Closed loop control hydraulics (Workbook) Learning System for Automation and Technology 094469 Closed loop hydraulics Workbook TP511 • Festo Didactic Authorised applications and liability The Learning[.]
Learning System for Automation and Technology Closed loop hydraulics Workbook 094469 Authorised applications and liability The Learning System for Automation and Communication has been developed and prepared exclusively for training in the field of automation and communication The training organisation 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 organisation 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: 094469 ARBB.REGELH.GS D:S511-C-SIBU-GB 08/2000 17.08.2000, OCKER Ingenieurbüro OCKER Ingenieurbüro A.Zimmermann, D.Scholz © Copyright by Festo Didactic GmbH & Co., D-73770 Denkendorf 2000 The copying, distribution and utilisation of this document as well as the communication of its contents to others without expressed authorisation 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 TP511 • Festo Didactic Preface Festo Didactic’s Learning System for Automation and Communications is designed to meet a number of different training and vocational requirements The Training Packages are structured accordingly: Basic Packages provide fundamental knowledge which is not limited to a specific technology Technology Packages deal with the important areas of open-loop and closed-loop control technology Function Packages explain the basic functions of automation systems Application Packages provide basic and further training closely oriented to everyday industrial practice Technology Packages deal with the technologies of pneumatics, electropneumatics, programmable logic controllers, hydraulics, electrohydraulics, proportional hydraulics closed loop pneumatics and hydraulics Fig 1: Example of Hydraulics 2000: Mobile laboratory trolley Mounting frame U = 230V~ Profile plate p = MPa Storage tray TP511 • Festo Didactic The modular structure of the Learning System permits applications to be assembled which go beyond the scope of the individual packages It is possible, for example, to use PLCs to control pneumatic, hydraulic and electrical actuators All training packages have an identical structure: Hardware Courseware Software Courses The hardware consists of industrial components and installations, adapted for didactic purposes The courseware is matched methodologically and didactically to the training hardware The courseware comprises: Textbooks (with exercises and examples) Workbooks (with practical exercises, explanatory notes, solutions and data sheets) OHP transparencies, electronic transparencies for PCs and videos (to bring teaching to life) Teaching and learning media are available in several languages They have been designed for use in classroom teaching but can also be used for self-study purposes In the software field, CAD programs, computer-based training programs and programming software for programmable logic controllers are available Festo Didactic’s range of products for basic and further training is completed by a comprehensive selection of courses matched to the contents of the technology packages TP511 • Festo Didactic Latest information about the technology package Closed loop hydraulics TP511 New in Hydraulic 2000: Industrial components on the profile plate Exercises with exercise sheets and solutions, leading questions 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 equipment lists Part D Appendix Storage tray, mounting technology and datasheets TP511 • Festo Didactic Table of contents Technology package TP511 “Closed loop hydraulics” 12 Safety recommendations 13 Notes on procedure 13 Standard method of representation used in circuit diagrams 14 Technical notes 15 Component/exercise table 16 Equipment set TP511 18 Section A – Course Pressure control loop Exercise 1: Exercise 2: Exercise 3: Exercise 4: Exercise 5: Exercise 6: Exercise 7: Exercise 8: Exercise 9: Pipe-bending machine Characteristics of a pressure sensor A-3 Forming plastic products Pressure characteristic curve of a dynamic directional control valve A-13 Cold extrusion Regulated pressure control A-25 Thread rolling machine Characteristics of a PID controller card A-33 Stamping machine Transition function of a P controller A-39 Clamping device Control quality of a pressure control loop with P controller A-49 Injection moulding machine Transition functions of I and PI controllers A-61 Pressing-in of bearings Transition functions of D, PD and PID controllers A-75 Welding tongs of a robot Empirical setting of parameters of a PID controller A-89 Exercise 10: Pressure roller of a rolling machine Setting parameters using the Ziegler-Nichols method A-97 TP511 • Festo Didactic Exercise 11: Edge-folding press with feeding device Modified controlled system with disturbance variables A-105 Position control loop Exercise 12: Table-feed of a milling machine Characteristic curve of a displacement sensor A-115 Exercise 13: X/Y-axis table of a drilling machine Flow characteristic curves of a dynamic directional control valve A-125 Exercise 