cd-rom included
TRANSCRIPT
WorkbookTP 220
CD-ROM included
Festo Didactic
559880 EN
1M1 1M2
1V1 24
351
1A11B2 1B31B1
1
21V2
1
21V3
K1
14 1412 12
11 11
1M1 1M2
7 98
S1 S2
+24 V
0 V
K1 K2
10 11
A1 A1
A2 A2
K2
13 13
14 14
1B31B1
1 2 65
G1-S3_STOP G1-S1_START
1B2
3 4
G1-S2_STOPG1-S3_START
G1-S1_STOPG1-S2_START
Pneumatic drives
2 © Festo Didactic GmbH & Co. KG • 559880
The Festo Didactic Learning System has been developed and produced solely for
vocational and further training purposes in the field of automation and technology.
The company undertaking the training and/or the instructors is/are to ensure that
trainees observe the safety precautions specified in this workbook.
Festo Didactic herewith excludes any liability for damage or injury caused to
trainees, the training company and/or any third party, which may occur if the system
is in use for purposes other than purely for training; unless the said damage/injury
has been caused by Festo Didactic deliberately or through gross negligence.
Order No.: 559880
Status: 01/2009
Authors: Frank Ebel, Jürgen Hasel
Graphics: Frank Ebel, Doris Schwarzenberger
Layout: 01/2008
© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 20013
Internet: www.festo-didactic.com
E-Mail: [email protected]
The purchaser shall receive a single right of use which is non-exclusive, non-time-
limited and limited geographically to use at the purchaser's site/location as follows.
The purchaser shall be entitled to use the work to train his/her staff at the
purchaser's site/location and shall also be entitled to use parts of the copyright
material as the basis for the production of his/her own training documentation for
the training of his/her staff at the purchaser's site/location with acknowledgement
of source and to make copies for this purpose. In the case of schools/technical
colleges and training centres, the right of use shall also include use by school and
college students and trainees at the purchaser's site/location for teaching purposes.
The right of use shall in all cases exclude the right to publish the copyright material
or to make this available for use on intranet, Internet and LMS platforms and
databases such as Moodle, which allow access by a wide variety of users, including
those outside of the purchaser's site/location.
Entitlement to other rights relating to reproductions, copies, adaptations,
translations, microfilming and transfer to and storage and processing in electronic
systems, no matter whether in whole or in part, shall require the prior consent of
Festo Didactic GmbH & Co. KG.
Intended use
© Festo Didactic GmbH & Co. KG • 559880 3
Preface ___________________________________________________________ 7
Introduction __________________________________________________________ 9
Safety and operating instructions _______________________________________ 11
Technology package for electropneumatics (TP 200) ________________________ 13
Training aims of advanced level (TP 220) _________________________________ 15
Allocation of training aims and exercises _________________________________ 16
Equipment set of advanced level (TP 220) _________________________________ 18
Allocation of components and exercises __________________________________ 22
Methodological training aids for the trainer _______________________________ 24
Methodological structure of the exercises _________________________________ 25
Designation of equipment _____________________________________________ 26
CD-ROM contents ____________________________________________________ 27
Part A – Exercises
Exercise 1:
Designing a compressed air network (theory) ______________________________ A-3
Exercise 2:
Sizing of the pneumatic power section (theory) ____________________________ A-9
Exercise 3:
Sizing of the pneumatic power section in relation to
the required stroke time (theory) _______________________________________ A-15
Exercise 4:
Sizing of cylinders in relation to
the required speed and given pressure (theory) ___________________________ A-23
Exercise 5:
Sizing of connecting lines for cylinders (theory) ___________________________ A-27
Exercise 6:
Analysing the speed of travel of linear drives (practical exercise) _____________ A-33
Exercise 7:
Reducing costs by means of different pressures for
forward and return strokes (theory) _____________________________________ A-53
Exercise 8:
Reducing costs by means of preventing leakage (theory) ___________________ A-59
Exercise 9:
Analysing the operating behaviour of linear drives (practical exercise) ________ A-63
Exercise 10:
Describing the end position cushioning of linear drives (theory) ______________ A-81
Exercise 11:
Calculating mass moments of inertia (theory) _____________________________ A-87
Contents
Contents
4 © Festo Didactic GmbH & Co. KG • 559880
Exercise 12:
Analysing the operating behaviour of semi-rotary drives (practical exercise) ____ A-93
Exercise 13:
Describing the function and actuation of
the Fluidic Muscle (practical exercise) _________________________________ A-107
Exercise 14:
Selecting a Fluidic Muscle (theory) ___________________________________ A-119
