Contents

Part A Exercises


Exercise 1: Realising a sorting device ____________________________________A-3
Exercise 2: Realising a shut-off device___________________________________A-15
Exercise 3: Realising a lid press ________________________________________A-25
Exercise 4: Realising the operation of a hinged lid _________________________A-35
Exercise 5: Realising a diverting device__________________________________A-43
Exercise 6: Actuation of a stacking magazine _____________________________A-53
Exercise 7: Sorting of packages ________________________________________A-65
Exercise 8: Actuation of a sliding platform _______________________________A-73
Exercise 9: Expanding a diverting device_________________________________A-81
Exercise 10: Designing a stamping device________________________________A-91
Exercise 11: Realising a pallet loading station __________________________ A-101
Exercise 12: Eliminating a fault on the pallet loading station_______________ A-107


Festo Didactic GmbH & Co. KG 541090 A-1
Contents



A-2 Festo Didactic GmbH & Co. KG 541090
Exercise 1: Realising a sorting device
To familiarise yourself with the design and mode of operation of a single-acting
cylinder.
Training aims
To familiarise yourself with the design and mode of operation of a 3/2-way
solenoid valve.
To be able to identify and draw various types of actuation of directional control
valves.
To be able to explain and design an example of direct actuation.

A sorting device is to be used to sort water samples according to the size of the
sample bottle. Design a control system whereby this process can be carried out.
Problem definition

A single-acting cylinder is to be used. Parameters
The control of the cylinder is to be effected by means of a pushbutton.
In the event of a power failure the cylinder piston rod is to return into the
retracted end position.

1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
Project task
2. Draw the pneumatic and electrical circuit diagram.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile an equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.

Festo Didactic GmbH & Co. KG 541090 A-3
Exercise 1: Realising a sorting device

Positional sketch

Sorting device


1. Pressing of a pushbutton causes the piston rod of a single-acting cylinder to
push the sample bottle off the conveyor.
2. When the pushbutton is released, the piston rod is to return into the retracted
end position.


A-4 Festo Didactic GmbH & Co. KG 541090
Exercise 1: Realising a sorting device
Exercise 1: Realising the operation of a sorting device
Name: Date:
Fundamentals: Function of pneumatic working components Sheet 1 of 7

Pneumatic working components can be divided into two groups:
Working components using linear movement
Working components using rotary movement

Describe the function of the working components shown.

Symbol 1 Symbol 2 Symbol 3






Description of function
Symbol 1:




Symbol 2:




Symbol 3:





Festo Didactic GmbH & Co. KG 541090 A-5
Exercise 1: Realising a sorting device
Exercise 1: Realising the operation of a sorting device
Name: Date:
Fundamentals: Completing solenoid valve symbols Sheet 2 of 7

Complete the individual symbols with the help of the corresponding component
descriptions.

Description Symbol
Directly actuated 3/2-way
solenoid valve, normally open,
with manual override, with
spring return

2
3 1

Pilot actuated 3/2-way solenoid
valve, normally closed, with
manual override, with spring
return

2
3 1



A-6 Festo Didactic GmbH & Co. KG 541090
Exercise 1: Realising a sorting device
Exercise 1: Realising the operation of a sorting device
Name: Date:
Fundamentals: Normal positions of directional control valves Sheet 3 of 7

An electrically actuated 3/2-way solenoid valve has two switching positions. It can
be in the normal position (unactuated) or in the switching position (actuated). In the
normal position the valve can be open or closed.

Describe the effects on the motion sequence of the following application arising
as a result of the different normal positions. The single-acting cylinder shown is
controlled by an electrically actuated 3/2-way solenoid valve.


2
1M1
3 1

2
1M1
3 1



Description: Normal position closed Description: Normal position open



Festo Didactic GmbH & Co. KG 541090 A-7
Exercise 1: Realising a sorting device
Exercise 1: Realising the operation of a sorting device
Name: Date:
Fundamentals: Direct and indirect actuation Sheet 4 of 7

An electrically actuated solenoid valve can be actuated either directly or indirectly.

