Exercise 4:

Stamping device

A-9

Exercise 5:

Drilling jig

A-11

Exercise 6:

Clamping unit for grinding

A-15

Exercise 7:

Forming press

A-19

Consolidating exercises
Exercise 8:

Embossing device

A-21

Exercise 9:

Handling device

A-23

Exercise 10:

Drilling and reaming machine

A-25

Exercise 11:

Loading station

A-29

Exercise 12:

Internal grinding machine

A-33

Exercise 13:

Assembly unit

A-37

Exercise 14:

Moulding press

A-41

Exercise 15:

Pick-and-place unit

A-45

Exercise 16:

Galvanising process

A-49

Exercise 17:

Loading station

A-53

Exercise 18:

Rotary indexing station

A-57

Exercise 19:

Checking station

A-63

Exercise 20:

Handling device

A-67

Part B Fundamentals

TP202 Festo Didactic

Part C Solutions
Solution 1:

Bench drill

C-3

Solution 2:

Feed unit for sheet metal strip

C-9

Solution 3:

Filling device

C-17

Solution 4:

Stamping device

C-21

Solution 5:

Drilling jig

C-27

Solution 6:

Clamping unit for grinding

C-35

Solution 7:

Forming press

C-41

Solution 8:

Embossing device

C-45

Solution 9:

Handling device

C-49

Solution 10:

Drilling and reaming machine

C-55

Solution 11:

Loading station

C-59

Solution 12:

Internal grinding machine

C-63

Solution 13:

Assembly unit

C-69

Solution 14:

Moulding press

C-75

Solution 15:

Pick-and-place unit

C-81

Solution 16:

Galvanising process

C-87

Solution 17:

Loading station

C-95

Solution 18:

Rotary indexing station

C-103

Solution 19:

Checking station

C-111

Solution 20:

Handling device

C-117

Part D Appendix
Storage tray

D-2

Mounting technology

D-3

Plastic tubing

D-5

Data sheets

...

TP202 Festo Didactic

Introduction
This workbook forms part of Festo Didactics Learning System for Automation and Technology. The system provides a solid basis for practiceorientated vocational and further training. Technology package TP200 is
concerned exclusively with electro-pneumatic control systems.
The basic level TP201 is suitable for basic training in electro-pneumatic
control technology. It conveys knowledge concerning the physical fundamentals of electropneumatics as well as the function and use of
electro-pneumatic components. The equipment set permits the construction of simple electro-pneumatic control systems.
The advanced level TP202 is intended for further training in electropneumatic control technology. The equipment set permits the construction of a wide range of combinatorial circuits with logic operations of the
input and output signals as well as program controls.
Prerequisites for assembling control circuits are a fixed workstation and
a Festo Didactic profile plate. The profile plate has 14 parallel T-grooves
arranged at intervals of 50 mm. A short-circuit proof power supply unit
provides a constant power supply (Input: 230 V, 50 Hz, Output: 24 V,
max. 5 A). A mobile, silenced compressor may be used for compressed
air supply (230 V, maximum 8 bar = 800 kPa).
Working pressure should be a maximum of p = 6 bar (= 600 kPa)
Optimum operational safety is achieved by operating the control system
with unlubricated air at a pressure of p = 5 bar = 500 kPa.
The training hardware of both equipment sets (TP201 and TP202) will
be required for the practical assembly of the controls documented here.
The theoretical fundamentals required to understand this book of exercises can be found in the following textbook:
Learning System for Control Technology


Introduction to Electropneumatics

Also available are data sheets on the various components (cylinders,


valves, measuring devices, etc.).

TP202 Festo Didactic

10

TP202 Festo Didactic

11

Notes on safety and operation


In the interests of your own safety, the following advice should be observed:


Pressurised air lines that become detached can cause accidents.


Switch off supply immediately.

Lines must be connected up and secured before the compressed air


is switched on.

Warning!
Cylinders may advance or retract as soon as the compressed air is
switched on.

Do not operate the electrical limit switches manually during fault


finding (use a suitable tool).

Observe general safety regulations (DIN 58126 and VDE 100).

Distinction is to be made between the two different designs of the


electrical limit switches
Actuation from the left
Actuation from the right

Limit switches should be placed so that they contact only the side of
the trip cam and never the front at high piston speeds.

In the pneumatic circuits cylinders are shown without magnetic pistons, since these are only required when magnetic end-position
switches are used. Festo Didactic training sets only contain cylinders
with magnetic pistons.

Do not exceed permissible operating pressure (observe data sheets).

Only use extra-low voltage 24 V.

All components are provided with 4 mm safety sockets respectively


safety plugs. For electical connections use only electrical cable with
safety plugs.

Pneumatic circuit design:


Components are to be connected by means of the silver-metallic
plastic tubing with a 4 mm external diameter. Insert the tubing into the
QS push-in fitting up to the stop; no further securing necessary!

Releasing of the QS straight push-in fitting:


The tubing can be released by simply pressing the clamping collet
(blue ring). (Cannot be disconnected under pressure!)

Switch off the pressure and power supply prior to disconnecting the
circuit.

TP202 Festo Didactic

12

The profile plate for the assembly of components is equipped for


mounting variants A to D:
Variant A, Detent system
Light, non load-bearing components (e.g. directional control valves).
Simply clip the components into the groove of the profile plate. The
components can be released by pressing the blue lever.
Variant B, Rotational system
Medium-weight, load-bearing components (e.g. actuators). These
components are clamped onto the profile plate by means of T-head
bolts. The components are clamped or released by means of the blue
triple grip nut.
Variant C, Screw-in system
For heavy, load-bearing components, i.e. components which are
rarely removed from the profile plate (such as start-up valves with filter regulator). The components are secured by means of cheese
head screws and T-head nuts.
Variant D, Plug-in system
Light, non load-bearing components with locating pins (e.g. signalling
device). These components are secured by means of plug-in adapters.

Please observe the data sheets in Part D for information regarding


the individual components.

TP202 Festo Didactic

13

Training contents of basic level and advanced level


Basic level (TP201)


Physical fundamentals of electricity and pneumatics

Function and application of electropneumatic components

Designation and drawing of electropneumatic symbols

Representation of motion sequences and switching statuses

Drawing pneumatic and electrical circuit diagrams

Assembly of control systems with relays

Direct and indirect manual control systems

Direct and indirect stroke-dependent control systems

Logical AND/OR functions of the input signals

Electrical latching circuits

Using a magnetic proximity switch

Using a pressure switch

Fault finding in simple electropneumatic control systems

Advanced level (TP202)




Function and use of electro-pneumatic components

Stroke-dependent control systems with sensors

Stroke-dependent control systems with preselect counter

Control systems with marginal conditions


(e.g. Single/continuous cycle, EMERGENCY-STOP)

Position-scheduled control/process orientated sequence controls

Timing controls/time orientated sequence controls

Program control systems with latching and resetting sequence

Fault finding in extensive electro-pneumatic control systems

TP202 Festo Didactic

14

List of training aims

Exercise

Training aim

To teach the student the principle of the latching sequence.

To teach the student the principle of the resetting sequence


(with reliable switching reversal).

To familiarise the student with the procedure for skipping program steps
and with the use of a timer.

To teach the student how to realise a stroke-dependent sequence


control with resetting sequence.

To teach the student how to realise multiple movements of a cylinder


and monitor service life using a preselect counter.

To familiarise the student with the use of a pneumatic/electric converter


To teach the student how to construct a control system using single and
double solenoid valves (resetting sequence with extension).

To teach the student how to realise a control system with specified


EMERGENCY-STOP conditions and how to realise a two-hand safety
start-up control via a timer with switch-on delay.

To teach the student how to incorporate step repetitions and manual


step mode into a sequence.

To teach the student how to incorporate EMERGENCY-STOP and


marginal conditions in a latching sequence.

10

To teach the student how to realise a control system with an alternative


program by means of program switching.

11

To teach the student to program repetition using an additional movement.

12

To familiarise the student with step repetition using the preselect counter.

13

To teach the student how to set up manual activation of the cylinder with
protection against collision.
To familiarise the student with automatic setting conditions.

14

To teach the student how to construct a two-handed safety start-up with


relay. To familiarise the student with restart before the end of the cycle.

15

To teach the student how to develop a latching sequence with marginal


conditions.

16

To teach the student how to realise program branchings.


To teach the student how to make multiple use of time relays.
To familiarise the student with program section repetitions using the
preselect counter.

17

Consolidating the students knowledge. Program section repetition.

18

To familiarise the student with parallel program division.

19

To familiarise the student with the use of a timer with delayed switch-on
as a delayed starting element.

20

Familiarisation with an alternative solution to electropneumatics.

TP202 Festo Didactic

15

Equipment set for the basic level (TP201)


This equipment set is designed for basic training in electro-pneumatic
control technology. It contains all the components required to achieve
the specified training aims and may be extended as required with the
addition of other equipment sets. To construct fully operational controls,
it is also necessary to have a profile plate, a power supply unit and a
compressed air supply.
Designation

Order No.

Quantity

Relay, 3-off*

162241

Signal input plate, electrical *

162242

Indicator/distributor plate, electrical *

162244

Plastic tubing, 10 m, silver metallic

151496

Single-acting cylinder

152887

Double-acting cylinder

152888

On/off valve with filter regulator

152894

Manifold

152896

Proximity sensor, with cylinder mounting

167060

Limit switch, electrical, actuation from the left

183322

Limit switch, electrical, actuation from the right

183345

Pneumatic-electric converter

177459

3/2-way solenoid valve, normally closed

167073

5/2-way solenoid valve

167074

5//2-way double solnoid valve

167076

* These components can be attached to the profile plate by means of 4 adapters (Order
No. 323571).

TP202 Festo Didactic

Equipment set for the


basic level (TP201)
(Order No.: 080243)

16

Symbols of the
equipment set

Signal input plate, electrical

Indicator/distributor, electrical

Relay, 3-off

Single-acting cylinder

Double-acting cylinder

On/off valve with filter regulator

Manifold

TP202 Festo Didactic

17

Proximity sensor with cylinder mounting

Pneumatic-electric converter

Limit switch, electrical,


Actuation from left or right*

3/2-way solenoid valve,


normally closed

5/2-way solenoid valve

5/2-way double solenoid valve

TP202 Festo Didactic

Symbols of the
equipment set

18

Equipment set for the advanced level (TP202)


This equipment set for the advanced level is designed for further training
in electro-pneumatic control technology. The two equipment sets (TP201
and TP202) contain all the components required to achieve the specified
training aims and may be extended as required with the addition of other
equipment sets from the Learning System for Automation and Technology.
Equipment set for
the advanced level
(TP202)
(Order No: 184461)

Designation

Order No.

Quantity

Relay, 3-off*

162241

Signal input plate, electrical*

162242

Time relay, 2-off*

162243

Preselect counter, electrical, incrementing*

162355

5/2-way double solenoid valve

167076

Proximity sensor, inductive

178574

Proximity sensor, capacitive

178575

Proximity sensor, optical

178577

EMERGENCY-STOP button

183347

* These components can be attached to the profile plate by means of 4 adapters (Order
No. 323571).

TP202 Festo Didactic

19

Signal input plate, electrical

Relay, 3-off

Time relay, 2-off


with switch-on delay

with switch-off delay

Preselect counter, electrical, incrementing

EMERGENCY-STOP button

Proximity sensor, inductive

Proximity sensor, capacitive

Proximity sensor, optical

5/2-way double solenoid valve

TP202 Festo Didactic

Symbols of the
equipment set
advanced level

20

Component and exercise allocation (table)


Exercise
Designation

10 11 12 13 14 15 16 17 18 19 20

Relay, 3-off*

6* 6* 6* 6* 6* 6*

Signal input module,


electrical *

Time relay, 2-off

Preselet counter, electrical,


incrementing
Distributor plate, electrical

1
1

Single-acting cylinder

Double-acting cylinder

3* 3* 3* 3*

On-off valve with


filter regulator

Manifold

EMERGENCY-STOP button

Proximity sensor, inductive


Proximity sensor, capacitive

Proximity sensor, optical

Limit switch, electrical,


Actuation from the left

Limit switch, electrical,


Actuation from the right

Pneumatic-electric converter

5/2-way solenoid valve

2* 2* 2*

1
2
2

3/2-way solenoid valve,


normally closed

Proximity sensor with


cylinder mounting

5/2-way double solenoid


valve

1
1

* Components which are not available in full quantity in equipment sets 201 and 202.

TP202 Festo Didactic

21

Methodical structure of the exercises


All 20 exercises in part A are of the same methodical design.
The two exercise sheets are divided into:
-

Subject

Title

Training aim

Exercise

sowie
-

Problem description

Positional sketch

Displacement-step diagram

The proposed solutions in part C cover a minimum of four pages and are
divided into:
-

Circuit diagram, pneumatic

Circuit diagram, electrical

Solution description

Component list

TP202 Festo Didactic

22

Designation of components
The components in the circuit diagrams are designated in accordance
with ISO 1219-2. All components within a circuit have the same main
code. Letters are assigned dependent on the component. If there are
several components within a circuit, these are numbered consecutively.
Pressure lines are identified with the designation P and are numbered
separately.
Actuators:

1A, 2A1, 2A2, ...

Valves:

1V1, 1V2, 1V3, 2V1, 2V2, 3V, ...

Signal detecter:

1S1, 1S2, ...

Accessories:

0Z1, 0Z2, 1Z, ...

Electrical sensors:

1B1, 1B2, ...

Pressure lines:

P1, P2, ...

TP202 Festo Didactic

A-1

Part A Course
Basic exercises
Exercise 1:

Bench drill

A-3

Exercise 2:

Feed unit for sheet metal strip

A-5

Exercise 3:

Filling device

A-7

Exercise 4:

Stamping device

A-9

Exercise 5:

Drilling jig

A-11

Exercise 6:

Clamping unit for grinding

A-15

Exercise 7:

Forming press

A-19

Consolidating exercises
Exercise 8:

Embossing device

A-21

Exercise 9:

Handling device

A-23

Exercise 10:

Drilling and reaming machine

A-25

Exercise 11:

Loading station

A-29

Exercise 12:

Internal grinding machine

A-33

Exercise 13:

Assembly unit

A-37

Exercise 14:

Moulding press

A-41

Exercise 15:

Pick-and-place unit

A-45

Exercise 16:

Galvanising process

A-49

Exercise 17:

Loading station

A-53

Exercise 18:

Rotary indexing station

A-57

Exercise 19:

Checking station

A-63

Exercise 20:

Handling device

A-67

TP202 Festo Didactic

A-2

TP202 Festo Didactic

A-3
Aufgabe 1

Electropneumatics

Subject

Bench drill

Title

To teach the student the principle of a latching sequence.

Training aim

Drawing the pneumatic and electrical circuit diagrams.

Exercise

Construction of the pneumatic and electrical circuits.

Checking the circuit sequence.

TP202 Festo Didactic

A-4
Aufgabe 1

Problem description

Workpieces are inserted into the clamping device by hand. Clamping


cylinder 1A is to extend when the start button is pressed. When the
workpiece is clamped, it is to be drilled via feed unit 2A and the drill
retracted once again. At the same time, the swarf is to be blown away by
an air jet 3Z. Then, the clamping cylinder 1A is to release the workpiece.

Fig. 1/1:
Positional sketch

2A

3Z

1A

Fig. 1/2:
Displacement-step diagram

5=1

1S2

1S1

2B2

2B1

1A

2A

TP202 Festo Didactic

A-5
Aufgabe 2

Electropneumatics

Subject

Feed unit for sheet metal strip

Title

To teach the student the principle of a resetting sequence


(with reliable switching reversal).

Training aim

Drawing the pneumatic and electrical circuit diagrams.

Exercise

Construction of the pneumatic and electrical circuits.

Checking the circuit sequence.