Exercise 15:
Comparing standard cylinders and Fluidic Muscles (practical exercise) ______ A-123
Exercise 16:
Evaluation of pneumatic control systems in the event of
a power failure (practical exercise) ___________________________________ A-133
Part B – Fundamentals
1. Pneumatics in automation ______________________________________ B-3
1.1 Overview ____________________________________________________ B-3
1.2 Areas of application for pneumatics _______________________________ B-4
1.3 Comparison with other forms of energy ____________________________ B-6
2. Cost-effectiveness of compressed air equipment ___________________ B-9
2.1 Compressed air costs ________________________________________ B-10
2.2 Example of correct use of compressed air ________________________ B-12
2.3 Example of incorrect use of compressed air _______________________ B-13
2.4 Cost of leakage in compressed air networks ______________________ B-15
3. Compressed air distribution and service units ____________________ B-17
3.1 Air distribution ______________________________________________ B-17
3.2 Sizing of lines _______________________________________________ B-20
3.3 Service unit ________________________________________________ B-24
4. Pneumatic drives ____________________________________________ B-33
4.1 Linear drives ________________________________________________ B-34
4.2 Semi-rotary drives ___________________________________________ B-41
4.3 Fluidic Muscle ______________________________________________ B-45
5. Optimisation of power section _________________________________ B-51
5.1 Structure and design of a compressed air system __________________ B-51
5.2 Working cylinders ___________________________________________ B-55
5.3 Reducing costs by means of using smaller valves __________________ B-64
Contents
© Festo Didactic GmbH & Co. KG • 559880 5
Part C – Solutions
Exercise 1:
Designing a compressed air network – solution ____________________________ C-3
Exercise 2:
Sizing of the pneumatic power section – solution ___________________________ C-7
Exercise 3:
Sizing of the pneumatic power section in relation to
the required stroke time – solution _____________________________________ C-11
Exercise 4:
Sizing of cylinders in relation to
the required speed and given pressure– solution __________________________ C-17
Exercise 5:
Sizing of connecting lines for cylinders – solution _________________________ C-19
Exercise 6:
Analysing the speed of travel of linear drives – solution ____________________ C-23
Exercise 7:
Reducing costs by means of different pressures for
forward and return strokes – solution ___________________________________ C-37
Exercise 8:
Reducing costs by means of preventing leakage – solution __________________ C-41
Exercise 9:
Analysing the operating behaviour of linear drives – solution ________________ C-43
Exercise 10:
Describing the end position cushioning of linear drives – solution ____________ C-55
Exercise 11:
Calculating mass moments of inertia – solution ___________________________ C-59
Exercise 12:
Analysing the operating behaviour of semi-rotary drives – solution ___________ C-63
Exercise 13:
Describing the function and actuation of
the Fluidic Muscle – solution __________________________________________ C-71
Exercise 14:
Selecting a Fluidic Muscle – solution ____________________________________ C-77
Exercise 15:
Comparing standard cylinders and Fluidic Muscles – solution ________________ C-79
Exercise 16:
Evaluation of pneumatic control systems in the event of
a power failure – solution _____________________________________________ C-83
Contents
6 © Festo Didactic GmbH & Co. KG • 559880
Part D – Appendix
Organiser _________________________________________________________ D-2
Mounting technology ________________________________________________ D-3
Plastic tubing _______________________________________________________ D-4
© Festo Didactic GmbH & Co. KG • 559880 7
The Festo Didactic Learning System for Automation and Technology is designed to
meet a number of different training and vocational aims. The training packages are
therefore structured on this basis as follows:
Basic packages convey basic knowledge covering all areas of technology
Technology packages address the major topics of open and closed-loop control
technology
Function Packages explain the basic functions of automated systems
Application packages facilitate vocational and further training orientated towards
industrial practice
Technology packages deal with the following technologies: pneumatics,
electropneumatics, programmable logic controllers, hydraulics, electrohydraulics,
proportional hydraulics and electric drive technology.
Preface
Preface
8 © Festo Didactic GmbH & Co. KG • 559880
The modular design of the learning system facilitates applications that extend
beyond the limits of the individual packages such as PLC actuation of pneumatic,
hydraulic and electrical drives.
All training packages are of identical structure:
Hardware
Teachware
Software
Seminars
The hardware consists of didactically designed industrial components and systems.
