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Part A – Course
Exercise 1 - 10
When controlling a cylinder, the following actions of piston and piston rod are possible:
Forward stroke (from end position to end position)
Return stroke (from end position to end position)
Remain in the retracted end position
Remain in the forward end position
Motion reversal from an end position
Motion reversal during part of a stroke
Cylinder remains between the end positions (e. g. intermediate position)
The first six actions are put into practice in this chapter. The set of equipment for basic level
TH101 consists of 19 different components (valves, cylinders, gauges, push buttons, etc.). The
set contains some components in duplicate or even in triplicate. Within the first ten exercises,
18 of the 19 different components are used at least twice. (The roller lever valve with idle return
comes into use in exercise 15.)
1. Allocating device
2. Sorting device for metal stampings
3. Separating parcel post
4. Vertical switching point for briquettes
5. Edge folding device
6. Marking machine
7. Separating out plain pins
8. Foil welding drum
9. Swithing point for workpieces
10. Vibrator for paint buckets
We hope you enjoy designing the circuits and assembling the control Systems
1. Allocating device
The allocating device supplies aluminium valve blanks to a
machining station. By operating a push button, the piston rod of
the single-acting cylinder (1A) is made to advance. After releasing
the actuating button, the piston rod returns.
6. Marking machine
Surveyor’s measuring rods in 3 or 5 m length are marked in
red with 200 mm graduations. There is a choice of two push
buttons to start the forward movement of the measuring rods
via cylinder (1A), which has the exhaust air throttled. The idle
stroke, also started by a push button, can only take place
when the double-acting cylinder (1A) has reached its forward
end position.
Exercise 11 – 13
In exercises 11, 12, and 13, two or three cylinders are controlled simultaneously. Cylinders
either move in synchronisation or / and in a pushpull motion. As the cylinders extend and
retract, it is necessary to overcome frictional forces. Frictional forces limiting movement occur
both between piston and cylinder wall and between piston rod and bearing bush. As these
forces are generally not the same for tho cylinders, synchronisation of the moving parts is only
possible unter certain conditions. This problem is shown in exercise 11. Exercise 12 and 13 are
intended to offer a better insight into the matter.
The circuit is switched on by means of a push button valve. A detented valve makes it
possible to change over from signle to continuous cycle. The separating station must not
restart on its own after a power failure. 1A1+ 1A1– 1A2– 1A2+ In this abbreviated form of
notation, movements which occur simultaneously are noted one underneath the other
(1A1+, 1A2– or 1A1–, 1A2+).
Exercise 14 and 15
Exercise 14 is the first exercise in this series with two cylinders extending over more than two
steps. The motion sequence is governed by limit switches (roller lever valves). The main
problem in exercise 15 is the cancelling of pilot signals no longer required at the final control
valve. Locked-on pilot signals in sequential control systems can be influenced pneumatically by
different means. One simple possiblility is the fitting of roller lever valves with idle return. The
use of reversing valves (auxiliary reservoirs) for switching off signals forms a further possibility
(see alternative circuit B). In the course of the follow up to exercise 15, a displacement time
diagram of the assembled system is shown for the first time.
Exercise 16 – 19
In exercises 16 - 19, reversing valves (auxiliary memories, 5/2-way double pilot valves)
are used for switching off signals. The advantage of reversing valve technology over systems
with roller lever valves with idle return lies in the higher reliability of operation.
Several alternative circuits using reversing valves provide an insight into this circuit
technology. In exercise 18, the cylinder carries out a double motion (1A+ 1A- 1A+ 1A-). For this,
a division into four groups is necessary which is achieved by connecting three reversing valves
in series.However, nowadays only circuits with one or two reversing valves are designed.
An even higher level ol operational reliability is achieved by employing stepper modules
from the set of equipment for advanced course TP102 of Learning System for Automation and
Technology. (See alternative solution D, exercise 16, alternative solution C, exercise 17 and
alternative solution B, exercise 18). Within the scope of the follow-up to exercise 16, a
displacement-time diagram of the assembled circuit is drawn up for the second time.
Alternative circuit B: Control system with reversing valve and active signal generators
Alternative circuit C: Control system using roller lever valve with idle return
Alternative circuit D: Control system with steper module (circuit diagram, circuit design)
Square steel end pieces are fed from a gravity magazine to a drilling machine, clamped,
machined and ejected. A horizontally installed double-acting cylinder with exhaust air
throttling (1A) pushes end pieces out of a gravity feed magazine under the drilling
spindle and holds them clamped against the fixed stop. When the required clamping
pressure of p = 4 bar (400 kPa) has been reached, the drilling spindle (2A) extends via
the feed unit with the hydraulic cushioning cylinder, exhaust air likewise throttled, for
lowering the drill. The maximum feed force is set via a pressure regulator. It is set to p =
5 bar (500 kPa). After reaching the adjustable depth control stop established via a roller
lever valve, the unthrottled return stroke is commenced.