TP202 Festo Didactic

A-6
Aufgabe 2

Problem description

A sheet metal strip is to be fed from a drum towards the cutting tool. The
feed unit may only start when the punch-tool is in the upper position (this
signal must be simulated by a push button S3). Cylinder 1A holds the
sheet metal strip and cylinder 2A retracts. Cylinder 1A releases the strip
and cylinder 2A returns to the forward end position.

Operating condition

The sheet metal strip feed unit must be provided with a main switch S1.
When cylinder 2A has retracted and cylinder 1A has released the strip, a
signal (optical indicator) is to be passed on to the press for the next part
to be punched out.

Fig. 2/1:
Positional sketch

1A

2A

Fig. 2/2:
Displacement-step diagram

6=1

1B2

1B1

2S2

2S1

1A

2A

TP202 Festo Didactic

A-7
Exercise 3

Electropneumatics

Subject

Filling device

Title

To familiarise the student with the procedure for skipping program


steps.

Training aim

To familiarise the student with the use of a timer with switch-on delay.

Drawing the pneumatic and electrical circuit diagrams.

Construction of the pneumatic and electrical circuits.

Checking the circuit sequence.

TP202 Festo Didactic

Exercise

A-8
Exercise 3

Problem description

Bottles are transported along a conveyor belt to a rotary table. Cylinder


1A is to retract only when a bottle has arrived on the conveyor belt
(position 1) and the START signal (continuous/single cycle) has been
given. The table is then to continue indexing (2A+), when the signal
bottle on indexing table (position 2) has been sent. When a bottle has
reached the filling station (position 3), cylinder 3A is to open the filling
valve, remain it open for approx. 2 seconds and then reclose it.

Operating condition

If no bottle is reported as present at the filling station (position 3), the


installation must be indexed manually until a bottle is present for filling.
Sensing of the bottles is to be simulated by push button.

Fig. 3/1:
Positional sketch

1A

3A

2A

TP202 Festo Didactic

A-9
Aufgabe 4

Electropneumatics

Subject

Stamping device

Title

To teach the student how to realise a stroke-dependent sequence


control with a resetting sequence.

Training aim

Drawing the displacement-step diagram and the pneumatic and


electrical circuit diagram.

Exercise

Construction of the pneumatic and electrical circuits.

Checking the circuit sequence.

TP202 Festo Didactic

A-10
Aufgabe 4

Problem description

Cylinder 1A is to push parts out of the gravity feed magazine and clamp
them. Only then can cylinder 2A stamp the part and retract once again.
Next, clamping cylinder 1A is to unclamp. The part is to be ejected by
cylinder 3A, which then returns to the retracted end position.

Fig. 4/1:
Positional sketch

Fig. 4/2:
Displacement-step diagram

7=1

1S2

1S1

2B2

2B1

3B2

3B1

1A

2A

3A

TP202 Festo Didactic

A-11
Exercise 5

Electropneumatics

Subject

Drilling jig

Title

To teach the student how to realise multiple movements of a cylinder.

Training aim

To familiarise the student with the use of an incrementing preselect


counter.

Drawing the pneumatic and electrical circuit diagrams.

Drawing the pneumatic and electrical circuits.

Checking the circuit sequence.

TP202 Festo Didactic

Exercise

A-12
Exercise 5

Problem description

Rectangular castings are to be drilled in 4 positions. Castings are inserted by hand and clamped by an eccentric cam.
Feed unit 3A with hydraulic cushioning cylinder is aligned vertically (Zaxis). Positioning cylinders 1A and 2A move the table in X- and Ydirection so that drilling positions (1), (2), (3) and (4) can be approached
consecutively.
The first hole is drilled by means of feed unit 3A after the START button
has been pressed. Next, double-acting cylinder 1A retracts and the
second drilling process takes place. After double-acting cylinder 2A has
retracted, feed unit 3A carries out the third double stroke. When cylinder
1A has once again reached its forward end position, the fourth hole is
drilled. In the 12th step, cylinder 2A extends once again and the initial
position is obtained.

Operating condition

To ensure that the service life of the drill is not exceeded, it is to be


monitored via a counter. This is to emit a signal and interrupt the cycle
once a predetermined number of drilling operations has taken place.
Once the drill has been replaced and the counter has been reset by
hand, the cycle is to continue again.

TP202 Festo Didactic

A-13
Exercise 5

Fig. 5/1:
Positional sketch

1
4

2
3

Fig. 5/2:
Displacement-step diagram
1

10

11

12

13=1

1B2

1B1

2B2

2B1

3S2

3S1

1A

2A

3A

TP202 Festo Didactic

A-14
Exercise 5

TP202 Festo Didactic

A-15
Exercise 6

Electropneumatics

Subject

Clamping unit for grinding

Title

To familiarise the student with the use of a pneumatic/electric converter.

Training aim

To teach the student how to construct a control system using single


and double solenoid valves (Resetting sequence with extension).

Drawing the pneumatic and electrical circuit diagrams.

Construction of the pneumatic and electrical circuits.

Checking the circuit sequence.

TP202 Festo Didactic

Exercise

A-16
Exercise 6

Problem description

Semi-finished flanges of workpieces are to be placed manually in a


clamping and grinding unit, pneumatically clamped and ground on the
right and lefthand flanges.
Once single-acting clamping cylinder 1A has reached its forward end
position and the clamping pressure has built up in the piston chamber,
feed unit 2A performs a double stroke. The righthand flange is ground.
Double-acting cross-feed cylinder 3A extends prior to feed unit 2A
carrying out the second double stroke and grinding the lefthand flange.
Clamping cylinder 1A releases the workpiece when cylinder 3A has
reached its retracted end position.

Operating condition

Clamping cylinder 1A, single-acting, controlled via a solenoid valve.


Feed cylinders 2A and cross feed cylinder 3A are both double-acting
and each controlled via a double solenoid valve.
Monitoring of clamping pressure.

TP202 Festo Didactic

A-17
Exercise 6

Fig. 6/1:
Positional sketch

1A

2A

3A

9=1

1S2

1S1

2B2

2B1

3B2

3B1

1A

2A

3A

TP202 Festo Didactic

Fig. 6/2:
Displacement-step diagram

A-18
Exercise 6

TP202 Festo Didactic

A-19
Aufgabe 7

Electropneumatics

Subject

Forming press

Title

To teach the student how to realise a control system with specified


EMERGENCY-STOP conditions.

Training aim

To teach the student how to realise a two-hand safety control via a


timer with switch-on delay.

Drawing the pneumatic and electrical circuit diagrams.

Construction of the pneumatic and electrical circuits.

Checking the circuit sequence.

TP202 Festo Didactic

Exercise

A-20
Aufgabe 7

Problem description

A metal plate is inserted by hand into the forming press. A profile is to be


stamped into the metal plate by means of a two-handed operation.
When the operation is complete, the formed metal part is to be ejected
by means of ejecting cylinder 2A.

Operating condition

The START signal is obtained through a two-hand safety control with


delayed switch-on timer. When the EMERGENCY-STOP button is
pressed, the two cylinders must return immediately to their initial positions.

Fig. 7/1:
Positional sketch

1A

Fig. 7/2:
Displacement-step diagram

5=1

1S2

1S1

2B2

2B1

1A

2A

TP202 Festo Didactic

A-21
Exercise 8

Electropneumatics

Subject

Embossing device

Title

To teach the student how to incorporate step repetitions and manual


step mode into a sequence.

Training aim

Drawing the pneumatic and electrical circuits.

Exercise

Construction of the pneumatic and electrical circuits.

Checking the circuit sequence.

TP202 Festo Didactic

A-22
Exercise 8

Problem description

Workpieces to be embossed are inserted manually into a retainer and


pushed under the embossing stamp by cylinder 1A. Cylinder 2A extends
and embosses the workpiece. Then, cylinder 2A retracts again followed
by cylinder 1A.

Operating condition

It must be possible to carry out the individual movements step by step


via a push button (manual step mode). In addition, steps 2A+/2A- must
be repeatable to enable adjustment of the embossing cylinder. Cylinder
2A+ is to be moved in manual step mode, meaning that the 2A- movement must be effected via an additional push button. Step repetition and
manual step mode should only be possible when no START signal is
present.

Fig. 8/1:
Positional sketch

Fig. 8/2:
Displacement-step diagram

5=1

1B2

1B1

2S2

2S1

1A

2A

TP202 Festo Didactic

A-23
Exercise 9

Electropneumatics

Subject

Handling device

Title

To teach the student how to incorporate EMERGENCY-STOP and


marginal conditions in a latching sequence.

Training aim

Drawing the pneumatic and electrical circuit diagrams.

Exercise

Construction of the pneumatic and electrical circuits.

Checking the circuits sequence.

TP202 Festo Didactic

A-24
Exercise 9

Problem description

Round parts are to be fed by a handling device from the outlet channel
of processing station I to the inlet channel of processing station II. As an
additional start condition, the outlet channel is to be interrogated for
round parts.

Operating condition

Separate push buttons for SINGLE/CONTINUOUS CYCLE. EMERGENCY-STOP: Linear drive 2A must be unpressurised. Gripper 1A must
remain closed or open according to status. When EMERGENCY-STOP
is no longer being actuated, pressing a push button is to bring the linear
drive back into the initial position. A second push button is then to release the gripper (if this was closed in the EMERGENCY-STOP status).
This push button must also simultaneously latch the start button (after
the EMERGENCY-STOP), so that it is only possible to restart via the
START button after this button has been pressed.

Fig. 9/1:
Positional sketch

Fig. 9/2:
Displacement-step diagram

5=1

1S2 open

1A

Gripper
0

1S1 closed

2B2

2A

Linear drive
0

2B1

TP202 Festo Didactic

A-25
Exercise 10

Electropneumatics

Subject

Drilling and reaming machine

Title

To teach the student how to realise a control system with an alternative program by means of program switching step jump.

Training aim

Drawing the pneumatic and electrical circuit diagrams.

Exercise

Construction of the pneumatic and electrical circuits.

Checking the circuit sequence.

TP202 Festo Didactic

A-26
Exercise 10

Problem description

Program 1: - Drilling
Parts, which only need to be drilled, are clamped by hand. The part is
drilled when the START button is actuated. (Cylinder 1A).
Program 2: - Drilling and reaming
Parts, which also need to be reamed, are also clamped by hand. Then,
upon actuation of a PROGRAM SELECTOR button and the START
button, cylinder 1A starts the drilling process. When the drilling process
is completed, positioning cylinder 2A extends and transfers the drilled
part to the reaming station (cylinder 3A). When reaming of the part has
taken place, positioning cylinder 2A retracts and the part can be removed. The PROGRAM SELECTOR button must be actuated before the
START button in order to start up program 2. If these buttons remain
unactuated, then program 1 is to automatically run.

TP202 Festo Didactic

A-27
Exercise 10

Fig. 10/1:
Positional sketch

Fig. 10/2:
Displacement-step diagram
Program 1
1

Program 2
3=1

1S2

1S1

2B2

1A

7=1

1S2

1S1

2B2

1A

2A

2A
0

2B1

2B1

3B2

3B2

3B1

3A

3A
0

TP202 Festo Didactic

3B1

A-28
Exercise 10

TP202 Festo Didactic

A-29
Exercise 11

Electropneumatics

Subject

Loading station

Title

To teach the student to program repetition using an additional movement.

Training aim

To familiarise the student with the use of an incrementing preselect


counter.

Drawing the pneumatic and electrical circuit diagrams.

Construction of the pneumatic and electrical circuits.

Checking the circuit sequence.

TP202 Festo Didactic

Exercise

A-30
Exercise 11

Problem description

A plate on a conveyor belt is fitted with two steel parts.


The parts advanced via a rail are centred by a spigot and held by an
electromagnet whilst being transferred.
The motion sequence towards position 1 is to be executed via cylinders
1A and 2A.
Position 2 is to be reached by means of the same sequence as that
employed for position 1, with the addition of cylinder 3A (see displacement-step diagram).

Operating condition

Sensing of steel parts is to be realised via a push button S2.


When the conveyor belt has passed on the next plate for loading and
transmitted a signal to the loading unit (simulated by push button S1),
the machine is to proceed automatically.
The functioning of the electromagnet is to be simulated by means of a
lamp H1.

TP202 Festo Didactic

A-31
Exercise 11

Fig. 11/1:
Positional sketch

Conveyor belt
Plate

Position 2

Position 1

Fig. 11/2:
Displacement-step diagram
1

10

11

12

13=1

1S2

1S1

2B2

2B1

3B2

3B1

1A

2A

3A

Position 1

TP202 Festo Didactic

Position 2

A-32
Exercise 11

TP202 Festo Didactic

A-33
Exercise 12

Electropneumatics

Subject

Internal grinding machine

Title

To familiarise the student with step repetition using the preselect


counter.

Training aim

Drawing the pneumatic and electrical circuit diagrams.

Exercise

Construction of the pneumatic and electrical circuit diagrams.

Checking the circuit sequence.

TP202 Festo Didactic

A-34
Exercise 12

Problem description

Workpieces are fed along a conveyor belt. The forwardmost workpiece


is pushed against the stop by the following one. When a workpiece is
present, it is signalled by a sensor (switch) and the clamping stop is
raised (cylinder 1A).
Next, cylinder 2A is to clamp the part and signal when the clamping
pressure has been reached so that the grinding process can commence.
Cylinder 3A is to advance and the grinding wheel switched on simultaneously (simulation by means of visual indicator). Then cylinder 3A is to
travel up and down ten times (half strokes) and then return to the initial
start position. Next, cylinders 1A and 2A are are to retract simultaneously.
Cylinder 2A now is to extend once again and push the part onto the
conveyor belt which is to carry it away (only a minimal section of the
stroke was required for the clamping operation). When cylinder 2A has
returned once again and another workpiece has reached the stop, the
cycle is to be repeated.

Operating condition

START and STOP at the end of each cycle are each controlled by one
push button.

TP202 Festo Didactic

A-35
Exercise 12

Fig. 12/1:
Positional sketch

3A

2A
1A

Fig. 12/2:
Displacement-step diagram
1

22

23

24

25

26=1

1B2

1B1

2S2

2S1

3B3

1A

2A

3A

3B2
0

TP202 Festo Didactic

3B1

A-36
Exercise 12

TP202 Festo Didactic

A-37
Exercise 13

Electropneumatics

Subject

Assembly unit

Title

To teach the student how to set up manual activation of a cylinder


including precautions with protection against collision.

Training aim

To familiarise the student with automatic setting conditions.

Drawing the pneumatic and electrical circuit diagrams.

Construction of the pneumatic and electrical circuits.

Checking the circuit sequence.

TP202 Festo Didactic

Exercise

A-38
Exercise 13

Problem description

Bushes which are placed ready for assembly in a gravity feed magazine
are pressed into metal blocks which are also introduced in a similar
manner.
Cylinder 1A pushes a metal block from the magazine to a stop and
clamps it. Then, cylinder 2A extends and presses the first bush into
place. Next, cylinder 3A is activated, pressing the second bush into
place. Then cylinders 1A and 3A retract simultaneously, followed by
cylinder 2A retracting. The assembled metal block drops onto a conveyor belt.

Operating condition

The installation is to operate in a continuous cycle.


It must be possible to select between manual and automatic operating
mode.
Manual operation is to be indicated by a lamp H1.
Separate push buttons are to actuate each of the cylinders. This installation may only be run in manual mode; only one cylinder is to extend at a
time.

TP202 Festo Didactic

A-39
Exercise 13

Fig. 13/1
Positional sketch

6=1

1S2

1S1

2B2

2B1

3B2

3B1

1A

2A

3A

TP202 Festo Didactic

Fig. 13/2:
Displacement-step diagram

A-40
Exercise 13

TP202 Festo Didactic

A-41
Exercise 14

Electropneumatics

Subject

Moulding press

Title

To teach the student how to construct a two-handed safetystart-up


control with relay.