The didactic-methodological framework of teachware is harmonised with the
training hardware and comprises:
Textbooks (with exercises and examples)
Workbooks (with practical exercises, supplementary notes and solutions)
Overhead transparencies and videos (to create an interesting training
atmosphere)
The teaching and training media is available in several languages and is designed for
use in lessons and also for self-tuition.
In terms of software, computer-based training programs (WBTs), simulation
software and programming software are available for programmable logical
controllers.
A comprehensive range of courses dealing with the topics of the various technology
packages completes the range of vocational and further training.
© Festo Didactic GmbH & Co. KG • 559880 9
This workbook is a component part of the Learning System for Automation and
Technology from Festo Didactic GmbH & Co. KG. The system provides a solid basis
for practice-oriented vocational and further training.
TP 220 supplements the training packages TP 201 and TP 202 with the fundamentals
of pneumatic drives. The training contents deal with the selection and sizing of
various advanced types of drive taking into consideration special characteristics as
well as commercial and safety-related aspects.
The prerequisite for the assembly of control systems is a fixed workstation equipped
with a Festo Didactic profile plate. The profile plate consists of 14 parallel slots
spaced 15 mm apart. A DC voltage supply is provided via a short-circuit-proof power
supply unit (input: 230 V, 50 Hz, output: 24 V, max. 5 A). A mobile, silenced
compressor (230 V, approx. 50 l/min, maximum 8 bar = 800 kPa) may be used for
compressed air supply.
The maximum working pressure to be used is p = 6 bar (600 kPa).
Optimum reliability is obtained by operating the control system with unlubricated
compressed air at a working pressure of p = 5 bar (5oo kPa).
You will need the components of equipment sets TP 101, TP 201 and TP 202 for the
practical implementation of the exercises.
The theoretical fundamentals to help you understand this collection of exercises can
be found in Part B of this workbook.
Also available are data sheets in respect of the individual devices (cylinders, valves,
measuring devices).
Introduction
Introduction
10 © Festo Didactic GmbH & Co. KG • 559880
© Festo Didactic GmbH & Co. KG • 559880 11
In the interest of your own safety you should observe the following instructions:
Pressurised air lines that become detached can cause accidents. Switch off the
supply immediately. Festo Didactic recommends the use of safety glasses when
carrying out the exercises of the technology packages Pneumatics (TP 100) and
electropneumatics (TP 200).
Select a tubing length so as to enable you to establish the shortest distance
between two connections.
Connect the tubing first, before switching on the compressed air.
Caution!
Cylinders may advance as soon as the compressed air is switched on.
Do not operate roller lever valves manually during fault finding. Use a tool.
Limit switches must be mounted laterally to the cam (not from the front).
Do not exceed the permissible working pressure (see data sheets).
Pneumatic circuit design:
Connect the plastic tubing with 4 mm/6 mm OD o the devices by plugging the
tubing into the connector. No additional securing required!
Switch off the compressed air supply prior to dismantling the circuit.
Dismantling of the pneumatic circuit:
Press the blue releasing ring to remove the tubing.
Observe the specifications in the data sheets for the individual devices.
Safety and operating instructions
Safety and operating instructions
12 © Festo Didactic GmbH & Co. KG • 559880
The mounting plates of the devices are equipped with mounting variants A, B
or C:
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
For medium, weight loadable devices (e.g. actuators). These devices are clamped
onto the profile plate by means of T-head screws. Clamping and releasing is
achieved by means of a blue knurled nut.
Variant C, screw system
For heavy, loadable devices rarely removed from the profile plate (e.g. on/off
valve with filter regulator).These components are mounted by means of socket
head screws and T-head bolts.
The function generator is used for the evaluation of the assembled control
system, and
– to measure travel times of the linear drive and semi-rotary drive and
– to realise the activation of the fast switching valve.
© Festo Didactic GmbH & Co. KG • 559880 13
The technology package TP 200 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 package TP 200 may also form part
of other packages.
