Tài liệu kỹ thuật điện - khí nén của hãng Festo ( advanced level )

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.

Workbook TP 202

CD-ROM included

Electropneumatics

Advanced Level

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

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

Intended use

Preface 5 Introduction 7 Notes on safety and operation _ 9 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

Contents

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’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

Preface

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

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 short-circuit protected power supply unit (input: 230 V, 50 Hz, output: 24 V, max 5 A) is used for DC voltage supply A mobile, silenced compressor (230 V, maximum 8 bar (800 kPa) can be used for compressed air supply

Working pressure must not exceed a maximum of p = 6 bar (600 kPa)

Optimum operational reliability is achieved if the control system is operated unlubricated at a working pressure of p = 5 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.)

Introduction

Introduction

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

• 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 4 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 4 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

Notes on safety and operation

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

The technology package TP200 consists of numerous individual training media as well as seminars The subject matter of this package is exclusively electropneumatic control systems Individual components from the technology package TP200 may also form a component part of other packages

• Fixed workstation with Festo Didactic profile plate

• Compressor (230 V, 0.55 kW, maximum 8 bar (800 kPa)

• Equipment sets or individual components

• Optional training aids

• Practical training models

• Complete laboratory setups

Training documentation

Fundamentals of pneumatic control technology Maintenance of pneumatic devices and systems

Advanced Level TP202 Optional Teachware Sets of overhead transparencies and overhead projector

Magnetic symbols, drawing template WBT Fluid Studio Electropneumatics Cutaway model sets 1 + 2 with storage case Simulation software FluidSIM ® Pneumatic

Technology package for electropneumatics (TP200)

Important elements of

TP200

Technology package for electropneumatics (TP200)

Seminars P111 Fundamentals of pneumatics and electropneumatics P121 Maintenance of and fault finding on pneumatic and electropneumatic systems IW-PEP Maintenance and servicing in control technology – pneumatic and electropneumatic

control circuits EP-AL Electropneumatics for vocational training

Details of venues, dates and prices can be found in the current seminar planner

Information regarding further training media is available in our catalogues and on the Internet The Learning System for Automation and Technology is continually updated and expanded The sets of overhead transparencies, films, CD-ROMs and DVDs as well as technical books are available in several languages

• To familiarise yourself with the design and function of valve terminals

• To be able to use valve terminals in accordance with requirements

• To be able to design a displacement-step diagram for a sequence control

• To be able to transcribe a function chart to GRAFCET

• To be able to solve the problem of signal overlaps in a sequence control according to the group method

• To be able to detect signal overlaps in a sequence control

• To be able to design a sequence chain using spring-return valves

• To be able to design a sequence chain using double solenoid valves

• To familiarise yourself with the mode of operation of different proximity sensors

• To be able to select proximity sensors in line with parameters

• To familiarise yourself with logic operations and to be able to realise these

• To familiarise yourself with the design and function of a pneumatic-electrical converter

• To familiarise yourself with the options for sensing pressure and time in pneumatic control systems

electro-• To familiarise yourself with the function and possible applications of a time relay with switch-on delay

• To familiarise yourself with modes of circuit operation and to be able to design circuits with which single cycle and continuous cycle modes can be realised

• To familiarise yourself with the function of an electrical preselect counter and to

be able to use this in circuits

• To be able to develop and design the EMERGENCY-STOP function for a control system with spring-return valves

• To be able to develop and design the EMERGENCY-STOP function for a control system with double solenoid valves

• To be able to design a specified motion sequence with EMERGENCY-STOP

• To be able to design the EMERGENCY-STOP condition „Cylinder remains in its current position during EMERGENCY-STOP“

• To familiarise yourself with the design and mode of operation of a 5/3-way valve

• To be able to replace a 5/3-way solenoid valve with 3/2-way solenoid valves

• To be able to integrate the mode of operation „resetset“

• To be able to identify and eliminate faults in complex electropneumatic control systems

Training aims of Advanced Level (TP202)

Training aims of Advanced Level (TP202)

Exercise 1 2 3 4 5 6 7 8 9 10 11 12

To familiarise yourself with the design

and function of valve terminals

To be able to use valve terminals in

accordance with requirements • •

To be able to solve the problem of

signal overlap in a sequence control

according to the group method

•

To be able to design a

displacement-step diagram for a sequence control

To be able to transcribe a function

chart to GRAFCET

•

To be able to design a sequence chain

with spring-return valves

•

To be able to detect signal overlaps in

a sequence control

•

To be able to design a sequence chain

using double solenoid valves

•

To familiarise yourself with the mode

of operation of different proximity

sensors

•

To be able to select proximity sensors

in line with parameters

•

To familiarise yourself with logic

operations and to be able to realise

these

•

To familiarise yourself with the

options for sensing pressure and time

in electro-pneumatic control systems

•

To familiarise yourself with the design

and function of a pneumatic-electrical

converter

•

To familiarise yourself with the

function and possible applications of a

time relay with switch-on delay

•

Allocation of training aims and exercises

Allocation of training aims and exercises

To familiarise yourself with modes of

circuit operation and to be able to

design circuits with which single cycle

and continuous cycle modes can be

realised

To familiarise yourself with the

function of an electrical preselect

counter and to be able to use this in

circuits

•

To be able to develop and design the

EMERGENCY-STOP function for a

control system with spring-return

valves

•

To be able to develop the

EMERGENCY-STOP function for a

control system using double solenoid

valves

•

To be able to develop and design a

specified motion sequence with

EMERGENCY-STOP

•

To be able to design the

EMERGENCY-STOP condition „Cylinder remains in

its current position“ during

EMERGENCY-STOP

•

To familiarise yourself with the design

and mode of operation of a 5/3-way

solenoid valve

•

To be able to replace a 5/3-way

solenoid valve with 3/2 way solenoid

To be able to identify and eliminate

faults in complex electropneumatic

control systems

•

The equipment set for the advanced level has been compiled for further training in electro-pneumatic control technology The two equipment sets (TP201 and TP202) contain all the components required to meet the specified training aims and can be expanded as desired with other equipment sets of the Learning System for

Automation and Technology

Equipment set – Advanced Level (TP202)

Equipment set – Advanced

Level (TP202

Order No.: 540713)

Equipment set – Advanced Level (TP202)

Description Symbol Relay, 3-off

14

32

44 42

Equipment set – Advanced Level (TP202)

Description Symbol Time relay, 2-off

with switch-on delay

with switch-off delay

17

17

27

27 18

Proximity sensor, inductive

Proximity sensor, capacitive

14

21

22 Non-return valve, piloted

2

Equipment set – Advanced Level (TP202)

Exercise 1 2 3 4 5 6 7 8 9 10 11 12

Pushbutton, electrical, normally

closed

1

Valve terminal with 4 valve slices

(MMJJ)

1 1 1 1 1 1 1 1 1 1 1 1

Pushbutton, electrical, normally

closed contact

Allocation of equipment and exercises

Equipment set TP202

Equipment set TP201

Allocation of equipment and exercises