Training aim

To familiarise the student with restart before the end of the cycle.

Drawing the pneumatic and electrical circuit diagrams.

Construction of the pneumatic and electrical circuits.

Checking the circuit sequence.

TP202 Festo Didactic

Exercise

A-42
Exercise 14

Problem description

Plastic plates are to be formed from duroplastic pellets. The pellets are
inserted manually into the lower part of the mould.
When the START button is pressed (two-handed safety control), the
upper part of the mould is guided into the lower part of the mould.
When the forward end position is reached, pressure must be sustained
for approximately ten seconds to guarantee hardening of the formed
part. Then, the plates are removed from the mould tool by the extractor
unit and stacked next to the press.

Operating condition

The START signal must continue until cylinder 1A has assumed its
forward end position.
The press cylinder may extend immediately the extractor unit has been
removed from the working area (half return stroke of cylinder 2A).
The two-handed safety control using a relay.
The function of the vacuum generator 4Z is to be represented by a lamp.

TP202 Festo Didactic

A-43
Exercise 14

Fig. 14/1:
Positional sketch

7=1

1B2

1B1

2B3

1A

2A

2B2
0

2B1

3S2

3S1

3A

TP202 Festo Didactic

Fig. 14/2:
Displacement-step diagram

A-44
Exercise 14

TP202 Festo Didactic

A-45
Exercise 15

Electropneumatics

Subject

Pick-and-place unit

Title

To teach the student how to develop a latching sequence with marginal conditions.

Training aim

Drawing the pneumatic and electrical circuit diagrams..

Exercise

Construction of the pneumatic and electrical circuits.

Checking the circuit sequence.

TP202 Festo Didactic

A-46
Exercise 15

Problem description

A triple-axis unit is used for insertion of parts from position 2 into positions 3 and 4 of a gear housing. The vacuum gripper 4Z is to be simulated by a lamp (gripper suction = lamp on, no gripper suction = lamp
off). The start position is to be position 1, where the gripper is raised
(Z-axis) and there is no suction. When the START button is pressed,
position 2 is to be approached and a part picked up from the feed hopper and then deposited in position 3. Another part is then picked up from
position 2 and deposited in position 4. The gripper then returns to initial
position 1.

Operating condition

Sensing of the magazine (simulated by a switch and indicated via a


lamp):
When the magazine is empty, the control system is to remain in position
1 or position 2 and must only proceed or restart when the magazine has
been filled and the start button pressed.
Sensing of the gear housing:
This is to guarantee that a gear housing which is inserted into a device
is removed after processing (switch and lamp off). The initial start positions of the double-acting cylinders are: 1A+, 2A+, 3A-.

TP202 Festo Didactic

A-47
Exercise 15

Fig. 15/1:
Positional sketch

2A
1A

3A

Fig. 15/2:
Displacement-step diagram

down
up
Vaccuum
generator on

TP202 Festo Didactic

Vaccuum
generator off

Vaccuum
generator on

Vaccuum
generator off

A-48
Exercise 15

TP202 Festo Didactic

A-49
Exercise 16

Electropneumatics

Subject

Galvanising process

Title

To teach the student how to realise program branchings.

Training aim

To teach the student how to make multiple use of time relays.

To familiarise the student with program section repetitions using the


preselect counter.

To teach the student how to realise a pressure-dependent control


system.

Drawing the pneumatic and electrical circuit diagrams.

Construction of the pneumatic and electrical circuits.

Checking the circuit sequence.

TP202 Festo Didactic

Exercise

A-50
Exercise 16

Problem description

An overhead trolley beam transports the parts to be galvanised from a


work surface across the three baths and back again. A doubleacting
cylinder positions the basket on the work surface or else lowers it into
the baths. It remains in the forward end position (bath 2) or swings the
basket up and down in the bath (baths 1 and 3). Partial strokes are
sensed by three limit switches.
If the trolley has approached a horizontal position, a control lamp is
illuminated (bath 1 lamp H1, bath 2 lamp H2, bath 3 lamp H3 and work
surface lamp H4).
In the initial position, the basket hangs above the work surface. When
the up/down switch S2 is actuated, the cylinder extends and the basket
is deposited on the work surface for loading. When the initial start position has once more been reached, the cylinder can be actuated via start
button S. The movements of the trolley (from work surface to bath 1,
from bath 1 to bath 2, from bath 2 to bath 3 and from bath 3 back to the
work surface) are simulated by four identical time periods t1 = 2 seconds.
Once the basket has been dipped into bath 1 (and bath 3), the piston
extends four half strokes in the forward stroke area. The basket remains
in bath 2 in the forward stroke area t2 = 3 seconds.

Operating condition

When the main power supply has been switched on, the control is to be
activated via the SET button S1 and the time interval t1 started simultaneously.
During this time period, the cylinder is to be brought into the initial position (as it would have moved into the forward end position by leakage
losses when the installation was stopped).
When the time t1 has expired, the positioning lamp H4 is illuminated.
The installation can only be started once a pneumatic-electrical converter has signalled the supply of compressed air.

TP202 Festo Didactic

A-51
Exercise 16

Fig. 16/1:
Positional sketch

Bath 1

Bath 2

Bath 3

Fig. 16/2:
Displacement-step diagram
START

Bath 1
2

Bath 2
7

10

Bath 3
11

t2

12

13

14

15

16

17=1

1B3

1A

1B2
1B1

S1

t1

t1
t1

TP202 Festo Didactic

t1

A-52
Exercise 16

TP202 Festo Didactic

A-53
Exercise 17

Electropneumatics

Subject

Loading station

Title

Consolidating the students knowledge.

Training aim

Program section repetition.

Drawing the pneumatic and electrical circuit diagrams.

Construction of the pneumatic and electrical circuits.

Checking the circuit sequence.

TP202 Festo Didactic

Exercise

A-54
Exercise 17

Problem description

A loading station is used for loading boxes. Empty boxes which are
supplied via a conveyor belt must be placed onto the transfer unit by
hand. Transfer unit 1A moves underneath the swivel device 4M, which
then fills the box with containers row by row. The motion sequence can
be seen in displacement-step diagram 1. Indicate on the diagram the
step which has been reached by the installation shown in the positional
sketch.

Operating condition

The functioning of the suction cups is to be simulated by lamp. The


motion sequences which recur (see displacement-step diagram 1, steps
3....21), should be brought together in a subroutine which is to be repeated itself a number of times (see displacement-step diagram 2).

Fig. 17/1:
Positional sketch

4M

3A

1A
2A

The loading station shown here is not in the initial position.

TP202 Festo Didactic

A-55

1B2

1B1

2B2

2B1

3S2

3S1

4B

4S

Fig. 17/2:
Displacement-step
diagram 1

4M

3A

2A

1A

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25=1
1

Exercise 17

1A+ 3A+ 4M+ 4M- 3A- 2A+ 3A+ 4M+ 4M- 2A- 3A- 2A+
3A+ 4M+ 4M- 2A- 3A- 2A+ 3A+ 4M+ 4M- 3A- 1A-

TP202 Festo Didactic

Abbreviated notation

A-56

1B1

2B2

2B1

3S2

3S1

4B

4S

1B2

Abbreviated notation

4M

3A

2A

1A

21

21

22

23

24

25=1

Fig. 17/3:
Displacement-step
diagram 2

Exercise 17

1A+ 3A+

4M+ 4M- 2A- 3A- 2A+ 3A+

4M+ 4M- 3A- 1A-

Main program

3 x Subroutine

Main program

TP202 Festo Didactic

A-57
Exercise 18

Electropneumatics

Subject

Rotary indexing station

Title

To familiarise the student with parallel program division.

Training aim

Drawing the pneumatic and electrical circuit diagram.

Exercise

Construction of the pneumatic and electrical circuits.

Checking the circuit sequence.

TP202 Festo Didactic

A-58
Exercise 18

Problem description

Workpieces are drilled vertically and horizontally on an eight-station


rotary indexing table. Six feed units are used for the various machining
operations. Two each for drilling, counterboring and countersinking.
Two transferring units load and unload the machine respectively.
Lifting cylinders 1A and 3A descend onto the workpieces. These are
picked up by suction (functioning of the vacuum generator is to be
indicated by a lamp) and then lifted.
The stroke of cylinder 5A then causes the table to index on by one
position. At the same time, transfer cylinders 2A and 4A approach the
positions for placing on the indexing table and depositing via the conveyor belt 2.
Then, cylinder 5A latches the rotary indexing table and the two lifting
cylinders 1A and 3A deposit the parts.
At the same time as the lifting cylinder retracts, processing via feed units
6A to 11A begins.
When these have reached their forward end positions, the feed units and
the transfer cylinders return to their initial positions.

Operating condition

Choice between manual and automatic operating modes.


Separate push buttons for START and STOP (continuous cycle).
The start signal must be maintained until the machine has been supplied
with lubricant via a centralised lubrication system (the pump motor is to
be simulated by a lamp). Then, the start signal is to be stored and indicated by a lamp.
Workpiece sensing on conveyor belt 1 is simulated by a switch.
The air blast for swarf removal is to be simulated using a solenoid valve.

TP202 Festo Didactic

A-59
Exercise 18

EMERGENCY-STOP
The electrical power to the control must be switched off.
The feed units are to retract.
The transfer units and the cylinder of the indexing table are to complete
their movements.
When the vacuum generators are active, they must continue to remain
active until, after the RESET and a renewed START, the controller gives
the command to deposit.
RESET
If, after indexing on, processing can no longer take place because the
EMERGENCY-STOP has been actuated, processing must be carried
out in RESET mode via a time control.
All cylinders must be brought into their initial position. In the case of the
transport units, cylinders 1A and 3A must retract before cylinder 2A and
4A.
Note regarding solution
For the purpose of simulation, this exercise can be solved using four
cylinders:
The transer units are to be represented by double-acting cylinders.
Cylinders 1A and 2A are sufficient for this as the movements of the two
units are synchronised.
Cylinder 5A for indexing of the table is also represented by a doubleacting cylinder.
All feed units are to be represented by a single-acting cylinder.
Only the limit switches of the four cylinders are to be drawn in the electrical circuit diagram.

TP202 Festo Didactic

A-60
Exercise 18

Fig. 18/1:
Positional sketch

Discharge
Conveyor 2

9A
Counter 2

8A

1A

Counter 1
Rotary indexing table

Conveyor 1

7A
Drilling 1

TP202 Festo Didactic

A-61
Exercise 18

Transfer 1

7=1

1S2 (1B2)

1S1 (1B1)

2S2 (2B2)

2S1 (2B1)

1A

2A

Transfer 2

7=1

3S2

3S1

4S2

4S1

3A

4A

7=1

1
Rotary indexing
table
5A

5S2

5S1
1

Drilling 1

7=1

6S2 (6B)

6S1 (6S)

7S2

7S1

8S2

8S1

9S2

9S1

10S2

10S1

11S2

11S1

6A
Drilling 2

Counterboring 1

Counterboring 2

Deburring 1

Deburring 2

7A

8A

9A

10A

11A

TP202 Festo Didactic

Fig. 18/2:
Displacement-step diagram

A-62
Exercise 18

TP202 Festo Didactic

A-63
Exercise 19

Electropneumatics

Subject

Checking station

Title

To familiarise the student with the use of a timer with delayed switchon as a delayed starting element.

Training aim

Drawing the pneumatic and electrical circuit diagrams.

Exercise

Construction of the pneumatic and electrical circuits.

Checking the circuit sequence.

TP202 Festo Didactic

A-64
Exercise 19

Problem description

Transfer cylinder 1A is to push a container onto the scales. Then, cylinder 2A is to release the scales and cylinder 1A is to return to its initial
position.
After a waiting time of approx. 3 seconds, cylinder 2A is to block the
scales again. If the container is within the weight tolerance (switch S4 is
activated), cylinder 3A is to push it onto the conveyor belt to move it on
and then to retract once again. However, if the tolerance limit is not
maintained (switch S4 not activated), cylinder 4A is to transfer the container to the outlet chute and then to retract again. Then, the container is
to be transferred on by the conveyor belt (simulated by a lamp H1).

Operating conditions

The installation is to operate in continuous mode and started by a push


button S1 and stopped at the end of the cycle by a second push button
S6.
The good parts are to be counted.
As the sensor for the containers is not attached directly to transfer
cylinder 1A, for technical reasons, the run-time of the conveyor belt must
be controlled as follows:
The conveyor belt continues running until a sensor (push button S4)
outside the transfer area, signals the presence of a container and uses
this to control a timer. When the time has expired, the conveyor belt can
stop and cylinder 1A then commences the cycle once again.

TP202 Festo Didactic

A-65
Exercise 19

Fig. 19/1:
Positional sketch

1A

3A

4A

6=1

1B2

1B1

2B2

2B1

3B1

3S1

4S2

4S1

1A

2A

3A

4A

TP202 Festo Didactic

Fig. 19/2:
Displacement-step diagram

A-66
Exercise 19

TP202 Festo Didactic

A-67
Exercise 20

Electropneumatics

Subject

Handling device

Title

Familiarisation with an alternative solution to Electropneumatics.

Training aim

Drawing the pneumatic and electrical circuit diagrams.

Exercise

Construction of the pneumatic and electrical circuits.

Checking the circuit sequence.

TP202 Festo Didactic

A-68
Exercise 20

Problem description

Cylindrical parts are to be distributed evenly from outlet channel 1 onto


the two inlet channels 2 and 3 (see displacement-step diagram)

Operating condition

The unit is to be operated in continuous cycle only. START and STOP


AT END OF CYCLE are each to be effected by one push button.
Sensing of parts at channel 1 is to be simulated by a switch. If this
switch is not activated, the unit is to stop at the end of the cycle.
After the swivel movement to inlet channels 2 and 3 has been carried
out, the gripper is not to open until a short delay time has expired.
After actuation of the EMERGENCY-STOP switch, cylinders 1A, 2A and
3A are to retract and cylinder 4M switched to an unpressurised condition.
When the EMERGENCY-STOP has been unlatched, the reset button is
to return cylinder 4M to the initial position.
It must be possible to limit the number of cycles using a preselect
counter.

TP202 Festo Didactic

A-69
Exercise 20

Fig. 20/1:
Positional sketch

Fig. 20/2:
Displacement-step diagram
1

10

11

12

13=1

1S2

1S1

2B2

2B1

3B2

3B1

4B

4S

1A

2A

3A

4A

TP202 Festo Didactic

A-70
Exercise 20

TP202 Festo Didactic

B-1

Part B - Fundamentals
The theoretical fundamentals for the training package Electropneumatics
are summarised in the textbook

Learning System for Automation and Technology

Introduction to
Electropneumatics.
Basic Level TP201

TP202 Festo Didactic

B-2

TP202 Festo Didactic

C-1

Part C Solutions
Solution 1:

Bench drill

C-3

Solution 2:

Feed unit for sheet metal strip

C-9

Solution 3:

Filling device

C-17

Solution 4:

Stamping device

C-21

Solution 5:

Drilling jig

C-27

Solution 6:

Clamping unit for grinding

C-35

Solution 7:

Forming press

C-41

Solution 8:

Embossing device

C-45

Solution 9:

Handling device

C-49

Solution 10:

Drilling and reaming machine

C-55

Solution 11:

Loading station

C-59

Solution 12:

Internal grinding machine

C-63

Solution 13:

Assembly unit

C-69

Solution 14:

Moulding press

C-75

Solution 15:

Pick-and-place unit

C-81

Solution 16:

Galvanising process

C-87

Solution 17:

Loading station

C-95

Solution 18:

Rotary indexing station

C-103

Solution 19:

Checking station

C-111

Solution 20:

Handling device

C-117

TP202 Festo Didactic

C-2

TP202 Festo Didactic

C-3
Solution 1

Bench drill

Fig. 1/3:
Circuit diagram, pneumatic

**

* For the purposes of this exercise, feed unit 2A is replaced by a


double-acting cylinder.
** Detailed representation of the on/off valve with filter regulator.