Fixed workstation with Festo Didactic profile plate
Compressor (230 V, 0.55 kW, maximum 8 bar = (800 kPa ))
Equipment set or individual components
Optional training aids
Practical training models
Complete laboratory set-ups
Training documentation
Textbooks Electropneumatics, Basic Level
Fundamentals of pneumatic control technology
Workbooks Basic Level TP 201
Advanced Level TP 202
Advanced Level TP 220
Optional teachware Set of overhead transparencies and overhead projector
Magnetic symbols, drawing template
Training program for electropneumatics
Cutaway model sets 1 + 2 with storage case
Simulation software FluidSIM®
Pneumatics
Measurement software Fluid Lab®
-P
Technology package for electropneumatics (TP 200)
Important components of
TP 200
Technology package for electropneumatics (TP 200)
14 © Festo Didactic GmbH & Co. KG • 559880
Seminars
P111 Fundamentals of pneumatics and electropneumatics
P121 Maintenance and fault finding on pneumatic and electropneumatic systems
IW-PEP Maintenance and servicing in control technology – pneumatic and electropneumatic
control systems
EP-AL Electropneumatics for vocational training
KONST1 Energy-efficient design of systems – Part 1
KONST2 Energy-efficient design of systems – Part 2
Details of venues, dates and prices can be found in the current seminar planner.
Information regarding additional 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.
© Festo Didactic GmbH & Co. KG • 559880 15
The design of a compressed air network
The sizing of the pneumatic power section
The influence of tubing and connectors on the speed of travel
Reducing costs by means of different forward and return strokes
Reducing costs by means of preventing leakage
The operating behaviour of linear drives
The calculation of mass moments of inertia
The operating behaviour of semi-rotary drives
The function, actuation and selection of a Fluidic Muscle
Comparison between standard cylinders and the Fluidic Muscle
Evaluation of pneumatic control systems in the event of a power failure
Training aims of Advanced Level (TP 220)
16 © Festo Didactic GmbH & Co. KG • 559880
Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Training aims
To be able to size compressed air
networks •
To familiarise yourself with the influence
of a network on the compressed air
medium
•
To be able to size a given pneumatic
control system with the help of diagrams • • •
To be able to size the connecting lines of
cylinders with the help of nomograms •
To familiarise yourself with the influence
of connectors on the speed of travel of a
cylinder
•
To familiarise yourself with the influence
of tubing lengths and diameters on the
speed of travel of a cylinder
•
To familiarise yourself with the savings
potential when operating a system using
different pressures for forward and return
strokes
•
To familiarise yourself with the effect of
leakage on the cost of a system •
To familiarise yourself with parameters
which influence the operating behaviour of
cylinders
•
To be able to take measures for
optimisation on the basis of the
application
•
To familiarise yourself with the difference
between air supply and exhaust air flow
control
•
Allocation of training aims and exercises
Allocation of training aims and exercises
© Festo Didactic GmbH & Co. KG • 559880 17
Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Training aims
To familiarise yourself with different types
of end position cushioning •
To be able to select shock absorbers for an
application using a software tool •
To be able to calculate mass moments of
inertia of different bodies using a software
tool
•
To familiarise yourself with the
significance of the mass moment of inertia
when selecting semi-rotary drives
•
To familiarise yourself with parameters
which influence the operating behaviour of
semi-rotary drives
•
To familiarise yourself with the design and
function of the Fluidic Muscle •
To be able to name typical applications for
the Fluidic Muscle •
To be able to select a Fluidic Muscle for an
application with the help of a software tool •
To be able to assess the advantages and
disadvantages of Fluidic Muscles •
To be able to evaluate the behaviour of
pneumatic control systems in the event of
a power failure
•
To familiarise yourself with different
parameters for the EMERGENCY-STOP
situation
•
To be able to correctly use piloted non-
return valves in a control system •
To familiarise yourself with the effects of
faults in pneumatic control systems •
18 © Festo Didactic GmbH & Co. KG • 559880
This equipment set for the advanced level has been compiled for further training in
electropneumatic control technology. The equipment sets (TP 201, TP 202 and
TP 220) 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.