Describe the difference with the help of the following application: Electrical
actuation of a spring-returned 3/2-way solenoid valve using a pushbutton.

Description: Direct actuation Description: Indirect actuation





A-8 Festo Didactic GmbH & Co. KG 541090
Exercise 1: Realising a sorting device
Exercise 1: Realising the operation of a sorting device
Name: Date:
Design and function of an electrical switch Sheet 5 of 7

Switches are basically divided into pushbutton and control switch designs and
perform the function of a normally open or normally closed contact or changeover
switch.

Describe the design and function of the switches shown.

Symbol 1 Symbol 2 Symbol 3

3
4



2
1



4 2
1


Description: Design/Function




Festo Didactic GmbH & Co. KG 541090 A-9
Exercise 1: Realising a sorting device
Exercise 1: Realising the operation of a sorting device
Name: Date:
Fundamentals: Mode of operation of different valve types Sheet 6 of 7

Electrically actuated directional control valves are switches with the help of
solenoids. Basically, these can be divided into two groups:
Spring-return solenoid valves
Double solenoid valves

Describe the differences between the two groups with regard to function and
behaviour in the event of power failure.

Valve type Mode of operation
Spring-return valve





Double solenoid valve






A-10 Festo Didactic GmbH & Co. KG 541090
Exercise 1: Realising a sorting device
Exercise 1: Realising the operation of a sorting device
Name: Date:
Fundamentals: Port designations of valves Sheet 7 of 7

In order to prevent incorrect tubing up of directional control valves, the valve ports
(working and pilot lines) are identified in accordance with ISO 5599, both on the
valve itself and in the circuit diagram.

Describe the meaning and function of the designations below.

Designation Meaning, function
3


12


10



Festo Didactic GmbH & Co. KG 541090 A-11
Exercise 1: Realising a sorting device
Exercise 1: Realising the operation of a sorting device
Name: Date:
Completing the pneumatic and electrical circuit diagram Sheet 1 of 1

Complete the pneumatic and electrical circuit diagram for the sorting device.

2
3 1


Pneumatic circuit diagram

1 +24 V
0 V

Electrical circuit diagram

A-12 Festo Didactic GmbH & Co. KG 541090
Exercise 1: Realising a sorting device
Exercise 1: Realising the operation of a sorting device
Name: Date:
Compiling the equipment list Sheet 1 of 1

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

Festo Didactic GmbH & Co. KG 541090 A-13
Exercise 1: Realising a sorting device



A-14 Festo Didactic GmbH & Co. KG 541090
Exercise 2: Realising a shut-off device
To familiarise yourself with the design and mode of operation of a double-acting
cylinder.
Training aims
To be able to explain and design an example of direct actuation.

Problem definition In a water treatment system numerous pipes need to be opened or and closed by
means of shut-off devices. A test setup is to be used to find a possible means of
actuating the shut-off valve.

A double-acting cylinder is to be used. Parameters
The cylinder control is to be effected by means of a pushbutton.
In the event of power failure the cylinder piston rod is to return into the retracted
end position.

1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
Project task
2. Design the pneumatic and electrical circuit diagrams.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile an equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.

Festo Didactic GmbH & Co. KG 541090 A-15
Exercise 2: Realising a shut-off device

Positional sketch

Shut-off device


1. Pressing of a pushbutton is to cause the valve to open the slide
2. Releasing of the pushbutton is to cause the slide to close.

A-16 Festo Didactic GmbH & Co. KG 541090
Exercise 2: Realising a shut-off device
Exercise 2: Realising a shut-off device
Name: Date:
Fundamentals: Comparison of directly actuated and pilot actuated valves Sheet 1 of 5

Differentiation is made between directly actuated and pilot actuated solenoid valves
with regard to the type of actuation of the valve piston.

Compare these two valve types and describe the respective advantages and
disadvantages.