TP202 Festo Didactic

K1

K4

1S1

24
A1

23

4
5
11

K2

K1

1S2

2
3
10

14

A2

K1

13

A2

42
A1

41

14
1

13

24 V- 1
K2
14

13

2B2

BU

BN

K3
A2

24
A1

23

11 7
9

K2

BK

6
K3
14

13

2B1

BU

BN

K4

K3

BK

A2

24
A1

23

1Y

34

1A+

K1

33

10

2Y

42

41

34

2A+

K3

K2

33

11

3Y

K3

3Z

34

33

12

C-4

Solution 1

Fig. 1/4
Circuit diagram, electrical
Ausblasen

TP202 Festo Didactic

C-5
Solution 1

Since in this case the memory function is via a relay, single solenoid
valves are generally activated using a latching sequence. It should be
remembered that the coil circuit should be interrupted by a second
contact for the return motion, for example, in order to achieve spring
return of the valve to the initial position. (The final step represents an
exception to this since it is possible to dispense with a normally closed
contact as all valves are returned to their initial positions through interruption of all the circuits). This is why a latching sequence is used since
in the case of power failure all cylinders will return to an accurately
defined initial position. This is important for accident prevention, although it is important to watch out for overlapping of movements which
may occur on reaching the initial position.

24 V- 1

13

13

K1
14
1

10
33

K1
14

34

1S1
4

41

K4
42
A1

K1

1Y
A2

1A+

When START button S is actuated and normally open contact 1S1 is


activated via cylinder 1A, the circuit to relay K1 is closed via the normally
closed contact of K4, which then goes into self-holding (latching) via the
parallel contact of K1.
A further normally open contact of K1 switches the circuit to solenoid coil
1Y. This in turn switches the solenoid valve and cylinder 1A travels into
the forward end position.

TP202 Festo Didactic

Solution description

Fig. 1/5:
Step 1, Cylinder 1A+

C-6
Solution 1

Fig. 1/6:
Step 2, Cylinder 2A+

24 V- 1

13

13

1S2

K1
14
1

14

13

K2
4

10

11

33

K1
14

33

K2
34

34

1S1
4

41

23

41

K1

K4
42
A1

K1

K3
24
A1

K2
A2

42

1Y

2Y

A2

1A+

2A+

When cylinder 1A has reached its forward end position, it actuates limit
switch 1S2. Then, the circuit for relay K2 is closed via S2 and the setting
condition K1, this then goes into self-latching via a parallel normally
open contact.
A second normally open contact of K2 switches the current to solenoid
coil 2Y via normally closed contact K3; this switches the valve and
cylinder 2A extends.
The principle of the latching sequence is to interrogate the preceding
step and its acknowledgement (limit switch) and then to set a new memory for the next step. Finally, the complete sequence (the self-latching
circuits) is reset by the last step (or cycle) no self-latching is required
for the last step.

TP202 Festo Didactic

C-7
Solution 1

Quantity

Designation

Relay, 3-off

Signal input plate, electrical

Indicator/distributor plate, electrical

Double-acting cylinder

On/off valve with filter regulator

Manifold

Proximity sensor with cylinder mounting

Limit switch, electrical, actuation from the left

Limit switch, electrical, actuation from the right

3/2-way solenoid valve, normally closed

5/2-way solenoid valve

Cable set with safety plug

Electrical power supply unit, 24 V

TP202 Festo Didactic

Components list

C-8
Solution 1

TP202 Festo Didactic

C-9
Solution 2

Feed unit for sheet metal strip

1B1

1B2

2S1

1A

Fig. 2/3:
Circuit diagram, pneumatic

2S2

2A

1Y1

1Y2
5

2Y1

2Y2
5

0Z2

0Z1

Simplified representation of on/off valve with filter regulator

TP202 Festo Didactic

K1

K4

K8

2S2

S2

S1

A1

22

23

12 5
17

K2

K1

2
3

14

13

A2

K1

A2

42
A1

41

14

4
11

14
1

14
13

13

BU

1B1 BN

K3

K6

K2

BK

6
7

A2

42
A1

41

14

13

5
K3
14

13

K4

K3

8
18

A2

A1

24

23

K5

K8

K4

2S1

9
10

A2

22
A1

21

14

4
13

8
K5
14

13

K6
A2

A1

24

23

5 12
16
19

K5

10

Fig. 2/4:
Circuit diagram, electrical
(1)

24 V- 1

C-10

Solution 2

TP202 Festo Didactic

1B2

TP202 Festo Didactic


K7

K8

K7

A1

24

21

1
20

14

SET 13

15

13
15

14

11

14

A2

K7

13

A2

42
A1

41

14

13

12

K2

K6

BK
BU

BN

24 V- 11

H1

K6
24

23

16

1Y1

24

23

1A-

K2

17

2Y1

24

23

2A-

K4

18

1Y2

34

33

1A+

K6

19

2Y2

34

31

2A+

K8

20

C-11
Solution 2

Fig. 2/5:
Circuit diagram, electrical
(2)

C-12
Solution 2

Solution description

When the SET button is pressed, relay K7 goes into self-latching and
switches relay K8, which represents the start condition.
If appropriate, the SET button should be latched in such a way that it can
only be active at the time when the main current supply is applied, in
order to safeguard the circuit sequence.
Once the feed has been initiated with S1 and S2, K1 goes into selflatching and K2 switches, self-latching at K7 is cancelled via a normally
closed contact of K2.
A further possibility is to replace the SET key by a relay (see exercise 13).

Fig. 2/6:
Step 1, Cylinder 1A-

24 V- 1

13

S1

13

K1
14
13

17

23

K1
14

23

K2
22

24

S2
14
1

2S2
4
11

K8
14
41

K4
42
A1

A1

K2

K1
A2

1Y1
A2

1A-

When START button S1 is actuated, the circuit for relay K1 is closed via
the signal from pressing S2, the limit switch S22, the setting signal for
relay K8 and the normally closed contact K4. The relay goes into selflatching via the parallel normally open K1. At the same time, a further
normally open contact of K1 switches the circuit for the relay K2.
A normally open contact of K2 switches the circuit in the power section
to solenoid coil 1Y1. The valve switches and cylinder 1A travels into the
retracted end position and there actuates limit switch 1B1.

TP202 Festo Didactic

C-13
Solution 2

Fig. 2/7:
Step 2, Cylinder 2A24 V- 1

13

S1

13

K1
14
13

23

13

K1
14

K3
22

S2

17

K3

18

23

23

14

1B1 BN
BK
BU

14
1

7
K2

23

K4
24

24

24

13

K2

2S2
4
11

14

K8
14
41

41

K4

K6
42
A1

K2

K1
A2

42
A1

A1

K3
A2

A1

K4
A2

1Y1

2Y1

A2

1A-

Now sensor 1B1 emits a signal which closes the circuit for relay K3 via
the normally open contact K2 and the normally closed contact K6. This
goes into self-latching via the parallel normally open contact K3. At the
same time, relay K4 is switched via a further normally open contact K3.
Only now, when self-latching of K3 has been established, is the setting
condition K1 or K2 reset by normally closed contact K4 and in the power
section, the normally open contact K4 switches the circuit to solenoid
coil 2Y1, which in turn switches the valve, cylinder 2A retracts and
activates 2S1 in the end position.
Owing to its additional switching time, relay K4 serves as a delay between the build-up of self-latching of K3 and the reset of setting condition K2. This guarantees that K3 is in self-latching before the setting
signal is set.
Then, the next step is activated (K5, K6) by 2S1 via K4. The principle of
the latching sequence is based on the interrogation of the preceding
step and its acknowledgement (limit switch). The next step is activated
on the basis of these conditions; when this happens, the preceding step
is reset.
The reset sequence is particularly suitable for the control of double
solenoid valves, since here the memory behaviour is assumed by the bistable solenoid valve.

TP202 Festo Didactic

2A-

C-14
Solution 2

This can be very important in the case of power failure, in respect of


accident prevention.
To be able to start up again after power failure or switch off the main
power supply (circuit dead), relays K7 and K8 must be switched. This
happens here via the SET key. The principle of reversal of the latched
sequence which is shown here is completely reliable owing to the use of
an additional relay per step and can be used for every type of relay.
Where there is a late opening or early closing relay, it may be possible to
get by without an additional one. (Normally, only contactors have this
type of switching behaviour). In such a case, the circuit up to step 2
would look as follows. Compare this simplified circuit diagram with the
electrical circuit diagram.
Fig. 2/8
Circuit diagram, simplified

24 V13

S1

13

13

K1
14
13

K2
14

1B1 BN

S2
14
1

23

K1
14

23

K2
24

24

BK
BU

23

K1

2S2
4
11

24

K8
14
41

K2

41

K4
42
A1

K1

42
A1

K3
A2

1Y1

2Y1

A2

1A-

2A-

TP202 Festo Didactic

C-15
Solution 2

Quantity

Designation

Relay, 3-off

Signal input plate, electrical

Indicator/distributor plate, electrical

Double-acting cylinder

On/off valve with filter regulator

Manifold

Proximity sensor with cylinder mounting

Limit switch, electrical, actuation from the left

Limit switch, electrical, actuation from the right

5/2-way double solenoid valve

Cable set with safety plug

Electrical power supply unit, 24 V

TP202 Festo Didactic

Components list

C-16
Solution 2

TP202 Festo Didactic

C-17
Solution 3

Filling device

Fig. 3/2:
Circuit diagram, pneumatic

1S1

2B1

1S2

1A

2B2

3A

2A

1Y

2Y
1

3Y
1

0Z2

0Z1

1
3

TP202 Festo Didactic

3B1

3B2

3B1

S1 = Single cycle
S2 = Continuous cycle

K1

K7

K1

K2
14

13

K3

K2

1S2

24
A1

23

8
10
19

24
A1

23

14

13

18 6
7

K2

S4

1S1

4
5
18

14

13

A2

K1

A2

14

13

A2

42
A1

36
41

35

14

S3 13

14

BK
S1 13 S2

K6

BU

BN

1
K3
14

13

8
2B2

BU

BN

K4
A2

24
A1

23

19 11
13
17

K3

BK

10
K4

14

13

11

Fig. 3/3:
Circuit diagram, electrical
(1)

24 V-

C-18

Solution 3

st
S3 = 1 interrogation
S4 = 2nd interrogation

TP202 Festo Didactic

2B1

24 V-

BU

BN

12

rd
S5 = 3 interrogation
S6 = Idle cycle without filling

TP202 Festo Didactic


K5

K4

S5

BK

14
16
20

A2

24
A1

23

14

13

13
K5
14

13

14
2B2

A2

24
A1
A2

34
A1

33

14

13

17

K4

K7

S6

23

16

K5

BK

K6

BU

BN

15

1Y

42

41

34

33

1A-

K2

K1

18

2Y

42

41

34

33

2A+

K4

K3

19

3Y

34

33

3A+

K5

20

C-19
Solution 3

Fig. 3/4:
Circuit diagram, electrical
(2)

C-20
Solution 3

Solution description

Components list

When S1 or S2 and S3 are activated, the control system is started up.


Cylinder 1A retracts and the bottles move along. If S4 is actuated, the
cylinder extends again. Then, the indexing table (cylinder 2A) inches
round one position. Once a bottle has reached the filling station, it is
filled until the time delay closes the container (cylinder 3A), and the
control system is brought back into the initial start position. If no bottle is
reported as being present at the filling station, the control can be returned to the initial start position via S6. Then the indexing table can be
supplied with bottles until a signal is received from S7.
Quantity

Designation

Relay, 3-off

Signal input plate, electrical

Time relay, 2-off

Indicator/distributor plate, electrical

Single-acting cylinder

Double-acting cylinder

On/off valve with filter regulator

Manifold

Proximity sensor, capacitive

Proximity sensor, optical

Proximity sensor with cylinder mounting

Limit switch, electrical, actuation from the left

Limit switch, electrical, actuation from the right

3/2-way solenoid valve, normally closed

5/2-way solenoid valve

Cable set with safety plug

Electrical power supply unit, 24 V

TP202 Festo Didactic

C-21
Solution 4

Stamping device

2B1

Fig. 4/3:
Circuit diagram, pneumatic

2B2

2A
1A

1S1

1S2

3A

2Y1
4

1Y1

3Y1

0Z2

0Z1

1
3

TP202 Festo Didactic

3B2

2Y2

1Y2
1

3B1

3Y2
1

3B1

K4

K1

K12

A1

24

23

K6

1S2

K2

41

14

13

K3
14

13

K4

K3

A1

24

23

7
2B2

BU

BN

A2

20 5
23

A2

3
4

42
A1

K3

6
7

A2

42
A1

9
24

A2

K5

K8

K4

BK

13

10
11

A2

12
A1

11

K2

K1

41

14

13

14

K1

14

14
13

11

K5
14

13

10

Fig. 4/4:
Circuit diagram, electrical
(1)

24 V- 1

C-22

Solution 4

TP202 Festo Didactic

TP202 Festo Didactic

K6

21

6
7

14
15

12
A1

K9

9
24

A2

24
A1

21

K12

K8

1S1

11

A1

24

21

24

K8

K7

16

14

13

14

11

15

5 13
25

K7

K10

K6

BK

K7

14

A2

BU

2B1 BN

13

A2

A1

24

23

12

A2

K5

24 V- 11
K9
14

11

17

K10

K9

9
24

A2

A1

24

21

18

C-23
Solution 4

Fig. 4/5:
Circuit diagram, electrical
(2)

3B2

K11

K2

K10

K11

16 2
20

A1

24

21

20
22

K12

K11

22

A2

14

SET 13

21

A2

42
A1

41

22

21

14

11

20

1Y1

24

23

1A+

K2

23

2Y1

24

23

2A+

K4

24

2Y2

24

23

2A-

K6

25

1Y2

34

31

1A-

K8

26

3Y1

34

31

3A+

K10

27

3Y2

34

31

3A-

K12

28

Fig. 4/6:
Circuit diagram, electrical
(3)

24 V- 19

C-24

Solution 4

TP202 Festo Didactic

C-25
Solution 4

This solution corresponds to a reset sequence of 6 steps with single


cycle operation. Only when the last step has been set via the SET
button, can another single cycle be started. The signal generators are
directly switched to limit the number of relays.
Quantity

Designation

Relay, 3-off

Signal input plate, electrical

Indicator/distributor plate, electrical

Single-acting cylinder

Double-acting cylinder

On/off valve with filter regulator

Manifold

Proximity sensor, capacitive

Proximity sensor, optical

Proximity sensor with cylinder mounting

Limit switch, electrical, actuation from the left

Limit switch, electrical, actuation from the right

5/2-way double solenoid valve

Cable set with safety plug

Electrical power supply unit, 24 V

TP202 Festo Didactic

Solution description

Components list

C-26
Solution 4

TP202 Festo Didactic

C-27
Solution 5

Drilling jig

Fig. 5/3:
Circuit diagram, pneumatic

1B2

1B1

2B1

1A

2B2

3S1

3A

3S2

2A

1Y

2Y
1

3Y
1

0Z2

0Z1

* For the purposes of this exercise, feed unit 3A is replaced by a single-acting cylinder.
A 3/2-way solenoid valve may also be used as a final control element.