Description Order No. Quantity
3/2-way solenoid valve, normally closed, fast switching valve 544312 1
5/3-way solenoid valve, mid-position closed 541132 1
One-way flow control valve, 2 off 548634 2
Air reservoir 152912 1
On/off valve with filter regulator 152894 1
Function generator 544315 1
Loading weight, 0.175 kg 548581 2
Loading weight, 2 kg 548582 1
Small parts 544316 1
Plastic tubing 3 x 0.5, 5 m 197118 1
Plastic tubing 4 x 0.75, 10 m 151496 1
Plastic tubing 6 x 1. 5 m 152963 1
Linear drive 548641 1
Proximity sensor, electronic 548589 1
Fluidic Muscle 544311 1
Semi-rotary drive 544313 1
Equipment set - Advanced Level (TP 220)
Equipment set -
Advanced Level (TP 220
Order No.: 541184)
Equipment set - Advanced Level (TP 220)
© Festo Didactic GmbH & Co. KG • 559880 19
Overview of small parts (544316)
Description Order No. Quantity
Self-closing push-in fitting,
for tubing OD 6 mm
153420 1
Push-in T-connector,
for tubing OD 4 mm
153366 2
Push-in T-connector, reducing,
2 off for tubing OD 6 mm and
1 off for tubing OD 4 mm
153369 1
Push-in fitting,
for tubing OD 6 mm
153325 1
Push-in fitting with push-in sleeve, reducing,
Push-in sleeve OD 4 mm,
for tubing OD 3 mm
153328 4
L-Push-in fitting with push-in sleeve,
Push-in sleeve OD 4 mm,
for tubing OD 4 mm
153347 4
Push-in sleeve, reducing,
Push-in sleeve OD 6 mm and
push-in sleeve OD 4 mm
153257 1
Push-in sleeve,
Push-in sleeve OD 4 mm
153251 2
Equipment set - Advanced Level (TP 220)
20 © Festo Didactic GmbH & Co. KG • 559880
Description Symbol
3/2-way solenoid valve,
normally closed,
fast switching valve
2
1M131
1M1
5/3-way solenoid valve,
mid-position closed
24
35
14 12
1
1M1
1M1
1M2
1M2
One-way flow control valve,
2 off 1 2
Air reservoir
On/off valve with filter regulator
2
31
Function generator with counter
and stop watch
G
Equipment set symbols
Equipment set - Advanced Level (TP 220)
© Festo Didactic GmbH & Co. KG • 559880 21
Description Symbol
Weight m
Linear drive
Proximity sensor, electronic
Fluidic Muscle
Semi-rotary drive
Equipment set symbols
(continuation)
22 © Festo Didactic GmbH & Co. KG • 559880
Note
Exercises 1 to 5, 7, 8, 10, 11 and 14 are theoretical exercises where software tools
are used in part to carry out calculations.
Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Equipment
3/2-way solenoid valve, normally closed,
fast switching valve
1 1
5/3-way solenoid valve, mid-position
closed
1
One-way flow control valve, 2 off 1 2
Air reservoir 1 1
On/off valve with filter regulator 1 1 1 1 1 1
Function generator with counter and stop
watch
1 1 1 1
Loading weight, 0,175 kg 2
Loading weight, 2 kg 1
Linear drive 1 1 1
Proximity sensor, electronic 1
Fluidic Muscle 1 1
Semi-rotary drive 1
Allocation of equipment and exercises
Equipment set TP 220
Allocation of equipment and exercises
© Festo Didactic GmbH & Co. KG • 559880 23
Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Equipment
2 x 3/2-way solenoid valve, normally
closed
1
5/2-way double solenoid valve 1 1 1 1
5/2-way solenoid valve 1
Double-acting cylinder 2 2 1
One-way flow control valve 2 2
Pressure sensor 1 1
Single-acting cylinder 1
On/off valve with filter regulator 1 1
Proximity sensor, electronic 2 2 2
Relay, 3-off 1 1 1 1 1 1
Signal input, electrical 1 1 1 1 1 1
Manifold 1 1 1 1 1 1
Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Equipment
EMERGENCY-STOP pushbutton 1
Non-return valve, piloted 2
Exercise 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Equipment
Pressure regulator with pressure gauge 1 1
Pressure gauge 2
Equipment set TP 201
Equipment set TP 202
Equipment set TP 101
24 © Festo Didactic GmbH & Co. KG • 559880
Training aims
The general training aims of this collection of exercises are the sizing of the
pneumatic power section, the evaluation of the behaviour of pneumatic drives
and the safety of electropneumatic control systems in the event of a power
failure. The direct interaction of theory and practice ensures quick progress with
learning. The specific training aims are documented in the matrix. Specific,
individual training aims are allocated to each exercise definition.
Time required
The time required to work through the exercises depends on the prior knowledge
of the trainees. For trainees who are skilled manual workers in the engineering or
electrical engineering field: approx. 1 week. For trainees with technician’s or
engineering training: approx. 2 days.
Components of the equipment sets
The collection of exercises and the equipment set are harmonised. For exercises
6, 9, 12, 13, 15 and 16, you will need the components of the Advanced Level
equipment set TP 220. For additional components for the configuration of control
systems from equipment sets of Basic Level TP 101, Basic Level TP 201 and
Advanced Level, please refer to the equipment/exercise matrix. The above
exercises of the advanced level can be configured on a profile plate.
Theoretical exercises
Exercises 1 to 5, 7, 8, 10, 11 and 14 are theoretical exercises where software
tools are used in part to carry out calculations.
