Đang tải... (xem toàn văn)
The Festo Didactic Learning system has been developed and produced solely for vocational and further training in the field of automation and technology. The training company and/or instructor need to ensure that trainees observe the safety precautions specified in this workbook. Festo Didactic hereby disclaims any legal liability for damages or injury to trainees, the training company and/or other parties, which may occur during the use/application of this equipment set other than in a training situation and unless such damages are caused with intention or through gross negligence on the part of Festo Didactic.
Electropneumatics Advanced Level Workbook TP 202 CD-ROM included Festo Didactic 541091 en Intended use The Festo Didactic Learning system has been developed and produced solely for vocational and further training in the field of automation and technology The training company and/or instructor need to ensure that trainees observe the safety precautions specified in this workbook Festo Didactic hereby disclaims any legal liability for damages or injury to trainees, the training company and/or other parties, which may occur during the use/application of this equipment set other than in a training situation and unless such damages are caused with intention or through gross negligence on the part of Festo Didactic Order No.: Status: Authors: Editor: Graphics: Layout: 541091 04/2005 M Pany, S Scharf Frank Ebel Doris Schwarzenberger 10/2005 © Festo Didactic GmbH & Co KG, 73770 Denkendorf, Germany, 2005 Internet: www.festo-didactic.com e-mail: did@festo.com The copying, distribution and utilisation of this document as well as the communication of its contents to others without express 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 registration Parts of this documentation may be copied by the authorised user exclusively for training purposes © Festo Didactic GmbH & Co KG • 541091 Contents Preface Introduction Notes on safety and operation _ Technology packages for electropneumatics (TP200) _ 11 Training aims of Advanced Level (TP202) _ 13 Allocation of training aims and exercises _ 15 Equipment set – Advanced Level (TP202) _ 17 Allocation of equipment and exercises _ 21 Methodological help for the trainer 23 Methodological structure of the exercises _ 25 Designation of equipment _ 26 Contents of the CD-ROM _ 27 Equipment set – Basic Level (TP201) _ 29 Training aims – Basic Level (TP201) 30 Part A – Exercises Exercise 1: Realising a diverting device _A-3 Exercise 2: Insertion of drinks bottles _A-15 Exercise 3: Realising a selection station _A-23 Exercise 4: Machining of key blanks A-39 Exercise 5: Bending of mounting brackets _A-49 Exercise 6: Realising a filling system A-57 Exercise 7: Bonding of components _A-67 Exercise 8: Selecting modes of operation A-75 Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function A-85 Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function A-95 Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function A-103 Exercise 12: Eliminating a fault on a machining station _ A-113 © Festo Didactic GmbH & Co KG • 541091 Contents Part B – Fundamentals Part C – Solutions Exercise 1: Realising a diverting device _C-3 Exercise 2: Insertion of drinks bottles _C-13 Exercise 3: Realising a selection station _C-21 Exercise 4: Machining of key blanks C-37 Exercise 5: Bending of mounting brackets C-47 Exercise 6: Realising a filling system C-57 Exercise 7: Bonding of components _C-67 Exercise 8: Selecting modes of operation C-75 Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function C-85 Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP function C-95 Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function _C-107 Exercise 12: Eliminating a fault on a machining station C-117 Part D – Appendix Organiser _ D-2 Assembly technology D-3 Plastic tubing _ D-4 Data sheets Circuit diagrams © Festo Didactic GmbH & Co KG • 541091 Preface Festo Didactic’s Learning System for Automation and Technology is orientated towards different training and vocational requirements and is therefore structured into the following training packages: • Basic packages to provide technology-spanning basic knowledge • Technology packages to address the major subjects of open and closed-loop technology • Function packages to explain the basic functions of automated systems • Application packages to facilitate vocational and further training based on actual industrial applications The technology packages deal with the following technologies: Pneumatics, electropneumatics, programmable logic controllers, automation using a personal computer, hydraulics, electrohydraulics, proportional hydraulics and handling technology â Festo Didactic GmbH & Co KG ã 541091 Preface The modular design of the learning system enables applications beyond the limits of the individual packages For example, to facilitate PLC actuation of pneumatic, hydraulic and electrical drives All the training packages are of identical structure: • Hardware • Teachware • Software • Seminars The hardware