3A

3Y

TP202 Festo Didactic

3S1

3S2

Fig. 5/4:
Part of circuit diagram,
pneumatic

K1

K14

A1

K1

K2

23

14

11

K3
14

13

K4

3S1

A1

A2

5
13
20
27

A2

3
5
35

12
A1

A2

35 6
8

K3

24
A1

8
15
22
29

A2

K5

K3

K16

K4

11

14

11

9
11
33

A2

24
A1

23

K2

3S2

11

14

13

12

K1

14

13

K5
14

13

Fig. 5/5:
Circuit diagram, electrical
(1)

2B2

24 V- 1

C-28

Solution 5

TP202 Festo Didactic

1B1

24 V- 10

TP202 Festo Didactic


K6

K5
24
A1

23

24

21

36 14
15

K7

K6

K2

12
13
36

14

13

13

A2

K6

12

A2

24
A1

23

11
K7
14

13

14

K8

K7

K16

K4

16
18
34

A2

24
A1

23

22

21

24

21

15
K8
14

13

16

BU

2B1 BN

17

K9

K8

BK

19
20
37

A2

24
A1

23

18
K9
14

11

19

C-29
Solution 5

Fig. 5/6:
Circuit diagram, electrical
(2)

K10

K11

K10

K16

K4

24
A1

21

32

31

34

31

33 23
25

14

11

37 21
22

K10

A2

24
A1

21

34

31

22

A2

K9

K2

21
K11
14

11

23
1B2

BU

BN

24

K12

K11

BK

26
27
38

A2

24
A1

21

25
K12
14

11

26

K13
A2

24
A1

21

44

41

38 28
29

K12

K2

27
K13
14

11

28

K14

K13

K16

K4

A2

24
A1

21

42

41

44

41

29

K15

31

A2

A1

30

Fig. 5/7:
Circuit diagram, electrical
(3)

24 V- 20

C-30

Solution 5

TP202 Festo Didactic

TP202 Festo Didactic


K16

8
15
22
29

K15

A2

A1

14

11

24 V- 31

32

1Y

32

31

34

33

1A-

K11

K5

33

2Y

34

33

2A-

K8

34

3Y

42

K7
42

41

41

33
34

K6

36

34

33

3A+

K3

K1

35

K10

K9

32

31

34

31

37

K13

K12

32

31

34

31

38

C-31
Solution 5

Fig. 5/8:
Circuit diagram, electrical
(4)

C-32
Solution 5

Solution description

The preselect counter receives pulses from 3S2. When the preselect
figure or the end of the drill life has been reached, the sequencer is
stopped. It will not continue running until the drill has been changed
(counter reset).
Signal generators 3S1 and 3S2 must be switched indirectly to ensure
reliable sensing. Otherwise, self-latching would supply a continuous
signal (see example) when a latching sequence is being used.

Example

Fig. 5/9:

Kn+1 can be set without acknowledgement 3S1 being activated since


current can flow via the self-latching of K3 and Kn.

24 V3S1

K2
K3

K3

Kn+1

Kn
Kn+1

TP202 Festo Didactic

C-33
Solution 5

The signal generators indirectly switched (as in the solution to the exercise).
Fig. 5/10:
Alternative circuit (1)

24 VK1

3S1

K3

K2
K1

K1

Kn+1

Kn

K3

Kn+1

As the connection is interrupted here by K4 via K3, Kn+1 may only be


set if Kn and 3S1 are activated.
Fig. 5/11:
Alternative circuit (2)

24 V3S1

K3

3S2

K4

Kn+1

K4

K2
K3

TP202 Festo Didactic

K3
K4

Kn
Kn+1

C-34
Solution 5

Components list

Quantity

Designation

Relay, 3-off

Signal input plate, electrical

Preselect counter, electrical, incrementing

Indicator/distributor plate, electrical

Single-acting cylinder

Double-acting cylinder

On/off valve with filter regulator

Manifold

Proximity sensor, inductive

Proximity sensor, capacitive

Proximity sensor with cylinder mounting

Limit switch, electrical, actuation from the left

Limit switch, electrical, actuation from the right

3/2-way solenoid valve, normally closed

5/2-way solenoid valve

Cable set with safety plug

Electrical power supply unit, 24 V

TP202 Festo Didactic

C-35
Solution 6

Clamping unit for grinding

Fig. 6/3:
Circuit diagram, pneumatic

1A

1S1

1S2

2A

2B1

2B2

3A

3B1

3B2

1B

P1
4

2Y1

2Y2

1Y

3Y1
1

0Z2

0Z1

* For the purposes of this exercise, feed unit 2A is replaced by a double-acting cylinder.

TP202 Festo Didactic

3Y2
1

K1

K14

1S1

1B

BU

BN

24
1

23

K9

K7

K5

K2

K13

BK

K2

A1

42

41

14

13

4
5

P2

P1

1S2

K1

2
3
28

14

13

A2

K1

A2

12
A1

11

14

13

K3

K2

7
29

A2

A1

24

23

5
2B2

K4

K7

K3

BK
BU

BN

8
9

A2

12
A1

11

14

13

7
K4
14

13

K5
A2

A1

24

23

4 11
31

K4

BU

2B1 BN

10

K6

K9

K5

BK

12
13

A2

12
A1

11

14

13

11
K6

14

13

12

Fig. 6/4:
Circuit diagram, electrical
(1)

24 V- 1

C-36

Solution 6

TP202 Festo Didactic

TP202 Festo Didactic


K7

A1

24

21

12
A1

11 18
4 30

A2

K10

K13

K9

21

19
20

A2

12
A1

11

K9

K8

18

11

14

11

17

24

K8

16

24

21

16
17

K8

K11

K7

7 15
4 33

3B2

15

A2

A1

24

23

14

A2

K6

24 V- 13
K10
14

11

19

K11
A2

A1

24

21

15 21
32

K10

20

K12
A2

24
A1

21

24

21

27 22
23

K14

K11

21
K12
14

11

22

C-37
Solution 6

Fig. 6/5:
Circuit diagram, electrical
(2)

12
A1

11

24

21

1 26
21

K14

K15

K13

18 25
4 34

3B1

25

A2

A1

24

21

24

A2

K13

K12

24 V- 23

K14
34

31

26

K12

25

K15

A2

32
A1

31

24

23

27

1Y

34

33

1A+

K1

28

2Y1

24

23

2A+

K3

29
K9
34

31

30

2Y2

24

23

2A-

K5

31
K11
34

31

32

3Y1

34

31

3A+

K7

33

3Y2

44

41

3A-

K13

34

C-38

Solution 6

Fig. 6/6:
Circuit diagram, electrical
(3)

TP202 Festo Didactic

C-39
Solution 6

In this exercise, two problems can be solved with minimal modifications


to the reset sequence:


Memorising of the start signal (K1) for the movement 1A+,

Resetting of the final step (K14) via START button S.

Solution description

The pressure switch does not switch over until the clamping pressure
has been reached; consequently the sequencer stops until the required
pressure has built up.
In this exercise, sensor 2B1 and 2B2 can be interrogated directly several
of times without faulty actuation of the control taking place (compare with
exercise 5).
Quantity

Designation

Relay, 3-off

Signal input plate, electrical

Indicator/distributor plate, electrical

Single-acting cylinder

Double-acting cylinder

On/off valve with filter regulator

Manifold

Proximity sensor, inductive

Proximity sensor, capacitive

Proximity sensor with cylinder mounting

Limit switch, electrical, actuation from the left

Limit switch, electrical, actuation from the right

Pneumatic-electric converter

3/2-way solenoid valve, normally closed

5/2-way double solenoid valve

Cable set with safety plug

Electrical power supply unit, 24 V

TP202 Festo Didactic

Components list

C-40
Solution 6

TP202 Festo Didactic

C-41
Solution 7

Forming press

1A

1S1

2B1

1S2

2B2

2A

1Y

2Y
5

0Z2

0Z1

1
3

TP202 Festo Didactic

Fig. 7/3:
Circuit diagram, pneumatic

K1

ES

36
A1

35

14

14
13

14
13

12
13

4 14

K2

K3

S2

S1

K4

K5

11

14

A2

K1

13

A2

A1

22

21

24 V- 1

K3

K2

A2

42
A1

41

24

23

= 0,5s

24

23

5
2B1

BU

BN
BK

K4

A2

A1

C-42

Solution 7

Fig. 7/4:
Circuit diagram, electrical
(1)

TP202 Festo Didactic

TP202 Festo Didactic


K6

K5

1S1

34
A1

31

11
13
15

24

21

10

3 9
14 10

K5

A2

42
A1

41

A2

K5

K7

1S2

24 V-

K6
14

11

11
2B2

BU

BN

12

K7

K6

BK

A2

24
A1

21

13

1Y

42

41

14

13

1A+

K5

K2

14

2Y

34

31

2A+

K6

15

C-43
Solution 7

Fig. 7/5:
Circuit diagram, electrical
(2)

C-44
Solution 7

Solution description

If the EMERGENCY-STOP switch ES is not activated, current path (1) is


supplied with current. In order to switch relay K2, the two push buttons
S1 and S2 must be actuated simultaneously (START signal). If one of
the push buttons is pressed before the other, the time relay with switchon delay is energised which then switches after 0.5 secs. (For safety
reasons, the switch-on delay must not exceed 0.5 seconds). The result
of this is that the normally closed contact K3 in current path 3 opens
and, thus the connection to K2. If two buttons are actuated simultaneously so that the time relay does not switch through, relay K2 is switched
and cylinder 1A extends.
When the EMERGENCY-STOP switch is actuated, the current to path 1
is interrupted and the solenoid coils are no longer supplied with current.
The result of this is that the reset springs reverse the solenoid valves
and the cylinders return to the initial position.

Components list

Quantity

Designation

Relay, 3-off

Signal input plate, electrical

Time relay, 2-off

Indicator/distributor plate, electrical

Double-acting cylinder

On/off valve with filter regulator

Manifold

EMERGENCY-STOP button

Proximity sensor with cylinder mounting

Limit switch, electrical, actuation from the left

Limit switch, electrical, actuation from the right

5/2-way solenoid valve

Cable set with safety plug

Electrical power supply unit, 24 V

TP202 Festo Didactic

C-45
Solution 8

Embossing device

1A

1B1

1B2

2A

2S1

1Y

2Y
1

0Z2

0Z1

1
3

TP202 Festo Didactic

2S2

Fig. 8/3:
Circuit diagram, pneumatic

K1'

A1

18 13
16

14

11

4 2
6
10

K1

A2

A1

12

11

14

13

A2

K6

K1

S1

K2

K1

S2

7
11
14
17

A2

22
A1

21

14

13

1B1

K3

K7

K1

8
10
19

A2

22
A1

21

34

31

K2
14

11

7
K3
14

11

1B2

K4

K7

K3

K1

12
13
20

A2

12
A1

24
11

21

44

41

10

K2
24

21

11
K4

14

11

12

Fig. 8/4:
Circuit diagram, electrical
(1)

24 V- 1

C-46

Solution 8

S1 = START-button
S2 = Manual step mode

TP202 Festo Didactic

TP202 Festo Didactic


S3 = Step repetition
A2

24
A1

21

14

11

20 15
16

K5

K1

K1'

2S2

24 V- 13

K2
34

31

14
K5
14

11

15

K6

1
6

K5

K1'

2S1

A2

24
A1

21

24

21

16

K2
44

41

17

10

K1'

K7

S3

A2

32
A1

31

14

13

18

1Y

34

31

1A+

K3

19

2Y

32

31

34

31

2A+

K5

K4

20

C-47
Solution 8

Fig. 8/5:
Circuit diagram, electrical
(2)

C-48
Solution 8

Solution description

By pressing the START button, the program is started in accordance


with the displacement-step diagram.

Manual step mode

By pressing push button S2, it is possible to carry out one movement per
actuation in accordance with the program or control sequence.

Step repetition

When, after pressing S2, cylinder 1A has advanced via K3 and cylinder
2A via K4, self-latching at K4 can be reset via K7 by means of push
button S3. As a result of this, K4 is de-energised and cylinder 2A retracts. Cylinder 2A is now able to advance again via S2.

Components list

Quantity

Designation

Relay, 3-off

Signal input plate, electrical

Indicator/distributor plate, electrical

Double-acting cylinder

On/off valve with filter regulator

Manifold

Proximity sensor, inductive

Proximity sensor, capacitive

Limit switch, electrical, actuation from the left

Limit switch, electrical, actuation from the right

5/2-way solenoid valve

Cable set with safety plug

Electrical power supply unit, 24 V

TP202 Festo Didactic

C-49
Solution 9

Drilling and reaming machine

2B1
1S1

1S2

Fig. 9/3:
Circuit diagram, pneumatic

2B2

2A

1A

1Y

2Y1
1

2Y2

0Z2

0Z1

* For the purposes of this exercise, linear drive 2A is replaced by a double-acting


cylinder.
2A

2B1

2Y1

2Y2
1

TP202 Festo Didactic

Fig. 9/4:
Part of circuit diagram,
pneumatic

2B2

S1 = Single cycle
S2 = Continuous cycle
S3 = STOP
4
6

32
A1

31

24

21

14

13

2
5

K2

S3

K5

S2

A2

14

13

A2

12
A1

11

14

K1

2
K2
14

13

K3

K1

11
25

A2

A1

24

23

5
K2
24

23

A2

A1

22

21

19 8
26

K4

ES

K1

K9

K5

11

14

13

NA

K5

1S2

K4

1
3
18

A2

A1

14

11

1B

2B1

BU

BN

10

K6

K9

K3

BK

12
13
21

A2

24
A1

21

14

13

11

K6
14

11

12

Fig. 9/5:
Circuit diagram, electrical
(1)

S1

24 V-

C-50

Solution 9

1B = Sensing of parts
ES = EMERGENCY-STOP

TP202 Festo Didactic

S4 = RESET linear drive

TP202 Festo Didactic


BU

BN

K8

K7

BK

24
A1

21

17
18
23

2B2

16

30 14
15
29

14

11

15

A2

K7

14

A2

K7

24
A1

21

13

K6

1S1

24 V-

K8
12

11

17

K9

K8

K5

A2

24
A1

21

34

31

18

A2

32
A1

31

22

29 20
30

K10

S4

K4

21

19
K10
14

11

20

K11

K13

K12

K6

22
28

A2

14
A1

12
13

11

32

31

21
K11
14

11

22

C-51
Solution 9

Fig. 9/6:
Circuit diagram, electrical
(2)

K12

A1

24

21
23

K13

K3

21 24

24

A2

24
A1

K12

23

25

A2

K13

42
23

41

34

21

24
K4
24

23

26
S5
32

31

27

1Y

24

1A+

K11

21

28

2Y1

22

34
21

31

2A+

K10

K7

29

2Y2

32

42
31

41

3A-

K10

K7

30

Fig. 9/7:
Circuit diagram, electrical
(3)

K5

K8

31

24 V- 23

C-52

Solution 9

S5 = RESET gripper

TP202 Festo Didactic

C-53
Solution 9

Line 1 is supplied with current via relay K4 (provided the EMERGENCYSTOP button has not been pressed). The cycle is started via S1 or S2. A
latching sequence is then constructed for this motion sequence through
current paths 9 to 18.
When the EMERGENCY-STOP switch (ES) has been actuated, the
gripper is to remain in its current position, whether open or closed. The
signal close gripper is acquired via relay K6. This signal must be stored
after actuation of EMERGENCY-STOP to keep the gripper in a closed
position (see current paths 21 and 22). However, this memory must be
erased if, at the time of the EMERGENCY-STOP actuation, the control
had opened the gripper. In this case, the open signal K8 MUST BE
STORED (SEE CURRENT PATHS 23 AND 24). Relay K13 is required
to ensure that the reset button for gripper S5 is only active when the
EMERGENCY-STOP key has already been switched off and the controller has been stopped. This is only released when no start signal or
EMERGENCY-STOP signal is present and push button S5 has been
actuated.
Coil Y2 is actuated by signal K7 and the linear drive proceeds. Selflatching of relay K10 is required to switch the linear drive to unpressurised on actuation of the EMERGENCY-STOP and to memorise this
status. This is then reset by RESET button S4 and the unit is returned
once again to the initial start position.
A new start signal is not memorised until the gripper has actuated limit
switch 1S2 (K5).
The cycle only starts if parts are present in the outlet channel (sensor 1B) and the initial position of the linear drive (sensor 2B1) is being
signalled.
Owing to multiple sensing, limit switch 1S2 must be switched indirectly
via relay K5.