Methodological help for the trainer
© Festo Didactic GmbH & Co. KG • 559880 25
All 16 exercises in Part A are of identical methodological structure.
The exercises are divided into:
Title
Training aims
Problem definition
Positional sketch
Work to be carried out
Worksheets
The proposed solutions in Part C are divided into:
Solution description
Circuit plan
Methodological structure of the exercise
26 © Festo Didactic GmbH & Co. KG • 559880
The designation of components in the circuit diagrams is effected in accordance with
DIN-ISO 1219-2. All components of a circuit have the same main identification
number. Depending on the component, letters are assigned. If there are several
components within a circuit, these are numbered consecutively. The designation of
multiple pressure ports is P and these are consecutively numbered separately.
Drives: 1A1, 2A1, 2A2, ...
Valves: 1V1, 1V2, 1V3, 2V1, 2V2, 3V1, ...
Solenoid coils: 1M1, 1M2, 2M1, ...
Sensors: 1B1, 1B2, ...
Signal input: 1S1, 1S2, ...
Accessories: 0Z1, 0Z2, 1Z1, ...
Multiple pressure ports: P1, P2, ...
Designation of equipment
© Festo Didactic GmbH & Co. KG • 559880 27
The CD-ROM supplied provides you with additional training media. The contents of
Parts A and C – exercises and solutions are stored in the form of pdf files.
The structure of the CD-ROM is as follows:
Operating instructions
Data sheets
Industrial applications
Software tools
Videos
Operating instructions and product information are available for the various devices
of the technology package. The purpose of these instructions is to assist you with
the use and commissioning of the devices.
The data sheets of the devices used in the technology package are available in the
form of pdf files.
Graphics of industrial applications are available whereby you can illustrate your own
exercise definitions. Similarly project presentations can also be supplemented with
the use of these illustrations.
The software tools required to work through the individual exercises are available on
the CD-ROM.
Note
Updates and additional software tools are available on the Internet at:
www.festo.com > Engineering > Selection & Sizing.
Videos of industrial applications complete the media for the technology package.
These demonstrate actual industrial applications in short sequences.
CD-ROM contents
Operating instructions
Data sheets
Industrial applications
Software tools
Videos
28 © Festo Didactic GmbH & Co. KG • 559880
© Festo Didactic GmbH & Co. KG • 559880 A-1
Exercise 1:
Designing a compressed air network (theory) ______________________________ A-3
Exercise 2:
Sizing of the pneumatic power section (theory) ____________________________ A-9
Exercise 3:
Sizing of the pneumatic power section in relation to
the required stroke time (theory) _______________________________________ A-15
Exercise 4:
Sizing of cylinders in relation to
the required speed and given pressure (theory) ___________________________ A-23
Exercise 5:
Sizing of connecting lines for cylinders (theory) ___________________________ A-27
Exercise 6:
Analysing the speed of travel of linear drives (practical exercise) _____________ A-33
Exercise 7:
Reducing costs by means of different pressures for
forward and return strokes (theory) _____________________________________ A-53
Exercise 8:
Reducing costs by means of preventing leakage (theory) ___________________ A-59
Exercise 9:
Analysing theoperating behaviour of linear drives (practical exercise) _________ A-63
Exercise 10:
Describing the end position cushioning of linear drives (theory) ______________ A-81
Exercise 11:
Calculating mass moments of inertia (theory) _____________________________ A-87
Exercise 12:
Analysing theoperating behaviour of semi-rotary drives (practical exercise) ____ A-93
Exercise 13:
Describing the function and actuation of
the Fluidic Muscle (practical exercise) _________________________________ A-107
Exercise 14:
Selecting a Fluidic Muscle (theory) ___________________________________ A-119
Exercise 15:
Comparing standard cylinders and Fluidic Muscles (practical exercise) ______ A-123
Exercise 16:
Evaluation of pneumatic control systems in the event of
a power failure (practical exercise) ___________________________________ A-133
Part A – Exercises
A-2 © Festo Didactic GmbH & Co. KG • 559880
© Festo Didactic GmbH & Co. KG • 559880 A-3
Trainees
– are able to size compressed air networks
– are familiarised with the influence of the network design on
the compressed air medium
The purpose of an optimally designed compressed air network is to convey the
compressed air medium to consuming devices with a minimum of loss of air. This
means without reducing
• the quality (water, rust, dirt particles, etc.),
• the quantity of air (leakage) and
• the pressure (insufficiently sized).