Directly actuated valve Pilot actuated valve











Festo Didactic GmbH & Co. KG 541090 A-17
Exercise 2: Realising a shut-off device
Exercise 2: Realising a shut-off device
Name: Date:
Port designations of valves Sheet 2 of 5

In order to prevent incorrect tubing up of directional control valves, valve ports
(working and pilot lines) are identified in accordance with ISO 5599-3, both on the
valve itself and in the circuit diagram.

Describe the meaning and function of the designations below.

Designation Meaning, function
4


14


82/84



A-18 Festo Didactic GmbH & Co. KG 541090
Exercise 2: Realising a shut-off device
Exercise 2: Realising a shut-off device
Name: Date:
Fundamentals: Mode of operation of a solenoid valve Sheet 3 of 5

A valve symbol provides information regarding the function of the valve, i.e. the
number of ports, switching positions and type of actuation, but not about the
constructional design.

Describe the mode of operation of the directional control valve shown.

1M1
2 4
3 5
1


Description: Mode of operation of a directional control valve












Festo Didactic GmbH & Co. KG 541090 A-19
Exercise 2: Realising a shut-off device
Exercise 2: Realising a shut-off device
Name: Date:
Fundamentals: IP classification Sheet 4 of 5

Depending on the installation and ambient conditions, electrical equipment is
protected by means of a housing or cover. The required protection class against
dust, humidity and foreign objects is to be identified.
The classification IP 65 is shown on a valve

Describe the meaning of this classification.

Description of IP 65 classification











A-20 Festo Didactic GmbH & Co. KG 541090
Exercise 2: Realising a shut-off device
Exercise 2: Realising a shut-off device
Name: Date:
Fundamentals: Symbols of pneumatic cylinders Sheet 5 of 5

Piston rod cylinders with linear action can be divided into two groups:
Single-acting cylinders
Double-acting cylinders

Describe the meaning of the cylinder symbol shown.

Symbol 1 Symbol 2






Description of symbolic representation




Festo Didactic GmbH & Co. KG 541090 A-21
Exercise 2: Realising a shut-off device
Exercise 2: Realising a shut-off device
Name: Date:
Completing the pneumatic and electrical circuit diagrams Sheet 1 of 1

Complete the pneumatic and electrical circuit diagrams for the sorting device.

2 4
3 5
1


Pneumatic circuit diagram

1 +24 V
0 V

Electrical circuit diagram

A-22 Festo Didactic GmbH & Co. KG 541090
Exercise 2: Realising a shut-off device
Exercise 2: Realising a shut-off device
Name: Date:
Compiling the equipment list Sheet 1 of 1

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

Festo Didactic GmbH & Co. KG 541090 A-23
Exercise 2: Realising a shut-off device




A-24 Festo Didactic GmbH & Co. KG 541090
Exercise 3: Realising a lid press
To familiarise yourself with the design and mode of operation of a double-acting
cylinder.
Training aims
To be able to explain and design an example of indirect actuation.

Problem definition In a filling plant, wall or ceiling paints are filled into plastic pots. Once filled, slip-lids
are to be pressed onto the plastic pots.

A double-acting cylinder is to be used. Parameters
The cylinder control is to be effected indirectly and by means of a pushbutton. In
the event of power failure the cylinder piston rod is to return into the retracted
end position.

1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
Project task
2. Design the pneumatic and electrical circuit diagrams.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile an equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.

Festo Didactic GmbH & Co. KG 541090 A-25
Exercise 3: Realising a lid press

Positional sketch

Filling of pots of paint


1. Pressing of a pushbutton is to cause the pressing ram to advance and the slip-lid
to be pressed on.
2. Once the pushbutton is released, the pressing ram is to be returned into the
initial position.

A-26 Festo Didactic GmbH & Co. KG 541090
Exercise 3: Realising a lid press
Exercise 3: Realising of a lid press
Name: Date:
Fundamentals: Mode of operation of relays Sheet 1 of 4

A relay is a remotely controlled electromagnetically actuated switch with several
contacts.

The main components are:
Coil with core
Winding of coil
Contact set
Return spring
Armature
Terminal lugs


The following illustration shows a sectional representation of a relay.