Completion of the return stroke causes the finished end piece to be ejected by a single-
acting cylinder (3A). After a period of t = 0.6 seconds, the rapid return stroke is
commenced. When the ejector cylinder has reached the retracted end position, a fourth
roller lever valve is actuated; its signal can be used to indicate a new cycle. A separate
pressure gauge indicates the clamping pressure of the cylinder (1A). A second pressure
gauge is connected to line P2. The control system is set in operation by pressing the
start button. To select continuous cycle a detented valve is reversed. 1A+ 2A+ 2A– 1A–
3A+ 3A–
Exercise 20
In the circuit diagram for a system, distinction is made between:
actuators (e. g. double-acting cylinders)
processors (e. g. dual-pressure valves)
sensors (e. g. roller lever valves)
The binary figures zero and one can be shown by means of a cylinder.
retracted dylinder signifies zero
extended cylinder signifies one
With two cylinders it is possible to show four figures.
20 Pneumatisc counter
Control of two double-acting cylinders via two final control valves. The actuator is
controlled by a processor. The processor receives signals from sensors giving the
position of the actuators. Logic control system
Training contents
1. Characteristics of valves and other components.
2. Uses of individual valves and other components.
3. Comparison of uses and functions of different valves and other components.
4. Measurement of variables such as pressure, flow rate and time.
5. Control of pressure and speed.
6. Calculations of area ratios, forces, power and speed.
7. Basic physical principles of hydraulics.
8. Use of basic hydraulics equations.
9. Understanding and drafting of circuit diagrams.
10. Drafting of displacement/step diagrams.
11. Use of symbols in accordance with DIN/ISO 1219.
12. Assembly and commissioning of control circuits, including faultfinding.
13. Assessment of energy consumption.
14. Basic hydraulic circuits such as a pressure sequence circuit, a bypass circuit to the
pump, a differential circuit, circuits with flow control valves in the inlet, outlet and bypass,
circuits with counter-holding and bypass circuits with a non-return valve.
HYDRAULICS
1. AUTOMATIC LATHE
Training aim :To teach the student how to draw the characteristic curve for a pump
Problem definition :
a. Drawing the hydraulic circuit diagram
b. Practical assembly of the circuit
c. Determining the various measured values and entering them into the table
d. Drawing the characteristic curve for the pump
e. Drawing conclusions
The main spindle on an automatic lathe is driven by a hydraulic motor, while a hydraulic cylinder is used
to execute a feed movement of the workpiece slide. It has been established that the specified speed is no
longer reached during the processing cycle. The pump characteristic curve is therefore to be evaluated
3. DRAWING PRESS
a. To teach the student how to measure flow resistances
b. Drawing the hydraulic circuit diagram
c. Practical assembly of the circuit
d. Setting a constant flow rate
e. Measuring the flow resistances
f. Drawing conclusions
A drawing press is used to shape metal workpieces. Following modification of the hydraulic system, the
workpieces are no longer dimensionally accurate. The reason for this may be that the required press
pressure is not being reached. Use a special test set-up to measure the hydraulic resistance of the
components used
Rolls of paper are lifted into a calender by a lifting device. The lifting device is
driven by a plunger cylinder (single-acting cylinder). When the hydraulic power pack is switched on, the
pump output flows directly to the cylinder. A 2/2-way valve, which is closed in its normal position, is fitted
in a branch line leading to the tank. A non-return valve is used to ensure that the pump is protected
against the oil back-pressure. A pressure relief valve is fitted upstream of the non-return valve to
safeguard the pump against excessive pressures.
5. HARDENING FURNACE
a. To familiarise the student with the applications of a 3/2-way
valve
b. To show how to determine times, pressures and forces during
the advance and return strokes of a single-acting cylinder
c. Drawing the hydraulic circuit diagram
d. Determining the necessary components
e. Practical assembly of the circuit
f. Measuring the travel pressure and travel time for the advance
and return strokes
g. Calculating the required advance-stroke pressure
h. Calculating the advance-stroke speed and time
The cover of a hardening furnace is to be raised by a single-acting cylinder. The cylinder is activated
by a 3/2-way valve. A 9 kg weight is attached to the cylinder to represent the load. Measure and
calculate the following values: . Travel pressure, load pressure, resistances and back pressure .
Advance-stroke time and speed
Parts are fed through a drying oven on a steel chain conveyor belt. It must be possible to correct the
tracking of the belt by means of a tensioning device to ensure that the belt does not run off its rollers.
This device consists of a steel roller fixed at one end and movable at the other by means of a double-
acting cylinder. Hydraulic power must be available continuously. The hydraulic system must switch to
the recirculating (pump bypass) condition when the directional control valve is not actuated. The
clamping station causes a continuous counter force to act on the cylinder. A piloted non-return valve is
used to prevent creepage of the piston rod of the positioning cylinder as a result of oil leakage losses
in the directional control valve. For the purposes of comparison, calculate the required drive power for
circuits firstly with a 4/3-way valve, recirculating in mid-position and secondly with a 4/3-way valve,
closed in mid-position.