The aim should therefore be to feed the compressed air, generated by the
compressor and subsequently prepared, to consuming devices under as little
changed conditions as possible. To ensure reliable and problem-free air distribution,
several points need to be taken into consideration, whereby the correct sizing of the
pipe system is equally important as the material, flow resistance, installation and
maintenance.
In the case of new installations, the future increase in air requirement should always
be taken into account. The size of the main line calculated on the basis of the current
requirement should therefore be increased accordingly. Blanking plugs and on/off
valves will enable problem-free expansion at a later stage.
Schematic representation of a compressed air network
Exercise 1:
Designing a compressed air network (theory)
Training aims
Problem definition
Positional sketch
Exercise 1: Designing a compressed air network (theory)
A-4 © Festo Didactic GmbH & Co. KG • 559880
1. Determine the diameter of the pipe with the help of the nomogram.
2. Determine the equivalent lengths of resistances in the compressed air network.
3. Determine the total length of the compressed air network.
Work to be carried out
Exercise 1: Designing a compressed air network (theory)
© Festo Didactic GmbH & Co. KG • 559880 A-5
Exercise 1: Designing a compressed air network
Name: Date:
Assumed values of the compressed air network Sheet 1 of 4
Current requirement = 1000.0 m3/h
Planned increase = 50 % = 500.0 m3/h
Max. Permissible leakage = 10 % = 150.0 m3/h
Total requirement = 1650.0 m3/h
Operating pressure min. = 7 bar (700.0 kPa)
Permissible pressure drop Δp = 0.1 bar (10.0 kPa)
Extended length of main network = 400.0 m
The equivalent lengths of the following resistances need to be determined:
• Normal elbow pieces (90°) 30 off
• T-pieces 20 off
• Gate valves or ball valves 20 off
• Through-flow valves 5 off
Assumed values
Resistances in the main line
Exercise 1: Designing a compressed air network (theory)
A-6 © Festo Didactic GmbH & Co. KG • 559880
Exercise 1: Designing a compressed air network
Name: Date :
Determing the pipe diameter Sheet 2 of 4
Step 1
– Determine the provisional diameter using the “determining the pipe diameter”
nomogram.
Information regarding the use of the “determining the pipe diameter” nomogram.
1. Draw a straight line from axis A (pipe length) to axis B (flow rate).
2. Extend the line until it intersects axis 1 (C).
3. Draw a second straight line from axis E (operating pressure) to axis G (pressure
loss). This results in an intersection at axis 2 (F).
4. A third straight line connects the intersections of axes 1 and 2. This third line cuts
axis D (inside pipe diameter).
Provisional diameter = ............ mm
Step 2
– Determine the equivalent lengths for the resistances using the “determining the
equivalent lengths” nomogram. Use the provisional diameter determined in
step 1 as the value for the diameter.
Normal elbow pieces (90°) 30 off @ ............ m = ............ m
T-pieces 20 off @ ............ m = ............ m
Gate valves or ball valves 20 off @ ............ m = ............ m
Through-flow valves 5 off @ ............ m = ............ m
Total equivalent length = ............ m
Total length = ............ m
Step 3
– Determine the definitive diameter using the “determining the pipe diameter”
nomogram.