Allocate the component designations.

1 2 4 A1 A2
2 3
1
5
6 7
4



Festo Didactic GmbH & Co. KG 541090 A-27
Exercise 3: Realising a lid press
Exercise 3: Realising a lid press
Name: Date:
Fundamentals: Design and mode of operation of relays Sheet 2 of 4

Describe the mode of operation of a relay.

Description of mode of operation of a relay















A-28 Festo Didactic GmbH & Co. KG 541090
Exercise 3: Realising a lid press
Exercise 3: Realising a lid press
Name: Date:
Fundamentals: Design and mode of operation of relays Sheet 3 of 4

One or several contacts can be switched by a relay coil. Relays with normally closed,
normally open or changeover contact(s) are used depending on the function
required.

Additional designs of electromagnetically actuated switches are for instance a
remanence relay, the time relay with switch-on delay, the time relay with switch-off
delay and the contactor.

Describe the design and contact alignment of the relays shown.

Description of design/contact alignment Symbol




13 23 31 41
14 24 32 4
A1
A2
2




14 12 24 22 34 32 44 42
11 21 31 41
A1
A2



Festo Didactic GmbH & Co. KG 541090 A-29
Exercise 3: Realising a lid press
Exercise 3: Realising a lid press
Name: Date:
Fundamentals: Design and mode of operation of relays Sheet 4 of 4

List the possible applications of relays in electrical or electropneumatic control
systems.

Description: Possible applications












A-30 Festo Didactic GmbH & Co. KG 541090
Exercise 3: Realising a lid press
Exercise 3: Realising a lid press
Name: Date:
Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

Design the pneumatic and electrical circuit diagrams for the lid press.



Pneumatic circuit diagram


Festo Didactic GmbH & Co. KG 541090 A-31
Exercise 3: Realising a lid press
Exercise 3: Realising a lid press
Name: Date:
Completing the pneumatic and electrical circuit diagrams Sheet 2 of 2

1 +24 V
0 V
2
12
22
32
42
14
24
34
44
11
21
31
41


Electrical circuit diagram


A-32 Festo Didactic GmbH & Co. KG 541090
Exercise 3: Realising a lid press
Exercise 3: Realising a lid press
Name: Date:
Compiling the equipment list Sheet 1 of 1

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

Festo Didactic GmbH & Co. KG 541090 A-33
Exercise 3: Realising a lid press



A-34 Festo Didactic GmbH & Co. KG 541090
Exercise 4: Realising the operation of a hinged lid
To be able to design an example of indirect actuation Training aims
To familiarise yourself with logic operations
To be able to select solenoid valve according to requirements

Plastic granulate is to be filled from a storage silo. The silo is to be opened or closed
using a hinged lid. The process is to be effected from two points.
Problem definition

A single-acting cylinder is to be used. Parameters
The cylinder control is to be indirect and via hand levers.
In the event of power failure, the cylinder piston rod is to advance into the
forward end position.

1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
Project task
2. Design the pneumatic and electrical circuit diagrams.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile an equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.


Festo Didactic GmbH & Co. KG 541090 A-35
Exercise 4: Realising the operation of a hinged lid

Positional sketch

Filling of plastic granulate


1. Pressing of either one of the pushbuttons is to cause the hinged lid to open and
to empty the bulk material from the container.
2. Once the pusbutton is released, the hinged lid closes.

A-36 Festo Didactic GmbH & Co. KG 541090
Exercise 4: Realising the operation of a hinged lid
Exercise 4: Realising the operation of a hinged lid
Name: Date:
Fundamentals: Converting solenoid valves Sheet 1 of 3

In industrial practice, there are numerous different requirements with regard to a
valve. If a valve with all the required features is not available, it is often possible to
use a valve with a different number of ports. The table below lists a selection of
directional control valves frequently in use in industrial applications.

Describe the valve types shown.
Identify all solenoid valves that can be replaced by a 5/2-way solenoid valve of
the type shown..
If measures are required to convert the valve, describe these.