TP202 Festo Didactic

Solution description

C-54
Solution 9

Components list

Quantity

Designation

Relay, 3-off

Signal input plate, electrical

Indicator/distributor plate, electrical

Double-acting cylinder

On/off valve with filter regulator

Manifold

EMERGENCY-STOP button

Proximity sensor, capacitive

Proximity sensor with cylinder mounting

Limit switch, electrical, actuation from the left

Limit switch, electrical, actuation from the right

3/2-way solenoid valve, normally closed

5/2-way solenoid valve

Cable set with safety plug

Electrical power supply unit, 24 V

TP202 Festo Didactic

C-55
Solution 10

Drilling and reaming machine

Fig. 10/3:
Circuit diagram, pneumatic

1A

1S1

2B1

1S2

2B2

3A

3B1

2A

1Y

2Y
5

3Y
5

0Z2

0Z1

* In order to assemble this control system on the profile plate, feed unit 1A is replaced
by a double-acting cylinder and feed unit 3A by a single-acting cylinder.

TP202 Festo Didactic

3B2

K1

K8

K2

2
5
8

A2

12
A1

11

42

14
41

13

K1
14

13

BU

2B1 BN

K4

K2

K3

BK

5
7
19

A2

A1

12

11

14

14
13

13

K8

K1

K2

22

24
21

23

14

13

K3

1S1

4
9

A2

A1

K4
A2

24
A1

23

4 8
19 9

K2

1S2

K4

K1

24

34
21

33

K5

K4

K3

10
12
20

A2

34
A1

31

24

23

9
K5

14

11

10

Fig. 10/4:
Circuit diagram, electrical
(1)

24 V- 1

C-56

Solution 10

S = START-button

PS = PROGRAM SELECTION button

TP202 Festo Didactic

2B2

TP202 Festo Didactic

BU

BN

24 V- 11

K6

K5

BK

K7

K6
24
A1

21

21 16
18

3B2

15

13
15
21

14

11

14

A2

K6

13

A2

24
A1

21

12
K7
14

11

16
3B1

17

K8

1
5

K7

A2

24
A1

21

18

1Y

42

41

34

33

1A+

K4

K2

19

2Y

34

31

2A+

K5

20

3Y

32

31

34

31

3A+

K7

K6

21

C-57

Solution 10

Fig. 10/5:
Circuit diagram, electrical
(2)

C-58
Solution 10

Solution description

Relay K1 is switched via the PROGRAM SELECTOR BUTTON PS. This


is only possible prior to actuation of the START button.
If program 2 (drilling and reaming) is selected, the latched sequence
runs through as usual. However, if program 1 (drilling) is required, it is
simply necessary to press the start button. If 1S2 and contact K2 switch
the relay K4, the sequencer is reset by K4 and cylinder 1A retracts.

Components list

Quantity

Designation

Relay, 3-off

Signal input plate, electrical

Indicator/distributor plate, electrical

Single-acting cylinder

Double-acting cylinder

On/off valve with filter regulator

Manifold

Proximity sensor, inductive

Proximity sensor, capacitive

Proximity sensor with cylinder mounting

Limit switch, electrical, actuation from the left

Limit switch, electrical, actuation from the right

3/2-way solenoid valve, normally closed

5/2-way solenoid valve

Cable set with safety plug

Electrical power supply unit, 24 V

TP202 Festo Didactic

C-59
Solution 11

Loading station

Fig. 11/3:
Circuit diagram, pneumatic

1A

1S1

1S2

2A

2B1

3B1

2B2

3B2

3A

1Y

2Y
5 1 3

5 1

3Y
5 1 3

0Z2

0Z1

* For the purposes of this exercise, cylinder 1A is replaced by a single-acting cylinder.

TP202 Festo Didactic

K1

K10

2
4
15

A2

A1

42

41

K1
14

11

2B1

S2

K2
A2

A1

42

41

24
1

14
21

11

5
6
21
22

K7

K1

K9

4
K2
14

11

K3
A2

A1

24

21

12

11

15 7
22 8

K2

K4

1S2

6
K3
14

11

K4
A2

A1

24

21

12

11

6 9
12
24

K3

K5

1S1

8
K4
24

21

K4'

25

A2

A1

10

2B2

11

K5
A2

34
A1

31

24

21

8 12
13
23

K4

K5

12

K6
A2

34
A1

31

12

11

21 13
22 14

K5

K6

13

Fig. 11/4:
Circuit diagram, electrical
(1)

S1

24 V-

C-60

Solution 11

S1 = START button
S2 = Sensing of steel parts

TP202 Festo Didactic

TP202 Festo Didactic

A2

25

A2

A1

K8

A1

31
32

K3

34

24

21

K1

31

15
K1

R2

R1

14

13

16

3B1

BU

BN

17

BK

K9

Electromagnet

K7

K6

14

A2

A1

18

3B2
BK

K10

BU

BN

19

1 16

A2

A1

20

32

31

34

42

41

1A+

K6

42

41

44

41

22

K5

K2

1Y

Electromagnet

H1

K6

K2

31

21
K5
44

41

23

44

2A+

2Y

K4

41

24

3Y

14

11

14

3A+

K4'

K8

11

25

C-61

Solution 11

Fig. 11/5:
Circuit diagram, electrical
(2)

C-62
Solution 11

Solution description

The cycles of the control are counted to enable cylinder 3A to extend.


Where there is a preselected figure 2, cylinder 3A is extended together
with cylinder 2A on the second cycle of the control system in order to
bring the part past position 2.
If cylinder 3A has extended, start condition K1 is reset via 3B2 (K10) and
the counter is reset to zero.

Components list

Quantity

Designation

Relay, 3-off

Signal input plate, electrical

Preselect counter, electrical, incrementing

Indicator/distributor plate, electrical

Single-acting cylinder

Double-acting cylinder

On/off valve with filter regulator

Manifold

Proximity sensor, inductive

Proximity sensor, capacitive

Proximity sensor with cylinder mounting

Limit switch, electrical, actuation from the left

Limit switch, electrical, actuation from the right

3/2-way solenoid valve, normally closed

5/2-way solenoid valve

Cable set with safety plug

Electrical power supply unit, 24 V

TP202 Festo Didactic

C-63
Solution 12

Internal grinding machine

Fig. 12/3:
Circuit diagram, pneumatic

3A

1A

1B1

2A

1B2

2S1

2S2

3B1

3B3

2B

P1

2Y

1Y
1

3Y
5

0Z2

0Z1

* For the purposes of this exercise, cylinder 1A is replaced by a single-acting cylinder


and feed unit 3A by a double-acting cylinder. The inductive proximity sensor 3B2 is
switched to mid-position by the trip cam.

TP202 Festo Didactic

3B2

K1

S3

S1

S2

A1

4
29

K2

2S1

2
4

14

13

A2

K1

A2

32
A1

31

14

13

K3

K14

K2

K1

5
7
32

A2

14
A1

11

14
1

24
13

23

4
K3
14

13

5
1B2

K4

K3

8
10
33

A2

24
A1

23

7
K4
p
14 p1
2

13

8
2B

BU

BN

K5

K4

BK

11
14
22
35

A2

A1

24

23

10

K5'

K5

37

A2

A1

14

13

11
3B3

BU

BN

12

K6

BK

20 14
16

A2

A1

13

Fig. 12/4:
Circuit diagram, electrical
(1)

24 V- 1

C-64

Solution 12

S1 = START-button
S2 = Part of the stop
S3 = STOP-button

TP202 Festo Didactic

C-65
Solution 12

Fig. 12/5:
Circuit diagram, electrical
(2)

TP202 Festo Didactic

1B1

K13

K12

K2

17
30
31
35

A2

24
A1

21

24

23

29
K13
24

21

30

K14

2S2

A2

A1

31

1Y

32

31

34

33

1A+

K12

K3

32

2Y

42

41

34

33

2A+

K12

K4

33
K13
42

41

34

3Y

42

41

32

31

44

41

3A+

K11

K7

K5

35

K10
34

31

36

H1

K12'

K5'

12

11

14

11

37

Fig. 12/6:
Circuit diagram, electrical
(3)

24 V- 28

C-66

Solution 12

Grinding wheel

TP202 Festo Didactic

C-67
Solution 12

When the installation is started up and the initial position of cylinder 2A


(2S1) and a workpiece (S2) are signalled, cylinder 1A extends. Then
cylinder 2A extends and clamps the part. When the clamping pressure
has been reached, cylinder 3A is extended via K5. Sensor B5 is activated in the forward end position. This in turn activates relay K6. Then
feed cylinder 3A retracts again. In addition, K6 passes on a counting
pulse to the preselect counter.

Solution description

Sensor 3B2 is activated when the cylinder has retracted by a half. This
then reverses the valve via further contacts (K6, K7, K9) and cylinder 3A
extends again. This sequence is carried out until the preselected figure
has been reached. If 3B2 is activated on the return stroke, the valve may
not switch since counter contact K9 interrupts the circuit. The sequence
is switched on via a second counter contact.
Quantity

Designation

Relay, 3-off

Signal input plate, electrical

Preselect counter, electrical, incrementing

Indicator/distributor plate, electrical

Single-acting cylinder

Double-acting cylinder

On/off valve with filter regulator

Manifold

Proximity sensor, inductive

Proximity sensor, capacitive

Proximity sensor, optical

Proximity sensor with cylinder mounting

Limit switch, electrical, actuation from the left

Limit switch, electrical, actuation from the right

Pneumatic-electric converter

3/2-way solenoid valve, normally closed

5/2-way solenoid valve

Cable set with safety plug

Electrical power supply unit, 24 V

TP202 Festo Didactic

Components list

C-68
Solution 12

TP202 Festo Didactic

C-69
Solution 13

Assembly unit

2A

1A

1S1

2B1

Fig. 13/3:
Circuit diagram, pneumatic

2B2

3B1

1S2

3B2

3A

2Y1
4

1Y1

2Y2
1

1Y2
1

3Y1

0Z2

0Z1

* For the purposes of this exercise, cylinder 1A is replaced by a single-acting cylinder.

TP202 Festo Didactic

3Y2
1

S2

4
32
36
40

K1

A2

2B1

K2

5
6

A2

12
A1

11

14

14
13

13

K5

K11

S1

24

23

K1
12

11

K2
14

11

A2

A1

24

21

19 7
29

K3

K2

K4

K7

K3

1S2

8
9

A2

12
A1

11

14

4
11

7
K4
14

11

K5
A2

A1

24

21

4 11
33

K4

9
2B2

10

K6

K9

K5

12
13

A2

12
A1

11

24

21

11
K6

14

11

12

Fig. 13/4:
Circuit diagram, electrical
(1)

A1

14

13

24 V- 1

C-70

Solution 13

S1 = OFF/ON
S2 = MAN/AUT

TP202 Festo Didactic

TP202 Festo Didactic


K7
K8

K11

K7

BK

42
A1

41

24

21

16
17
28

BU

BN

15

7 15
37

3B2

14

A2

A1

24

21

13

A2

K6

24 V-

K8
14

11

16

K9
A2

A1

24

21

11 19
31
39

K8

17

BU

3B1 BN

18

K10

K3

K9

1S1

BK

20
22
23

A2

22
A1

21

24

4
21

19
K10
14

13

20

K12
42

41

21

K11
A2

A1

24

23

15 4
35

K10

22

C-71

Solution 13

Fig. 13/5:
Circuit diagram, electrical
(2)

K12
K13

S5

S4

S3

A1

32

32
31

14
31

13

32 30

14

13

21 24

K12

A2

A1

34

33

24

A2

K10

23

25

K14

36 34

A2

A1

42

14
41

32
13

31

26

K15

40 38

A2

A1

14

42
13

42
41

41

27

H1

28

1Y1

34

31

1A+

K3

29
K13
14

13

30

1Y2

34

31

1A-

K9

31

K13

K1

42

41

22

21

32

Fig. 13/6:
Circuit diagram, electrical
(3)

24 V-

C-72

Solution 13

MAN

TP202 Festo Didactic

TP202 Festo Didactic

2Y1

34

31

33

2A+

K5

24 V-

K14
14

13

34

2Y2

24

23

2A-

K11

35

K14

K1

42

41

32

31

36

3Y1

34

31

3A+

K7

37
K15
14

13

38

3Y2

42

41

3A-

K9

39

K15

K1

42

41

42

41

40

C-73

Solution 13

Fig. 13/7:
Circuit diagram, electrical
(4)

C-74
Solution 13

Solution description

When the MAN/AUT switch S2 or relay K1 is not actuated, voltage is


applied at line 1 (MANUAL mode). The cylinder can be extended individually via push buttons S3, S4 and S5.
Cylinder 1A extends and remains in the extended position for as long as
push button S3 is actuated or an additional push button is pressed.
Movement is prevented if two or three push buttons are pressed simultaneously.
To ensure that there is no interference with AUTOMATIC mode, the
lines to the normally closed contacts of relays K13, K14 and K15 are
each interrupted by a normally closed contact of K1.
As soon as line 2 (AUTOMATIC mode) is supplied with current, selflatching is set via the normally closed contact K12 in current path 12. At
the same time, when K10 goes into self-latching, relay K12 is switched
via a normally open contact K10. This also goes into self-latching and
the normally closed contact K12 in current path 21 opens. Thus, the last
step which is normally required as a start condition can be activated
without the use of a SET button.

Components list

Quantity

Designation

Relay, 3-off

Signal input plate, electrical

Indicator/distributor plate, electrical

Single-acting cylinder

Double-acting cylinder

On/off valve with filter regulator

Manifold

Proximity sensor, inductive

Proximity sensor, capacitive

Proximity sensor with cylinder mounting

Limit switch, electrical, actuation from the left

Limit switch, electrical, actuation from the right

5/2-way double solenoid valve

Cable set with safety plug

Electrical power supply unit, 24 V

TP202 Festo Didactic

C-75
Solution 14

Moulding press

Fig. 14/3:
Circuit diagram, pneumatic

1A

1B1

2B1 2B2

1B2

2B3

3A

3S1

2A

1Y

2Y
1

3Y
1

0Z2

0Z1

* For the purposes of this exercise, the double-acting cylinder is replaced by a singleacting cylinder.

TP202 Festo Didactic

3S2

K3

K1

S1

A2

42
A1

41

14

13

S2
14

13

K2

K1

A2

14
A1

13

K3

K2

K5

K14

7
30

A2

42
A1

42
41

14
41

24
11

24
23

23

4
1B2

K4

24 7
9

A2

A1

K5

K11

K3

K4

8
10
31

A2

12
A1

11

14

14
13

13

7
K5
14

13

K6

K4

10

A2

A1

24

23

K7
A2

24
A1

23

18

17

31 11
13

K5

K6

10
K7

14

13

11

Fig. 14/4:
Circuit diagram, electrical
(1)

24 V- 1

C-76

Solution 14

S1, S2 = START-button

TP202 Festo Didactic

1B1

24 V- 12

TP202 Festo Didactic


K8

15
16
27
33

24 13
15
32

K9

24
A1
A2

24
A1

K10

24
A1

21

7 19

K11

K10

3S1

33 17
18
25

14

11

18

A2

K10

17

A2

24
A1

21

K9

21

K8

3S2

23

11
4

K9

16

14

2B3

15

14

11

14

A2

K7

K8

13
K11
24

21

19

BU

2B1 BN

20

K12

BK

27 26

A2

A1

21

C-77

Solution 14

Fig. 14/5:
Circuit diagram, electrical
(2)

2B2

24 V-

BU

BN

22

K13

BK

4
25

24

42
A1

41

32

31

14

11

A2

K14

K4

K8

K13

24

A2

A1

23

K10

K14

34

31

24

21

25
K12
14

11

26

K15

K12

K9

28
29

A2

22
A1

21

34

31

27
K15
14

11

28

H1

K15
24

21

29

1Y

24

23

1A+

K3

30

K7

K5

42

41

34

33

31

2Y

44

41

2A+

K8

32

3Y

42

41

44

41

3A+

K10

K9

33

C-78

Solution 14

Fig. 14/6:
Circuit diagram, electrical
(3)

Vacuum generator

TP202 Festo Didactic

C-79
Solution 14

The two-hand safety control is realised in current paths 1 to 4. Relay K2


serves here as a delaying element. The maximum time duration allowable between the actuation of S1 and S2 is dependent on the switching
time of this relay.