Definitive diameter = ............ mm
Exercise 1: Designing a compressed air network (theory)
© Festo Didactic GmbH & Co. KG • 559880 A-7
Exercise 1: Designing a compressed air network
Name: Date :
“Determining the pipe diameter” nomogram Sheet 3 of 4
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Pressure loss[10 kPa (bar)]
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Pipe length [m]
Flow rate [m /h]3
Inside pipediameter [mm] Axis 2
Axis 1
Operatingpressure
[10 kPa (bar)]2
Exercise 1: Designing a compressed air network (theory)
A-8 © Festo Didactic GmbH & Co. KG • 559880
Exercise 1: Designing a compressed air network
Name: Date :
“Determining the equivalent lengths” nomograms Sheet 4 of 4
2015
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1 1.5 2 3 4 5 7 8 9 10 12 Inches6
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Nominal width
1: Through-flow valve, 2: Angle valve , 3: T-piece, 4: Gate valve, 5: Normal elbow piece
© Festo Didactic GmbH & Co. KG • 559880 C-1
Exercise 1:
Designing a compressed air network – solution ____________________________ C-3
Exercise 2:
Sizing of the pneumatic power section – solution ___________________________ C-7
Exercise 3:
Sizing of the pneumatic power section in relation to
the required stroke time – solution _____________________________________ C-11
Exercise 4:
Sizing of cylinders in relation to
the required speed and given pressure – solution _________________________ C-17
Exercise 5:
Sizing of connecting lines for cylinders – solution _________________________ C-19
Exercise 6:
Examining of speed of travel of linear drives – solution _____________________ C-23
Exercise 7:
Reducing costs by means of different pressures for
forward and return strokes – solution ___________________________________ C-37
Exercise 8:
Reducing costs by means of leakage prevention – solution __________________ C-41
Exercise 9:
Analysing the operating behaviour of linear drives – solution ________________ C-43
Exercise 10:
Describing the end position cushioning of linear drives – solution ____________ C-55
Exercise 11:
Calculating mass moments of inertia – solution ___________________________ C-59
Exercise 12:
Analysing the operating behaviour of semi-rotary drives – solution ___________ C-63
Exercise 13:
Describing the function and actuation of
the Fluidic Muscle – solution __________________________________________ C-71
Exercise 14:
Selecting a Fluidic Muscle – solution ____________________________________ C-77
Exercise 15:
Comparing standard cylinders and Fluidic Muscles – solution ________________ C-79
Exercise 16:
Evaluation of pneumatic control systems in the event of
a power failure – solution _____________________________________________ C-83
Part C – Solutions
C-2 © Festo Didactic GmbH & Co. KG • 559880
© Festo Didactic GmbH & Co. KG • 559880 C-3
Exercise 1: Designing a compressed air network
Name: Date:
Assumed values of the compressed air network Sheet 1 of 4
Current requirement = 1000.0 m3/h
Planned increase = 50 % = 500.0 m3/h
Max. Permissible leakage = 10 % = 150.0 m3/h
Total requirement = 1650.0 m3/h
Operating pressure min. = 7 bar (700.0 kPa)
Permissible pressure drop Δp = 0.1 bar (10.0 kPa)
Extended length of main network = 400.0 m
The equivalent lengths of the following resistances need to be determined:
• Normal elbow pieces (90°) 30 off
• T-pieces 20 off
• Gate valves or ball valves 20 off
• Through-flow valves 5 off
Exercise 1:
Designing a compressed air network – solution
Assumed values
Resistances in the main line
Exercise 1: Designing a compressed air network – solution
C-4 © Festo Didactic GmbH & Co. KG • 559880
Exercise 1: Designing a compressed air network
Name: Date:
Determining the pipe diameter Sheet 2 of 4
Steps for the optimal configuration of the compressed air network
Step 1
– Determine the provisional diameter using the “determining the pipe diameter”
nomogram.
Provisional diameter = 120 mm
Step 2
– Determine the equivalent lengths for the resistances from the “determining the
equivalent lengths” nomogram. Use the provisional diameter determined in
step 1 as the value for the diameter.
Normal elbow pieces (90°) 30 off @ 1.6 m = 48.0 m
T-pieces 20 off @ 16.0 m = 320.0 m
Gate valves or ball valves 20 off @ 2.3 m = 46.0 m
Through-flow valves 5 off @ 49.0 m = 246.0 m
Total equivalent length = 660.0 m
Total length = 1060.0 m
Step 3
– Determine the definitive diameter using the “determining the pipe diameter”
nomogram.
Definitive diameter = 140 mm
Exercise 1: Designing a compressed air network – solution
© Festo Didactic GmbH & Co. KG • 559880 C-5
Exercise 1: Designing a compressed air network
Name: Date:
“Determining the pipe diameter” nomogram Sheet 3 of 4
5000
100
10
1.0
0.5
0.1
0.05
50
500
250
2015
1.5
0.7
0.4
0.2
0.15
0.07
0.03
0.04
0.3
7
3
2
40
70
150
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A B D FC E G
1000
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Pressure loss[10 kPa (bar)]
2
Pipe length [m]
Flow rate [m /h]3
Inside pipediameter [mm] Axis 2
Axis 1
Operatingpressure
[10 kPa (bar)]2
Exercise 1: Designing a compressed air network – solution
C-6 © Festo Didactic GmbH & Co. KG • 559880
Exercise 1: Designing a compressed air network
Name: Date:
“Determining the equivalent lengths” nomogram Sheet 4 of 4
2015
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1 1,5 2 3 4 5 7 8 9 10 126
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B
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Inches
Nominal width
1: Through-flow valve, 2: Angle valve, 3: T-piece, 4: Gate valve, 5: Normal elbow piece