consists of didactically designed industrial components and systems The didactic, methodological design of the teachware is harmonised with the training hardware and comprises: • Textbooks (with exercises and examples) • Workbooks (with practical exercises, additional information, solutions and data sheets) • Overhead transparencies and videos (to create an interesting and lively training environment) Tuition and training media are available in several languages and are suitable for use both in the classroom and for self-tuition Software is available in the form of computer training programs and programming software for programmable logic controllers A comprehensive range of seminars dealing with the topics of the technology packages completes the range of vocational and further training available © Festo Didactic GmbH & Co KG • 541091 Introduction This workbook is a component part of the Learning System for Automation and Technology of Festo Didactic GmbH & Co KG This system provides a solid basis for practice-oriented vocational and further training Technology package TP200 is comprised exclusively of electropneumatic control systems Basic Level TP201 is suitable for basic training in electropneumatic control technology and provides knowledge regarding the physical fundamentals of electropneumatics and the function and use of electropneumatic equipment The equipment set enables you to construct simple electropneumatic control systems Advanced Level TP202 focuses on further training in electropneumatic control technology The two equipment sets enable you to construct complex combinational circuits with logic operations of input and output signals and program controls Prerequisite for the assembly of control systems is a fixed workstation using a Festo Didactic profile plate, consisting of 14 parallel T-slots with 50 mm spacing A shortcircuit protected power supply unit (input: 230 V, 50 Hz, output: 24 V, max A) is used for DC voltage supply A mobile, silenced compressor (230 V, maximum bar (800 kPa) can be used for compressed air supply Working pressure must not exceed a maximum of p = bar (600 kPa) Optimum operational reliability is achieved if the control system is operated unlubricated at a working pressure of p = bar = 500 kPa The equipment set of Basic Level TP201 is used to construct complete control systems for all of the 12 problem definitions The theoretical fundamentals to help you understand this collection of exercises can be found in the textbook • Electropneumatics Also available are data sheets in respect of the individual devices (cylinders, valves, measuring devices, etc.) © Festo Didactic GmbH & Co KG • 541091 Introduction â Festo Didactic GmbH & Co KG ã 541091 Notes on safety and operation The following advice should be observed in the interest of your own safety: • Pressurised air lines that become detached can cause accidents Switch off supply immediately • Do not switch on compressed air until tubing is securely connected • Caution! Cylinders may advance automatically as soon as the compressed air is switched on • Do not operate an electrical limit switch manually during fault finding (use a tool) • Observe general safety regulations (DIN 58126 and VDE 100) • With electrical limit switches you need to distinguish between two designs – Actuation from the left – Actuation from the right • At high piston speeds, limit switches must be approached only in the designated direction of the trip cam of the cylinder Limit switches must not be actuated from the front • Do not exceed the permissible working pressure (see data sheets) • Only use extra-low voltage ≤ 24V • All components are equipped with mm safety sockets, i.e jack plugs Only use cables with jack plugs for the electrical connections • Pneumatic circuit assembly: Connect devices using the silver-metallic plastic tubing of mm outer diameter, the tubing is plugged into the push-in fitting up to the stop; no need for securing! • Releasing of push-in fitting: The tubing can be released by pressing down the releasing ring (disconnection under pressure is not possible!) • Switch off compressed air supply and power supply prior to dismantling the circuit © Festo Didactic GmbH & Co KG • 541091 Notes on safety and operation • The mounting plates of the devices are equipped with mounting variants A to D: Variant A, latching system For lightweight non-loadable devices (e.g directional control valves) Simply clip the device into the slot in the profile plate Devices can be released by pressing the blue lever Variant B, rotary system Medium weight loadable devices (e.g actuators) These devices are clamped onto the profile plate by means of T-head bolts Clamping and releasing is effected by means of the blue knurled nut Variant C, screw system For heavy loadable devices rarely removed from the profile plate (e.g On/off valves with filter regulating valve) These components are mounted by means of socket head screws and T-head bolts Variant D, plug-in system Lightweight non-loadable devices with locking pins (e.g indicating devices) These devices are