Note
By conversion measures we understand the simplest of conversions such as the
sealing of working ports 2 or 4 using a blanking plug.



1M1
2 4
3 5
1
14


Symbol Description of valve type Replacement
possible
Description of necessary conversions
2
1M1
1
12




2
1M1
3 1
12




2
1M1
3 1
10




4
1M1
3 1
14
2





Festo Didactic GmbH & Co. KG 541090 A-37
Exercise 4: Realising the operation of a hinged lid
Exercise 4: Realising the operation of a hinged lid
Name: Date:
Fundamentals: Selecting solenoid valves Sheet 2 of 3

Valves are selected according to the following criteria:
Exercise definition,
Required behaviour in the event of power failure,
Minimum possible overall costs

The following valves are available for selection for the actuation of a single-acting
cylinder:
A pilot actuated, spring return 3/2way solenoid valve with manual override,
A pilot actuated, spring-return 5/2-way solenoid valve with manual override

Select a valve and explain the reasons for your decision.

Note
Apart from the cost of the valve, the above overall costs also include the cost of
installation, maintenance and storage for replacement parts.

Valve type Reason



















A-38 Festo Didactic GmbH & Co. KG 541090
Exercise 4: Realising the operation of a hinged lid
Exercise 4: Realising the operation of a hinged lid
Name: Date:
Fundamentals: Logic operations: The OR function Sheet 3 of 3

Triggering the advancing of a cylinder piston rod is to be possible using two
pushbuttons S1 and S2. If at least one of the two pushbuttons is actuated, the valve
coil 1M1 is energised, the solenoid valve 1V1 switches into the actuated position
and the piston rod advances. If both pushbuttons are released, the valve switches
into the initial position and the piston rod retracts.

Create the appropriate function table and the logic symbol.

Note
0 means: Pushbutton not actuated, i.e. piston rod does not advance
1 means: Pushbutton actuated, i.e. piston rod advances

S1 S2 1M1 1V1





Function table




Logic symbol


Festo Didactic GmbH & Co. KG 541090 A-39
Exercise 4: Realising the operation of a hinged lid
Exercise 4: Realising the operation of a hinged lid
Name: Date:
Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

Design the pneumatic and electrical circuit diagrams for the operation of the
hinged lid.



Pneumatic circuit diagram


A-40 Festo Didactic GmbH & Co. KG 541090
Exercise 4: Realising the operation of a hinged lid
Exercise 4: Realising the operation of a hinged lid
Name: Date:
Completing the pneumatic and electrical circuit diagrams Sheet 2 of 2

K1
14 12
11
1
K1 1M1
+24 V 3 2
0 V
A1
A2
K1
12
22
32
42
14
24
34
44
11
21
31
41


Electrical circuit diagram


Festo Didactic GmbH & Co. KG 541090 A-41
Exercise 4: Realising the operation of a hinged lid
Exercise 4: Realising the operation of a hinged lid
Name: Date:
Compiling the equipment list Sheet 1 of 1

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



A-42 Festo Didactic GmbH & Co. KG 541090
Exercise 5: Realising a diverting device
To familiarise yourself with the design and mode of operation of a double-acting
cylinder.
Training aims
To familiarise yourself with the design and mode of operation of a double
solenoid valve.

Problem definition Packages are to be pushed from one conveyor to another via a diverting device.

A double-acting cylinder is to be used. Parameters
The cylinder control is to be effected indirectly and via a pushbutton. In the event
of power failure the cylinder piston rod is to remain in the current position.

1. Answer the questions and carry out the exercises regarding the training contents
listed.
Project task
2. Design the pneumatic and electrical circuit diagrams.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile an equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.

Festo Didactic GmbH & Co. KG 541090 A-43
Exercise 5: Realising a diverting device

Positional sketch

Diverting device


1. Pressing of a pushbutton is to cause the frame of the diverting device to be
advanced. The package is transferred and transported away.
2. Pressing of another pushbutton causes the frame to be moved into the initial
position.