Solution description

If the two push buttons S1 and S2 are activated simultaneously, cylinder 1A extends. These buttons must remain depressed until the cylinder
has reached its forward end position.
The start condition is decided by the connections in current paths 24 26. It has been established that the signal from signal generator B5 only
becomes effective when the extractor unit leaves the working area, i.e.
on the return stroke of cylinder 2A.
Relay K15 starts the operation of the vaccum generator which must be
specially stored as the sequence is set before the retraced end position
of cylinder 2A is reached.
Quantity

Designation

Relay, 3-off

Signal input plate, electrical

Time relay, 2-off

Indicator/distributor plate, electrical

Single-acting cylinder

Double-acting cylinder

On/off valve with filter regulator

Manifold

Proximity sensor, inductive

Proximity sensor, capacitive

Proximity sensor, optical

Proximity sensor with cylinder mounting

Limit switch, electrical, actuation from the left

Limit switch, electrical, actuation from the right

3/2-way solenoid valve, normally closed

5/2-way solenoid valve

Cable set with safety plug

Electrical power supply unit, 24 V

TP202 Festo Didactic

Components list

C-80
Solution 14

TP202 Festo Didactic

C-81
Solution 15

Pick-and-place unit

Fig. 15/3:
Circuit diagram, pneumatic

1A

1S1

2B1

1S2

2B2

3A

3B1

2A

1Y

2Y
1

3Y
1

0Z2

0Z1

* For the purposes of carrying out this exercise on the profile plate, cylinder 3A is
replaced by a single-acting cylinder.

TP202 Festo Didactic

3B2

S3

S2

K1

K15

S1

2
4
22

A2

12
A1

11

14

13

14

14
13

13

K1
14

13

H1

24

23

K2

K15

K1

K3

1S2

5
7
40

A2

22
A1

21

24

42
23

41

4
K2
14

13

BU

2B1 BN

K4

K3

K2

BK

8
10
36

A2

24
A1

23

12

11

7
K3
14

13

8
3B2

K4
A2

24
A1

23

12

11

7 11
41 13

K3

K5

10
K4

24

21

11

Fig. 15/4:
Circuit diagram, electrical
(1)

24 V- 1

C-82

Solution 15

Magazine

S1 = START-button
S2 = Gear housing
S3 = Magazine

TP202 Festo Didactic

3B1

24 V- 12

TP202 Festo Didactic

K5
A2

13 16
17
42

10 14
15
38

A1

A1

K6

34

34

K5

31

11

31

K7

1S1

12

24

21

15

12

K5

14

A2

K4

K6

11

13
K6
24

21

16

K7
A2

A1

34

31

12

15 18
36 20

K6

K8

11

17
K7
24

21

18

K7'

42

A2

A1

19

K8
A2

A1

34

31

12

17 21
38 22

K7

K9

11

20
K8
24

21

21

K9
A2

A1

34

31

34

12
33

11

20 23
25
37

K8

K1

K10

22
K9
24

21

23

K9'

43

A2

A1

24

C-83

Solution 15

Fig. 15/5:
Circuit diagram, electrical
(2)

K10

31

A2

25 28
31
39

22 26
43 27

A1

A1

K11

34

34

K10

31

41
42

K12

42

41

24

27

A2

K9

K11

K10

21

26
K11
14

13

28

K11'

40

A2

A1

29

BU

2B2 BN

30

K12
A2

A1

24

23

14

27 31
32
44

K11

BK

K12

13

31

K13
A2

A1

24

23

14

44 32
33

K12

K13

11

32

K14
A2

K15
A2

A1

24

21

32

31

34

1
4

K14

S2

A1

24

21

14

39 33
34

K13

K14

11

33

H2

24

23

35

Fig. 15/6:
Circuit diagram, electrical
(3)

24 V- 25

C-84

Solution 15

Gear
housing

TP202 Festo Didactic

TP202 Festo Didactic


H3

K7

K3

42

K13
32

31

41

41
44

K9

37

34

33

24 V- 36

1Y

42

41

44

41

1A-

K8

K5

38

K14

K11

32

31

34

33

39

2Y

42

41

34

33

2A-

K11'

K2

40

3Y

42

3A+

K4

41

41

K7'

K6

12

11

44

41

42

K10

K9'

42

41

14

11

43

K13

K12

32

31

34

33

44

C-85

Solution 15

Fig. 15/7:
Circuit diagram, electrical
(4)

Vacuum
generator

C-86
Solution 15

Solution description

If one of the magazines is empty, then the installation remains stationary


at position 1 or 2 by resetting the START signal, and waits there until the
magazine has been filled and a new START signal is issued (see current
paths 1, 4, 22).
In order to fulfil the gear sensing, it is necessary to establish whether a
gear housing is available (starting precondition). When the assembly has
been completed, the gear housing must be removed. Without this, it will
no longer be possible to start the installation (see current path 1, 4, 34).

Components list

Quantity

Designation

Relay, 3-off

Signal input plate, electrical

Indicator/distributor plate, electrical

Single-acting cylinder

Double-acting cylinder

On/off valve with filter regulator

Manifold

Proximity sensor, inductive

Proximity sensor, capacitive

Proximity sensor with cylinder mounting

Limit switch, electrical, actuation from the left

Limit switch, electrical, actuation from the right

3/2-way solenoid valve, normally closed

5/2-way solenoid valve

Cable set with safety plug

Electrical power supply unit, 24 V

TP202 Festo Didactic

C-87
Solution 16

Galvanising process

1B1

1B3

1B2

1A

1Y
5

0B

P1
0Z2

0Z1

1
3

TP202 Festo Didactic

Fig. 16/3:
Circuit diagram, pneumatic

1B1

BU

BN

K21

BK

K2

22 3
4
26

A1

42

41

14

14
13

11

14

14
11

11

K1

K21

K15

K13

A2

0B

1.2

A2

A1

1.1
K1
14

13

K2

5
6
42

A2

A1

42

41

24

24
23

21

1A+

K5

K1

K15

4
K2
14

13

Bad 1

H1

K3

K2

A2

A1

24

23

K4

9
10

A2

A1

12

11

14

14
13

11

1A-

K7

K3

K18

8
K4
14

13

K5
A2

A1

24

23

4 11
27

K4

10

Fig. 16/4:
Circuit diagram, electrical
(1)

24 V- 1.0

C-88

Solution 16

S = START-button

TP202 Festo Didactic

TP202 Festo Didactic


K6

12
14
44

A2

A1

12

11

14

34
13

1A+

K9

K5

K15

31

24 V- 11
K6
14

13

12

H2

13

K7
A2

K8

A1

24

1A-

16
17

A2

A1

12

11 18
28

A2

K10

44
21

19
21
43

A2

A1

22

1A+

K13

K9

K15

21

K9

K8

41

18

11

14

21

17

24

K8

11

16

24

36
21

35

15

K11

K7

K19

A1

24

8 15
36

K6

23

14
K10
14

11

19

H3

20

C-89

Solution 16

Fig. 16/5:
Circuit diagram, electrical
(2)

Bath 3

Bath 2

1A-

23
25
29
45

A1

42

41

24

24
21

21

15 22

K12

K1

K11

K18

A2

A1

24

21

A2

K11

K10

22

K12
14

11

23
S1
14

13

24

A2

A1

24

21

18 2
37

K13

K12

25

K14
A2

A1

34

33

t1

34 30
45

K1

26
K5
24

23

27
K9
34

31

28
K12
34

K15

K14

31

29

2
4
11
18

A2

A1

18

17

30
1B3

K16

BK
BU

BN

31

33
37

A2

A1

32

Fig. 16/6:
Circuit diagram, electrical
(3)

24 V- 21

C-90

Solution 16

S1 = SET-button

TP202 Festo Didactic

TP202 Festo Didactic

K14

35

A2

A1

14

11

R2

R1

36

35

34

K18

A2

A1

14

11

40 8
22

K17

35

K19
A2

A1

32

t2

15

K7

31

36

K20
A2

A1

12

11

32

31

24

21

42 38

K22

K13

K16

37
K20
14

11

38

1B2 1

39

37

K18

K22

S2

A2

A1

32

31

40

1Y

S2 =
Up/Down

K17

K16

24 V- 33

1A+

14

13

41

K20

K2

22

21

34

33

42
K10
34

31

43
K6

K12

H4

K14

34

33

44

28

44
27

41

45

C-91

Solution 16

Work surface

t1 > tReturn stroke

oscillate

Fig. 16/7:
Circuit diagram, electrical
(4)

C-92
Solution 16

Solution description

Initial position: Cylinder 1A is retracted and is located above the work


surface and lamp H4 is illuminated. Cylinder 1A can be extended via the
up/down switch (current path 41). Once the initial start position has been
regained, the cycle is started with the start button. Then lamp H4 is
switched off and the time t1 expires. This switches lamp H1 (bath 1
reached) and allows cylinder 1A to extend via relay K2. Counting pulses
are passed on to the counter via 1B3 (current paths 31-34). Additionally,
1B3 reverses the valve so that cylinder 1A retracts as far as 1B2. As a
result, cylinder 1A is switched back to Extend (current paths 37-40).
This oscillating movement of cylinder 1A is repeated until the counter
switches and interrupts the signal of sensor 1B2.
When the cylinder has retracted, time delay t1 is activated once again by
relay K5, which switches relay K6 when it has completed its cycle. Lamp
H2 is illuminated and cylinder 1A extends. Next, the delay period t2 of
the basket in bath 2 is switched via K7. Then, relay K8 switches, cylinder
1A retracts once again and the time t1 is repeated. When the time relay
has switched, the cylinder enters bath 3 and the motion sequence carried out for bath 1 is repeated. Time period t1 is then activated a final
time and signals the initial start position via lamp H4.
The time t1 must be longer than the time which the cylinder requires for
its return stroke.

TP202 Festo Didactic

C-93
Solution 16

Quantity

Designation

Relay, 3-off

Signal input plate, electrical

Time relay, 2-off

Preselect counter, electrical, incrementing

Indicator/distributor plate, electrical

Double-acting cylinder

On/off valve with filter regulator

Manifold

Proximity sensor, inductive

Proximity sensor, capacitive

Proximity sensor with cylinder mounting

Pneumatic-electric converter

5/2-way solenoid valve

Cable set with safety plug

Electrical power supply unit, 24 V

TP202 Festo Didactic

Components list

C-94
Solution 16

TP202 Festo Didactic

C-95
Solution 17

Loading station

Fig. 17/4:
Circuit diagram, pneumatic
1B 1

1A1

1B2

1A2

2B1

2B2

2A

1V1

1Y1

1V2

1Y2

2V

2Y1

2Y2
1

3A

3S1

3S2

4S

4M

3V

3Y1

4V

3Y2

4Y

4B

0Z2

* For the purposes of this


exercise, the rotary actuator
(4M) is replaced by a singleacting cylinder, and the rodless cylinder (1A) by a
double-acting cylinder.

TP202 Festo Didactic

0Z1
1
3

1B1

24 V- 1

3A+

24
A1

21

14

11

1A+

K2

K1

K2

35 5
6
39

1B2

3
5
35
36

14

11

A2

42
A1

41

14

K1

A2

K7

K1

13

K3

K2

K9

7
8
20

A2

24
A1

21

14

13

6
K3
14

11

7
11

K4
A2

24
A1

21

14

11

4M+

20 9
10
44

K3

K18

14

K19

12

K4
14

11

K5
A2

24
A1

21

14

13

4M-

44 11
12
34

K4

K11

10
K5

14

11

11

C-96

Solution 17

Fig. 17/5:
Circuit diagram, electrical
(1)

S = START-button

TP202 Festo Didactic

TP202 Festo Didactic

K7

K6

K8

A2

24
A1

23

14

13

1A-

14

13

3A-

K6

14

A2

24
A1

21

14

13

13

39 13
14
42

K6

K5

K10

24 V- 12

K8

3S1

14
28

A2

A1

15

K9

3S2

6
20

A2

A1

16

K10

4S

12
24

A2

A1

17
4B

18

K11

10
22

A2

A1

19

K12

21
22
33
43

A2

34
A1

22
31

32
21

31

24

23

4M+

K3

K18

K4

K9

20
K12
14

11

21

K13
A2

24
A1

21

24

23

4M-

33 23
43 24

K12

K11

22
K13
14

11

23

C-97

Solution 17

Fig. 17/6:
Circuit diagram, electrical
(2)

K14

24
A1

21

14

11

3A-

K15

K14

K15

2A-

2B1

39 27
28
41

14

11

25
27
37

K14

27

A2

24
A1

21

24

23

26

A2

K13

K10

25

A2

24
A1

21

24

23

2A+

37 29
31
38

K16

K15

K8

28
K16
14

11

29
2B2

30

K17
A2

24
A1

21

14

11

3A+

41 31
32
40

K16

K17

31

K18
A2

A1

24

21

20 8

K17

32

K19

K13

K12

A2

32
A1

31

34

31

33
K5

R2

R1

34

31

34

Fig. 17/7:
Circuit diagram, electrical
(3)

24 V- 24

C-98

Solution 17

TP202 Festo Didactic

TP202 Festo Didactic

1Y1

32

31

34

1A+

K2

K1

31

24 V- 35

1Y2

44

1A+

K1

41

36

2Y1

32

31

34

2A-

K16

K14

31

37

2Y2

44

2A+

K16

41

38

3Y1

42

41

32

44
31

3A+

K6

K15

K2

41

39
K17
34

31

40

3Y2

42

44
41

3A-

K17

K15

41

41
K6
34

33

42

4Y

42

44
41

4M+

K13

K12

41

43

H1

K5

K4

42

44
41

41

44

C-99

Solution 17

Suction
cups
Fig. 17/8:
Circuit diagram, electrical
(4)

C-100
Solution 17

Solution description
Main program

The loading station is located in step 21 of the subroutine.


When the START button has been pressed, K1 causes cylinder 1A to
extend. Then cylinder 3A is extended via K2 and cylinder 3A is switched
to the unpressurised condition.
Next, the jump from K3 to K12 into the subroutine takes place. When the
subroutine has run through, the return jump through K18 and K19 to K4
in the main program takes place. Cylinder 4M advances and is retracted
by K5. The, cylinder 3A is retracted by K6 and cylinder 1A by K7.

Subroutine

Movements 4M+, 4M-, 2A- (with every 2A- movement, cylinder 1A which
has been switched unpressurised, is pushed back by a partial stroke),
3A-, 2A+, 3A+ are executed in the subroutine and repeated three times
via a counter. When the counter has reached the preselected figure, the
return jump to the main program is carried out.

Comment

In the case of this motion sequence, costs make it necessary to realise


this by means of a repetition of a program section (subroutine).
Increased expenditure on planning is justified here by a considerable
saving on relays and very much simpler circuitry, so that in this case, the
solution shown is more economical than a solution with the full sequence
which requires less planning.