attached by means of plug-in adapters • The data for the individual devices, as specified in the data sheets in Part D, must be observed 10 © Festo Didactic GmbH & Co KG • 541091 Training aims of Basic Level (TP201) • To familiarise yourself with the design and mode of operation of a single-acting cylinder • To familiarise yourself with the design and mode of operation of a double-acting cylinder • To be able to calculate piston forces according to specified values • To familiarise yourself with the design and mode of operation of a 3/2-way solenoid valve • To familiarise yourself with the design and mode of operation of a double solenoid valve • To be able to select solenoid valves according to requirements • To be able to identify and draw the various types of actuation of directional control valves • To be able to convert solenoid valves • To be able to explain and design an example of direct actuation • To be able to explain and design an example of indirect actuation • To familiarise yourself with logic functions and to design these • To familiarise yourself with different types of end position control and to be able to select a suitable type • To be able to calculate electrical characteristic values • To familiarise yourself with latching circuits with different characteristics • To be able to explain and design an electrical latching circuit with dominant switch-off signal • To be able to design a pressure-dependent control system • To familiarise yourself with the design and mode of operation of magnetic proximity sensors • To familiarise yourself with displacement-step diagrams and to be able to design these for specified problem definitions • To be able to realise a sequence control using two cylinders • To be able to identify and eliminate errors in simple electropneuamtic control systems 30 © Festo Didactic GmbH & Co KG • 541091 Contents Part A – Exercises Exercise 1: Realising a diverting device _A-3 Exercise 2: Insertion of drinks bottles _A-15 Exercise 3: Realising a selection station _A-23 Exercise 4: Machining of key blanks A-39 Exercise 5: Bending of mounting brackets _A-49 Exercise 6: Realising a filling system A-57 Exercise 7: Bonding of components _A-67 Exercise 8: Selecting modes of operation A-75 Exercise 9: Machining of key blanks and the use of an EMERGENCY-STOP function A-85 Exercise 10: Bending of mounting brackets and the use of an EMERGENCY-STOP FUNCTION A-95 Exercise 11: Conveying bars of chocolate and the use of an EMERGENCY-STOP function A-103 Exercise 12: Eliminating a fault on a machining station _ A-113 © Festo Didactic GmbH & Co KG ã 541091 A-1 Contents A-2 â Festo Didactic GmbH & Co KG • 541091 Exercise 1: Realising a diverting device Training aims • To familiarise yourself with the design and function of valve terminals • To be able to use valve terminals in accordance with requirements Problem definition Drinks bottles are to be diverted from one conveyor to another using a diverting device By pressing a pushbutton the frame of the diverting device is to advance A bottle is transferred and conveyed in the opposite direction By pressing another pushbutton, the frame is to return into the initial position Parameters • A double-acting cylinder is to be used • Cylinder control is to be realised indirectly and via a pushbutton • In the event of a power failure the cylinder piston rod is to remain in the assumed position Project task Answer the questions or carry out the exercises regarding the fundamentals of the training contents listed Draw the pneumatic and electrical circuit diagrams Simulate the electropneumatic circuit diagram and check its correct functioning Compile an equipment list Carry out the pneumatic and electrical circuit assembly Check the circuit operation © Festo Didactic GmbH & Co KG • 541091 A-3 Exercise 1: Realising a diverting device Positional sketch Diverting device for drinks bottles Cylinder 1A1 is in the retracted end position The 5/2-way double solenoid valve 1V1 is to switch by pressing pushbutton S1 and the cylinder to move into the forward end position The 5/2-way double solenoid valve is to reverse by pressing pushbutton S2 and the cylinder to move into the retracted end position A-4 © Festo Didactic GmbH & Co KG • 541091 Exercise 1: Realising a diverting device Exercise 1: Realising a diverting device Name: Date: Fundamentals: Installation costs Sheet of The configuration, tubing and wiring of the components of an electropneumatic control system should be selected such as to keep the sum total of equipment, installation and maintenance costs as low as possible The following choices are available as regards wiring: • Conventional wiring technology, e.g terminal strips • Advanced installation concepts, e.g wiring using multi-pin connectors The following choices are available in respect of configuration, i.e number of drives and tubing requirements: • Individual mounting of solenoid operated directional control valves • Block mounting (manifold or valve terminal) © Festo Didactic GmbH & Co KG • 541091 A-5 Exercise 1: Realising a diverting device