A-44 Festo Didactic GmbH & Co. KG 541090
Exercise 5: Realising a diverting device
Exercise 5: Realising a diverting device
Name: Date:
Fundamentals: Use of solenoid valves Sheet 1 of 4

Two factors are to be considered regarding the question as to which valve type is to
be used for a particular application:
Duration, i.e. time frame,
Quantity or frequency
of required switching operations.

In order to utilise a directional control valve as efficiently as possible, you will need
to decide in each case whether the use
of a double solenoid valve or
a spring-return directional control valve
is more cost effective for the required application.

Decide whether a double solenoid or a spring-return solenoid valve seems more
cost effective for the applications listed and explain the reasons for your choice.

Application 1
The clamping cylinder of a milling device is to firmly hold in position a workpiece for
the duration of a milling operation (duration of approx. 10 min, 60 clamping
operations per day).

Valve type Reason






Application 2
The ejecting cylinder of a sorting device is to push defective workpieces from a
conveyor (duration of approx.1s, 600 ejecting operations per day).

Valve type Reason






Festo Didactic GmbH & Co. KG 541090 A-45
Exercise 5: Realising a diverting device
Exercise 5: Realising a diverting device
Name: Date:
Fundamentals: Mode of operation of a solenoid valve Sheet 2 of 4

Describe the mode of operation of the directional control valve shown.



1M1 1M2
2 4
3 5
1


Description of mode of operation of a directional control valve













A-46 Festo Didactic GmbH & Co. KG 541090
Exercise 5: Realising a diverting device
Exercise 5: Realising a diverting device
Name: Date:
Fundamentals: Calculating the current consumption of a valve coil Sheet 3 of 4

A spring-return solenoid valve is to be switched via pushbutton S1.

Calculate the current consumption of the valve coil 1M1 at a voltage supply of
24 V DC and a coil resistance of 48 (Ohm).

1M1
1
S1
13
14
+24 V
0 V

Current consumption in 1M1 Power rating of 1M1







Festo Didactic GmbH & Co. KG 541090 A-47
Exercise 5: Realising a diverting device
Exercise 5: Realising a diverting device
Name: Date:
Fundamentals: Calculate the current consumption of a valve coil Sheet 4 of 4

Would the current consumption in 1M1 be the same, higher or lower if the above
valve coil is connected to a 24V AC voltage? Explain the reasons for your answer.

Identical Higher Lower Reason












A-48 Festo Didactic GmbH & Co. KG 541090
Exercise 5: Realising a diverting device
Exercise 5: Realising a diverting device
Name: Date:
Completing the pneumatic and electrical circuit diagram Sheet 1 of 2

Design the pneumatic and electrical circuit diagrams for the diverting device.

1


Pneumatic circuit diagram


Festo Didactic GmbH & Co. KG 541090 A-49
Exercise 5: Realising a diverting device
Exercise 5: Realising a diverting device
Name: Date:
Completing the pneumatic and electrical circuit diagrams Sheet 2 of 2

1 2 +24 V
0 V
3 4
12 12
22 22
32 32
42 42
14 14
24 24
34 34
44 44
11 11
21 21
31 31
41 41


Electrical circuit diagram


A-50 Festo Didactic GmbH & Co. KG 541090
Exercise 5: Realising a diverting device
Exercise 5: Realising a diverting device
Name: Date:
Compiling the equipment list Sheet 1 of 1

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


Festo Didactic GmbH & Co. KG 541090 A-51
Exercise 5: Realising a diverting device




A-52 Festo Didactic GmbH & Co. KG 541090
Exercise 6: Actuation of a stacking magazine
To be able to use a double-acting cylinder. Training aims
To familiarise yourself with the design and mode of operation of a double
solenoid valve.
To familiarise yourself with the option of sensing the end positions of cylinders.

Problem definition Wooden boards are to be pushed from a stacking magazine into an assembly device.

The forward end position of the cylinder is to be sensed.

Parameters
1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
Project task
2. Design the pneumatic and electrical circuit diagrams.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile an equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.