14: Feed unit of an assembly station Linear unit as controlled system for position control A-141 Exercise 15: Automobile simulator Assembly and commissioning of a position control loop A-159 Exercise 16: Contour milling Lag error in position control loop A-173 Exercise 17: Machining centre Position control with modified controlled system A-185 Exercise 18: Drilling of bearing surfaces Commissioning of a position control loop with disturbance variables A-191 Exercise 19: Feed on a shaping machine Characteristics and transition functions of a status controller A-205 Exercise 20: Paper feed of a printing machine Parameterisation of a status controller A-215 Exercise 21: Horizontal grinding machine Position control loop with disturbance variables and active load A-227 TP511 • Festo Didactic Section B – Fundamentals Chapter Fundamentals B-3 1.1 Signals B-4 1.2 Block diagram B-8 1.3 Signal flow diagram B-10 1.4 Test signals B-12 1.5 Open-loop and closed-loop control B-14 1.6 Terminology of closed-loop technology B-16 1.7 Stability and instability B-19 1.8 Steady-state and dynamic behaviour B-20 1.9 Response to setpoint changes and interference B-23 1.10 Fixed-value, follower and timing control systems B-25 1.11 Differentiation of a signal B-27 1.12 Integration of a signal B-31 Chapter Hydraulic controlled systems B-35 2.1 Controlled systems with and without compensation B-37 2.2 Short-delay hydraulic controlled systems B-39 2.3 First-order hydraulic controlled systems B-40 2.4 Second-order hydraulic controlled systems B-41 2.5 Third-order hydraulic controlled systems B-43 2.6 Classification of controlled systems according to the step response behaviour B-45 Operating point and system gain B-46 2.7 Chapter Controller structures B-49 3.1 Non-dynamic controllers B-51 3.2 Block diagrams for non-dynamic controllers B-53 3.3 P controller B-55 3.4 I controller B-57 3.5 D controller element B-59 3.6 PI, PD and PID controller B-62 TP511 • Festo Didactic 3.7 Block diagrams for dynamic standard controllers B-68 3.8 Status controllers B-72 3.9 Selection of controller structure B-75 3.10 Response to interference and control factor B-77 Chapter Technical implementation of controllers B-83 4.1 Structure of closed control loops B-84 4.2 Hydraulic and electrical controllers B-90 4.3 Analogue and digital controllers B-92 4.4 Selection criteria for controllers B-95 Chapter Directional control valves B-97 5.1 Valve designs B-98 5.2 Purpose and modules of a directional control valve B-99 5.3 Designations and symbols for dynamic directional control valves B-102 5.4 Mode of operation of a dynamic 4/3-way valve B-105 5.5 Steady-state characteristic curves of dynamic directional control valves B-111 Dynamic behaviour of dynamic directional control valves B-116 Selection criteria for directional control valves B-120 5.6 5.7 Chapter Pressure regulators B-121 6.1 Function of a pressure regulator B-122 6.2 Pressure regulator designs B-123 6.3 Mode of operation of a pressure regulator B-124 6.4 Pressure control with a directional control valve B-128 6.5 Selection criteria for pressure regulating valves B-129 Chapter Measuring systems B-131 7.1 Function of a measuring system B-132 7.2 Measuring system designs and interfaces B-133 7.3 Selection criteria for measuring systems B-136 TP511 • Festo Didactic 10 Chapter Assembly, commissioning and fault finding B-137 8.1 Closed control loops in automation B-138 8.2 Planning B-141 8.3 Assembly B-144 8.4 Commissioning B-146 8.5 Controller setting B-149 8.6 Fault finding B-155 Section C – Solutions Exercise 1: Pipe-bending machine C-3 Exercise 2: Forming of plastic products C-5 Exercise 3: Cold extrusion C11 Exercise 4: Thread rolling machine C-13 Exercise 5: Stamping machine C-15 Exercise 6: Clamping device C-19 Exercise 7: Injection moulding machine C-23 Exercise 8: Pressing-in of bearings C-25 Exercise 9: Welding tongs of a robot C-29 Exercise 10: Pressure roller of a rolling machine C-31 Exercise 11: Edge-folding press with feeding device C-35 Exercise 12: Table-feed of a drilling machine C-39 Exercise 13: X/Y-axis table of a drilling machine C-41 Exercise 14: Feed unit of an assembly station C-49 Exercise 15: Automobile simulator C-55 Exercise 16: Contour milling C-61 Exercise 17: Machining centre C-65 Exercise 18: Drilling of bearing surfaces C-67 Exercise 19: Feed on a shaping machine C-73 Exercise 20: Paper feed of a printing machine C-77 Exercise 21: Horizontal grinding machine C-81 TP511 • Festo Didactic ... electropneumatics, programmable logic controllers, hydraulics, electrohydraulics, proportional hydraulics closed loop pneumatics and hydraulics Fig 1: Example of Hydraulics 2000: Mobile laboratory... commissioning of a position control loop A-159 Exercise 16: Contour milling Lag error in position control loop A-173 Exercise 17: Machining centre Position control with modified controlled system A-185... diagram B-8 1.3 Signal flow diagram B-10 1.4 Test signals B-12 1.5 Open -loop and closed- loop control B-14 1.6 Terminology of closed- loop technology B-16 1.7 Stability and instability B-19 1.8 Steady-state