Exercise 1: Realising a diverting device Name: Date: Fundamentals: Installation costs Sheet of – Compare the above listed concepts using the example of this control system in terms of reducing the tubing costs Note Use the individual valves from TP201 or the MPA valve terminal from TP202 and the respective technical descriptions Components Individual mounting Block mounting of Saving when using of directional control valves directional control valves block mounting Tubing Number of compressed air distribution units Amount of tubing for supply to compressed air distribution unit Amount of tubing for compressed air supply to control chains Amount of tubing between directional control valves and cylinders Silencers Number of silencers for control chains A-6 © Festo Didactic GmbH & Co KG • 541091 Exercise 1: Realising a diverting device Exercise 1: Realising a diverting device Name: Date: Fundamentals: Installation costs Sheet of – Which concept enables you to achieve a reduction in tubing costs? Explain the reason for your choice Note Use the individual valves from TP201 or the MPA valve terminal from TP202 and the respective technical descriptions Reason Block mounting of of directional control valves © Festo Didactic GmbH & Co KG • 541091 Individual mounting directional control valves A-7 Exercise 1: Realising a diverting device Exercise 1: Realising a diverting device Name: Date: Fundamentals: Installation costs Sheet of – Compare the above listed concepts using the example of this control system with regard to reducing wiring costs Note Use the individual valves of TP201 or the MPA valve terminal from TP202 and the respective technical descriptions Wiring table Components Cables Number of Number of terminals/components terminals/components Multi-pin wiring concept Conventional wiring technology Control cabinet Terminal strip in control cabinet 1 Earthing cable Supply voltage (24 V) PLC outputs (actuation of solenoid coils) PLC inputs (evaluation of proximity sensors) Terminal strip in control cabinet, overall Cable from control cabinet to terminal box Cable between terminal strips and Cable from terminal strip Proximity sensors (3 wires per (in terminal box) proximity sensor) Solenoids (2 wires per solenoid) Terminal strip 2, overall Cable to directional control valves and sensors A-8 Connection of solenoid coils Connection of sensors â Festo Didactic GmbH & Co KG ã 541091 Exercise 1: Realising a diverting device Exercise 1: Realising a diverting device Name: Date: Fundamentals: Reducing the wiring costs Sheet of – Which concept enables you to achieve a reduction in wiring costs? Explain the reason for your choice Note Use the individual valves from TP201 or the MPA valve terminal from TP202 and the respective technical descriptions Reason â Festo Didactic GmbH & Co KG ã 541091 Conventional wiring Multi-pin wiring technology concept A-9 Exercise 1: Realising a diverting device Exercise 1: Realising a diverting device Name: Date: Completing the pneumatic and electrical circuit diagrams Sheet of – Complete the pneumatic circuit diagram for the diverting device Pneumatic circuit diagram with individual valve A-10 © Festo Didactic GmbH & Co KG • 541091 Exercise 1: Realising a diverting device Exercise 1: Realising a diverting device Name: Date: Completing the pneumatic and electrical circuit diagrams Sheet of – Complete the pneumatic circuit diagram for the diverting device 0V1 -VM S 14 3/5 82/84 12/14 14 -M1 3/5 82/84 12/14 -VM -M1 3/5 82/84 12/14 1V1 J 14 1M1 3/5 82/84 12/14 -VJ 1M2 12 14 -M1 3/5 82/84 12/14 -M2 12 3/5 82/84 12/14 1 Pneumatic circuit diagram with valve terminal (circuit diagram in DIN A3 format in Part D) © Festo Didactic GmbH & Co KG • 541091 A-11 Exercise 1: Realising a diverting device Exercise 1: Realising a diverting device Name: Date: Completing the pneumatic and electrical circuit diagrams Sheet of – Complete the electrical circuit diagram for the diverting device +24 V A1 0V A1 A2 A2 11 12 14 11 12 14 21 22 24 21 22 24 31 32 34 31 32 34 41 42 44 41 42 44 Electrical circuit diagram A-12 © Festo Didactic GmbH & Co KG • 541091 Exercise 1: Realising a diverting device Exercise 1: Realising a diverting device Name: Date: Compiling the equipment list Sheet of Apart from the circuit diagram, comprehensive project documentation also requires an equipment list – Compile the equipment list by entering the required equipment in the table below Quantity Description Equipment list â Festo Didactic GmbH & Co KG ã 541091 A-13 Exercise 1: Realising a diverting device A-14 © Festo Didactic GmbH & Co KG • 541091 ... electropneumatics (TP20 0) _ 11 Training aims of Advanced Level (TP20 2) _ 13 Allocation of training aims and exercises _ 15 Equipment set – Advanced Level (TP20 2) ... systems 16 © Festo Didactic GmbH & Co KG • 541091 Equipment set – Advanced Level (TP20 2) The equipment set for the advanced level has been compiled for further training in electro-pneumatic control... _ 26 Contents of the CD-ROM _ 27 Equipment set – Basic Level (TP20 1) _ 29 Training aims – Basic Level (TP20 1) 30 Part A –