Festo Didactic GmbH & Co. KG 541090 A-53
Exercise 6: Actuation of a stacking magazine

Positional sketch

Stacking magazine


1. Pressing of a pushbutton causes a wooden board to be pushed out of the
stacking magazine.
2. Once the forward end position is reached, the slide is moved into the initial
position.

A-54 Festo Didactic GmbH & Co. KG 541090
Exercise 6: Actuation of a stacking magazine
Exercise 6: Actuation of a stacking magazine
Name: Date:
Fundamentals: Components of an electropneumatic system Sheet 1 of 6

The components of an electropneumatic system are represented in a pneumatic
circuit diagram and/or in an electrical circuit diagram.

Determine where the components below are to be represented.

Component Pneumatic circuit
diagram
Electrical circuit
diagram
Manually operated pushbutton
Cylinder
Valves
Valve coils
Relay
Electromechanical limit switch
Electronic proximity sensor
Indicating devices


Festo Didactic GmbH & Co. KG 541090 A-55
Exercise 6: Actuation of a stacking magazine
Exercise 6: Actuation of a stacking magazine
Name: Date:
Fundamentals: Components of an electropneumatic system Sheet 2 of 6

The function of sensors in electropneumatic control systems is to acquire
information and to transmit this for signal processing.

What function(s) can an electromechanical limit switch fulfill in an
electropneumatic control system?

Description: Function(s) of electromechanical limit switches










A-56 Festo Didactic GmbH & Co. KG 541090
Exercise 6: Actuation of a stacking magazine
Exercise 6: Actuation of a stacking magazine
Name: Date:
Fundamentals: Representation of limit switches Sheet 3 of 6

Limit switches can be actuated in different ways, via the function of a normally
closed or normally open contact or changeover switch and, in the normal position of
the system, can be either actuated or unactuated.

Describe the appropriate design or function of the symbols shown.

Description: Design/function Symbol


2
1




4
1



Festo Didactic GmbH & Co. KG 541090 A-57
Exercise 6: Actuation of a stacking magazine
Exercise 6: Actuation of a stacking magazine
Name: Date:
Fundamentals: Creating a logic element table Sheet 4 of 6

One possibility of recording the allocated contacts of a relay is by means of listing
these in a logic element table.

Create the logic element tables for relays K6 and K9.

K1
14 12
11
K5
14 12
11
K6 K7 K8 K9
10
A1 A1 A1 A1
A2 A2 A2 A2
K6 K7 K8 K9 K6 K7
14 14 14 14 34 34 14 14 14
24 24 34 34 24
12 12 12 12 32 32 12 12 12
22 22 32 32 22
11 11 11 11 31 31 11 11 11
21 21 31 31 21
1M1 2M1
12 14 16 18 19 13 15 17 11
K2 K4 K3
K6 K7 K9 K8 K9
+24 V
. . .
. . .
0 V
24 22
21
K8


Electrical circuit diagram


Logic element
table
Description: Logic element table

K6





K9




A-58 Festo Didactic GmbH & Co. KG 541090
Exercise 6: Actuation of a stacking magazine
Exercise 6: Actuation of a stacking magazine
Name: Date:
Fundamentals: Creating a logic element table Sheet 5 of 6

Another method of recording the allocated contact sets of a relay can be seen in the
electrical circuit diagram below.