TP202 Festo Didactic

C-101
Solution 17

Quantity

Designation

Relay, 3-off

Signal input plate, electrical

Preselect counter, electrical, incrementing

Indicator/distributor plate, electrical

Single-acting cylinder

Double-acting cylinder

On/off valve with filter regulator

Manifold

Proximity sensor, inductive

Proximity sensor, capacitive

Proximity sensor, optical

Proximity sensor with cylinder mounting

Limit switch, electrical, actuation from the left

Limit switch, electrical, actuation from the right

3/2-way solenoid valve, normally closed

5/2-way solenoid valve

5/2-way double solenoid valve

Cable set with safety plug

Electrical power supply unit, 24 V

TP202 Festo Didactic

Components list

C-102
Solution 17

TP202 Festo Didactic

C-103
Solution 18

Rotary indexing station

3
5

2
4

8Y

8A

3
5

7Y

7A

2
4

7S2
7S1

2Y1
3
1
5

1Y2
1Y1

3
1

8S1

3
5

2
4

2Y2

8S2

9Y

9A

9S1

3
1
5

3Y1
2A
2
4

10Y

10A
9S2

4Y1
3Y2
2
4

2S2
2S1

(2B1) (2B2)
1A

3
5

10S1 10S2

4A

4Y2
2

11Y

11S1 11S2
11A

5Y1

4S2
4S1
3S2
3S1
3A
1S2
1S1

(1B1) (1B2)

12Y

3
5

3
5

5A

5S1

5Y2

5S2

6Y

6A

(6S)
6S1

(6B)
6S2

Fig. 18/3:
Circuit diagram, pneumatic

For the purposes of this exercise, cylinders 3A and 4A are not constructed. Feed units 6A to 11A are represented in the construction by a
single-acting cylinder. The on/off valve with filter regulator and manifold
are not represented.

TP202 Festo Didactic

24 V-

36

35

K1

1 3
6

A2

A1

32

31

24

18

17

4
2B1

H2

S1 = ON
S3 = Sensing of parts
S2 = AUTO/MANUELL
S4 = OFF

H1

K1

S4

23

13

14

32

14

K1

31

K2

K1

A2

28
A1

42
27

41

14

14
11

4
13

36 7
8
34

K6

K16

S3

6S

6
K2
14

13

K3
A2

A1

24

23

28 11
44
57

K2

8
1B2

K4

11
24
34

A2

A1

10

K5

K9

K3

K4

13
14

A2

12
A1

11

14

13

14

13

11
K17
14

11

12
K5

14

13

13

K6
A2

A1

24

23

6 17
46

K5

14

Fig. 18/4:
Circuit diagram, electrical
(1)

S1

S2

13

C-104

Solution 18

START

Pump

TP202 Festo Didactic

1B1

24 V-

15

K7

TP202 Festo Didactic

18
19
52

17
28
51

12
A1

11

14

13

14

13

A2

K8

K11

K6

K7

17

A2

A1

16

K8
14

11

18

K9
A2

A1

24

21

11 21
36
49

K8

19
2B2

22
23

A2

12
A1

11

24

4
21

21

K13

K9

5S2

BK

K10

BU

BN

20
K10
14

11

22

K11
A2

A1

24

21

17 24
45
53

K10

23

K12
A2

22
A1

21

24

4
21

24

23

34 25
26

K16

K11

5S1

K4

24
K12
14

11

25

K13
A2

A1

24

21

21 28
47
55

K12

26
6B

27

K14

K3

K13

K7

29
31
33

A2

42
A1

41

24

24
21

23

28

C-105
Solution 18

Fig. 18/5:
Circuit diagram, electrical
(2)

K14

14

11

29

24 V-

K15

12

11

30

K15

S5 = EMERGENCY-Stop
S6 = RESET
K16

K14

A1

34

24 6
50

24

30 32

K15

31

33

A2

A1

24

21

32

A2

K14

21

31

K17
A2

32
A1

31

34

33

34

44 12
35
43

K12

K4

K2

33

K17
24

21

35

K18

K2

K9

37
56

A2

42
A1

41

34

31

36

K18
14

11

37

K19

S6

48
51
54

A2

A1

14

13

38

K20

56

A2

A1

24

23

39

S5
22

21

40

K21

50 42

A2

A1

32

31

14

13

41
K21

14

11

42

Fig. 18/6:
Circuit diagram, electrical
(3)

34

C-106

Solution 18

TP202 Festo Didactic

TP202 Festo Didactic

H3

K17

24 V-

34

31

43

1Y1

42

41

24

23

1A+

K17

K3

44

K11

24

23

46

1A-

K6

1Y2

34

31

45

K13
34

31

47

K19

44

41

49

2A+

K9

2Y1

14

11

48

2Y2

22

21

34

31

2A-

K21

K16

50
K7

K19

34

31

52

5A+

K8

5Y1

34

33

24

21

51

5Y2

44

41

5A-

K11

53

K19
34

31

54

6Y

K18

K20

44

41

6A+

K13

55
K3

12Y

18

17

24

21

56

34

33

57

C-107
Solution 18

Air blast
Fig. 18/7:
Circuit diagram, electrical
(4)

Vacuum generator

C-108
Solution 18

Solution description

Current paths 1 to 3 fulfill the following functions: START and STOP via
push buttons, display of the start signal and simulation of the central
lubrication system.
Power to the installation is switched off with the EMERGENCY-STOP in
order to add a memory and secure the movement 2A-. Otherwise,
cylinder 2A would retract as a result of the automatic setting condition if
cylinder 1A is already located in its initial start position.
The status of the vacuum generator is stored by current paths 33 and
34. After EMERGENCY-STOP, the unit is reset and a restart can be
made. If the fact that the vacuum generator is active has now been
stored, steps 1 and 2 (1A+, 1A-) are now skipped because a workpiece
has already been collected.
In manual mode, the initial start position of the machining station can be
achieved via the RESET button, cylinder 2A only being able to retract
when cylinder 1A is in its initial position. In addition, processing is started
via the RESET key if memory K18 reports that no processing has yet
been carried out. Memory K21 (EMERGENCY-STOP actuated) is reset.
In order to limit the cost incurred through additional equipment, relay
K21 can be replaced by the counter (preselected figure 1).

TP202 Festo Didactic

C-109
Solution 18

40

Fig. 18/8:
Circuit diagram, electrical
(3)
Addition with counter

41

21

13

22

14

S5

38

39

13

23

31

14

24

32

S6

A1

K19

A1

K20
A2

A2

S5 = EMERGENCY-STOP
S6 = RESET

TP202 Festo Didactic

A1

R1

A2

R2

K21

C-110
Solution 18

Components list

Quantity

Designation

Relay, 3-off

Signal input plate, electrical

Time relay, 2-off

Indicator/distributor plate, electrical

Single-acting cylinder

Double-acting cylinder

On/off valve with filter regulator

Manifold

EMERGENCY-STOP button

Proximity sensor, inductive

Proximity sensor, capacitive

Proximity sensor, optical

Proximity sensor with cylinder mounting

Limit switch, electrical, actuation from the left

Limit switch, electrical, actuation from the right

5/2-way solenoid valve

5/2-way double solenoid valve

Cable set with safety plug

Electrical power supply unit, 24 V

TP202 Festo Didactic

C-111
Solution 19

Checking station

Fig. 19/3:
Circuit diagram, pneumatic
2A
1B1

2B1

2B2

1B2

4A
3A

3S

4S1

3B

1A

2Y
4

4Y
1

3Y
1Y1

1Y2

0Z2

0Z1

* For the purposes of this exercise, cylinder 4A is to be replaced by a single-acting


cylinder.

TP202 Festo Didactic

4S2

S1 = START-button

K1

S2

K3

K2

S1

A1

1
5

K2

3S

2
5

14

A2

K1

13

A2

32
A1

31

14

14
13

14
13

13

K3

4S1

1
5

A2

K3

K2

K1

K4

K19
A1

6
9
37
39

A2

18
A1

17

24

24
23

24
23

23

5
K4
14

11

BU

1B2 BN

K5

BK

A2

A1

A2

24
A1

21

14

37 10
16
38

K6

K4

K5

11

9
K6
14

11

10

BU

1B1 BN

11

K7

BK

15

A2

A1

12

Fig. 19/4:
Circuit diagram, electrical
(1)

24 V- 1

C-112

Solution 19

S2 = STOP-button

TP202 Festo Didactic

2B1

24 V- 13

K8

S3 = Tolerance check

TP202 Festo Didactic


16

15

A1

K9

K6

K10

= 3s

14

14
13

13

A2

K9

K8

K7

15

A2

A1

14

17
21
23
33

A2

A1

24

21

18

17

16
K10
14

11

17

39

K10'
A2

A1

18
2B2

19

K11

23

A2

A2

A1

24

21

14

13

21

41 22
40

K12

K10

S3

A1

20
K12
14

11

22

C-113
Solution 19

Fig. 19/5:
Circuit diagram, electrical
(2)

K13

K10

K11

31

K15

A1

14

13

28
29

K14

A1

4S2

24
29
40
41

3B

27

A2

14

11

26

A2

K13

25

A2

A1

34

31

14

11

24

K16

K14

A2

A1

14

11

28

K17
A2

A1

24

21

24

21

40 32
33
36

K13

K14

29

K17'

41

A2

A1

30
K15
14

11

31
K17

14

11

32

Fig. 19/6:
Circuit diagram, electrical
(3)

24 V- 23

C-114

Solution 19

TP202 Festo Didactic

S4

K17

TP202 Festo Didactic

= Interrogate container

K18

A1

22

21

35 34

K19

14

11

35

A2

44
A1

41

K18

34

A2

K18

K10

14

24
13

21

24 V- 33

H1

K17
34

31

36

1Y1

32

31

34

31

1A+

K6

K4

37

1Y2

44

41

1A-

K6

38

2Y

12

11

44

41

2A-

K10'

K4

39

3Y

42

41

24

34
21

31

3A+

K17

K12

K13

40

4Y

12

11

32

44
31

41

4A+

K17'

K12

K13

41

C-115
Solution 19

Fig. 19/7:
Circuit diagram, electrical
(4)

Conveyor belt

C-116
Solution 19

Solution description

In this solution, end position sensing is indirectly interconnected. The


START and STOP conditions for continuous cycle using one push
button each, are both realised by means of relay K1.
Selection between tolerance conditions Good/Reject is made with the
switch S4 (K12), with the result that either cylinder 3A or 4A extends.
Parts are counted by 3B (position C+) indirectly via K14.
The conveyor belt is started by the final step (K17) and does not stop
until the timer which resets the sequence has run through. The time
delay is not started until the control is in the final step and a container
(S4) has been signalled as being present.
The time element with switch-on delay is activated immediately after
power supply has been switched on, meaning that interruption of this
causes delayed start-up behaviour. That is, the time element switches to
its normal position when the time has expired. However, for this purpose
it is necessary to store the interruption signal (see K18).

Components list

Quantity

Designation

Relay, 3-off

Signal input plate, electrical

Time relay, 2-off

Preselect counter, electrical, incrementing

Indicator/distributor plate, electrical

Single-acting cylinder

Double-acting cylinder

On/off valve with filter regulator

Manifold

Proximity sensor, inductive

Proximity sensor, capacitive

Proximity sensor, optical

Proximity sensor with cylinder mounting

Limit switch, electrical, actuation from the left

Limit switch, electrical, actuation from the right

3/2-way solenoid valve, normally closed

5/2-way solenoid valve

5/2-way double solenoid valve

Cable set with safety plug

Electrical power supply unit, 24 V

TP202 Festo Didactic

C-117
Solution 20

Handling device

1A

1S1

2B1

1S2

2B2

Fig. 20/3:
Circuit diagram, pneumatic

2A

1Y

2Y
1

4M

*
3A

3B1

4S

3B2
4B

3Y

4Y1

4Y2

4Y3

0Z2

0Z1

* For the purposes of this exercise, cylinder 1A is replaced by a single-acting cylinder.


Rotary actuator 4M is replaced by a double-acting cylinder.

TP202 Festo Didactic

4Y4

S6

S1 = START-button
S2 = MAN/AUT
S3 = Sensing of parts

S4 = STOP
S5 = RESET
S6 = EMERGENCY-STOP

3
12

46 2
48 45

A2

K2

12
A1

32
11

14
31

14
13

14
11

13

14

14
13

A2

K1

K3

S4

K18

S3

A1

K1

11

K2

14

13

32

31

H1

K3

K15

A2

A1

14

11

K2

R2

R1

42

24
41

23

6
K4

K4

14

S5

13

7
50

A2

A1

14

K5
A2

A1

12

11

18

17

22 10
30

K16

K10

13

K5
14

13

10

3B1

11

K6

1A+

A2

A1

24

23

24

2A+

K7

K6

K15
14

21

14

15
16
41

A2

A1

12

11

24

K6

13

13

13
14
42

K13

K2

23

12

K7

A2

A1

24

23

16

2A-

42 17
19

K7

K8

14

1S2

13

15

K8
14

13

17

Fig. 20/4:
Circuit diagram, electrical
(1)

S1

S2

22

21

24 V- 1

C-118

Solution 20

START

TP202 Festo Didactic

1B1

TP202 Festo Didactic

K9'
A2

45

A2

20
24
30
44

K10

11

14

11

42

K16

41

9
24

A2

A1

A1

K11

K17

K5

22

A1

3A+ 4M+

K9

14

11

21

12

K9

20

24

23

19

BK

K8

BU

BN

18

24 V-

24

K11

A2

A1

24

21

28

27

24

1A-

22 25
41 26

K9

K11

K10

21

23
K12

A2

A1

34

31

26

30 27
44 29

K11

K12

24

1S1

21

25

K12'

14

11

27

45 47
49

A2

A1

28

12

K12

A2

31
43

A2

A1

32

31

22

24
21

34
23

K14

31

30

K17

K5

K9

K14

A1

24

21

24

21

3A- 4M-

K13

K12

K18

29

14

11

31
1B2

5
14

A2

A1

33

BK

K15

BU

BN

32

C-119
Solution 20

Fig. 20/5:
Circuit diagram, electrical
(2)

3B2

K16

4S

30 22

K18

9 23

K17

A1

37

A2

4B

36

A2

A1

35

2
29

A2

A1

38

H2

39

H3

40

1Y

42

2Y

2A+

42

41

41

K8

34

K6

33

42

34

1A+

K11

K7

33

41

3Y

24

3A+

K14

21

43

42

41

44

4M+

4Y1

K12

K9

41

44

4Y2

12

14
11

24
11

4M+

K12'

K9'

K1

21

45

K1

4Y3

24

21

47

4M-

K12'

32

31

46

K1

4Y4

34

31

49

4M-

K12'

42

41

48

K4
24

23

50

Fig. 20/6:
Circuit diagram, electrical
(3)

34

24 V-

C-120

Solution 20

MAN

AUTO

TP202 Festo Didactic

C-121
Solution 20

The continuous cycle is introduced via the START button. The handling
device then runs until a STOP is actuated at the end of the cycle or until
the counter has reached the preselected figure or no parts are reported
as being present.

Solution description

At this point, lamp H1 indicates whether the start signal is still stored.
Memories K5 and K14 cause cylinder 3A to move every second cycle.
Lamp H2 indicates that the installation is operating in AUTOMATIC
mode. H3 lights up when MANUAL mode is operating (RESET).
Quantity

Designation

Relay, 3-off

Signal input plate, electrical

Time relay, 2-off

Preselect counter, electrical, incrementing

Indicator/distributor plate, electrical

Single-acting cylinder

Double-acting cylinder

On/off valve with filter regulator

Manifold

EMERGENCY-STOP button

Proximity sensor, inductive

Proximity sensor, capacitive

Proximity sensor, optical

Proximity sensor with cylinder mounting

Limit switch, electrical, actuation from the left

Limit switch, electrical, actuation from the right

5/2-way solenoid valve

5/2-way double solenoid valve

Cable set with safety plug

Electrical power supply unit, 24 V

TP202 Festo Didactic

Components list

C-122
Solution 20

TP202 Festo Didactic