8. COLD-STORE DOOR
a. To show the use of a hydraulic accumulator as a power source
b. To show how to use the accumulator to power advance and return strokes of the cylinder after the
pump is switched off
c. Drawing the hydraulic circuit diagram
d. Determining the necessary components
e. Practical assembly of the circuit
f. Determining the number of working cycles possible after the pump is switched off
g. Drawing conclusions
h. Explaining the design and mode of operation of a diaphragm accumulator
i. Naming possible applications of an accumulator
A heavy cold-store door is opened and closed by a hydraulic cylinder. A hydraulic accumulator is to be
installed to allow the door to be closed in the case of an electrical power failure. This will permit the
cold-store door to be opened and closed a number of times. A 4/2-way valve is to
be used to activate the cylinder. This valve should be connected up in
such a way that the piston rod is advanced with the valve in its normal
position.
No provision will be made here for the safety cut-out which is essential
to prevent persons from becoming trapped in the door. This cut-out
function is normally provided by an electrical control device for the
hydraulic system. Be sure to follow the operating instructions for the
accumulator. After switching off the control system, do not dismantle
the hydraulic components until you have relieved the pressure in the
accumulator and isolated this from the control system by means of the
built-in shut-off valve. It is essential to relieve the accumulator
pressure via a flow control valve!
Several stations on a rotary machining station are driven by a hydraulic power pack. As individual
stations are switched on and off, they produce pressure fluctuations throughout the hydraulic circuit.
This effect will be studied on a drilling station. The fluctuations in pressure and the tractive forces
created during drilling must not affect the feed of the drilling station. A flow control valve is to be used
to ensure a smooth adjustable feed rate, while a pressure relief valve is to be used as a counter-
holding valve to compensate for the tractive forces.
An endless chain conveyor feeds workpieces through a painting booth. The chain is driven by a
hydraulic motor via a right-angle gear unit. Due to changes in the production process, the weight of
the workpieces passing through the painting booth has changed. The speed of the conveyor should,
however, remain the same as before. It must be determined whether this can be achieved by fitting a
flow control valve, and if so which type is suitable.
A special machine is used to emboss graphic symbols on metal foil. The foil is fed through the
embossing machine with an adjustable cycle time. The downward motion of the stamp must be
capable of being varied in accordance with the feed speed. The return motion must always be
executed as a rapid traverse. A one-way flow control valve is used to control the speed of the
stamp, while a pressure relief valve is used to prevent the weight of the stamp from pulling the
piston rod out of the cylinder. A 4/2-way valve is used to switch between upwards and downwards
motion
The grinding table of a surface grinding machine is driven by a hydraulic cylinder. Since the speed is
required to be the same in both directions, the hydraulic control circuit must be designed to provide
compensation for the difference in volume of the two cylinder chambers. A differential circuit is
suggested with a 3/2-way valve and a flow control valve for speed adjustment.
A double-acting cylinder is used to open and close a bulkhead door. Closing must be carried out
smoothly and at a constant adjustable speed. The speed is adjusted by means of a one-way flow
control valve. A pressure relief valve must be fitted to provide counter-holding and prevent the heavy
door from pulling the piston rod out of the cylinder during the closing operation.
The loading ramp of a car ferry must be capable of being set to different heights. The ramp is raised
and lowered by a hydraulic cylinder. This motion must be carried out smoothly and at a constant
speed. A flow control valve is to be used to adjust the speed. This must be installed in such a way as
to prevent excessive pressures from developing within the system.
Exercise 16
The loading and unloading of skips from a skip transporter is carried out using two double-acting
cylinders. Each cylinder is subject to varying loads – tractive load during unloading and
compressive load during loading. The skip should be raised and lowered at a slow constant speed.
Each cylinder must therefore be hydraulically clamped on both sides.
Exercise 19
An assembly device is used to press workpieces together for drilling. The operating sequence is
described in exercise 18. Our objective here is to check the pressing operation of cylinder 1A1
mathematically. Determine the press-fitting force using the given data. Note that, while the press-fitting
pressure is available as specified, the resistances of the lines and directional control valve cause an
opposing pressure to act on the annular piston side, thus reducing the actual force available.The flow
rate is kept constant by a flow control valve. This together with the cylinder stroke is used to calculate
the travel time for the press-fitting operation.
A conveyor belt transports metal swarf into a tipping container. When the
container is full, it is emptied into a truck. A double-acting cylinder is used for this purpose, activated
by a solenoid-actuated 4/3-way valve. The piston rod of the cylinder is advanced while the container
is in position to receive swarf. To enable the hydraulic power pack to be switched off during this time,
the piston rod of the cylinder must be protected by hydraulic means against undesired retraction
(caused by leakage in the valve). The electrical activation of the valve must be manually controlled,
i.e. the cylinder must move only when the “Up” or “Down” pushbuttons are pressed.