NA
EMERGENCY
STOP
K1
14 12
11
K5
K11 K11 K11
14
14 24 34
12
12 22 32
11
11 21 31
K6 K7 K8 K9
11 25 27
A1 A1 A1 A1
A2 A2 A2 A2
12 12 12 12
22 22 22 22
32 32 32 32
42 42 42 42
.13 .15 .17 .19
.20
.26
.24
.14 .16 .18
.24
.23
.22 .23
.22
14 14 14 14
24 24 24 24
34 34 34 34
44 44 44 44
11 11 11 11
21 21 21 21
31 31 31 31
41 41 41 41
K6 K7 K8 K9
14 14 14 14 14 14 14
24 24 24 24
12 12 12 12 12 12 12
22 22 22 22
11 11 11 11 11 11 11
21 21 21 21
16 18 17 19 13 12
K4 K3
K6 K10 K7 K8
S1
Start
K1 K2 K3 K4 K5 K11
+24 V 2 4 6 8 10 1 3 5 7 9
0 V
1B1 1B2 2B1 2B2
A1 A1 A1 A1 A1 A1
A2 A2 A2 A2 A2 A2
13
21
14
22
12 12 12 12 12 12
22 22 22 22 22 22
32 32 32 32 32 32
42 42 42 42 42 42
.12
.20
.14 .18
.27
.12 .11
.25
.27
.16
14 14 14 14 14 14
24 24 24 24 24 24
34 34 34 34 34 34
44 44 44 44 44 44
11 11 11 11 11 11
21 21 21 21 21 21
31 31 31 31 31 31
41 41 41 41 41 41
2M1
1A1+ 2A1- 2A1+ 1A1-
K6 K8 K7 K9 K3
34 34 34 34 24 32 32 32 32 22
31 31 31 31 21
22 24 23 26
44 44 44 34 42 42 42 32
41 41 41 31
K7 K9 K8 K10
K10
A1
A2
12
22
32
42
.21
.12
.26
14
24
34
44
11
21
31
41
K10
14 24
24
12 22
22
11 21
21
20 21
K1
K9
1M1 1M2 2M2


Electrical circuit diagram


Festo Didactic GmbH & Co. KG 541090 A-59
Exercise 6: Actuation of a stacking magazine
Exercise 6: Actuation of a stacking magazine
Name: Date:
Fundamentals: Creating a logic element table Sheet 6 of 6

Complete the information regarding the relays shown by:
Indicating the current path in which the respective contact is used and
specifying the function fulfilled by the contact set (normally open or normally
closed contact).

Relay Current path Function:
Normally
open contact
Function:
Normally
closed
contact



Relay K9




Relay K10



A-60 Festo Didactic GmbH & Co. KG 541090
Exercise 6: Actuation of a stacking magazine
Exercise 6: Actuation of a stacking magazine
Name: Date:
Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

Design the pneumatic and electrical circuit diagrams for the stacking magazine.

1A1
1V1
2 4
3 5
1
1V2 1V3
1 1
2 2


Pneumatic circuit diagram


Festo Didactic GmbH & Co. KG 541090 A-61
Exercise 6: Actuation of a stacking magazine
Exercise 6: Actuation of a stacking magazine
Name: Date:
Completing the pneumatic and electrical circuit diagrams Sheet 2 of 2

K1 K2
14 14 12 12
11 11
1 2 +24 V
0 V
K1 K2
3 4
A1 A1
A2 A2
12 12
22 22
32 32
42 42
14 14
24 24
34 34
44 44
11 11
21 21
31 31
41 41


Electrical circuit diagram


A-62 Festo Didactic GmbH & Co. KG 541090
Exercise 6: Actuation of a stacking magazine
Exercise 6: Actuation of a stacking magazine
Name: Date:
Compiling the equipment list Sheet 1 of 1

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


Festo Didactic GmbH & Co. KG 541090 A-63
Exercise 6: Actuation of a stacking magazine



A-64 Festo Didactic GmbH & Co. KG 541090
Exercise 7: Sorting of packages
To be able to calculate piston forces according to specific values Training aims
To be able to calculate electrical characteristic values
To be able to explain and design an example of indirect actuation
To familiarise yourself with logic functions and to be able to design these

Problem definition Packages are to be transported on a conveyor past workstations. The packages can
be diverted by means of deflectors.

A double-acting cylinder is to be used. Parameters
The cylinder control is to be effected indirectly via pushbuttons and
electromechanical limit switches.
Triggering of the advancing movement is to be possible only if the piston rod is in
the retracted end position.

1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
Project task
2. Design the pneumatic and electrical circuit diagrams.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile an equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.

Festo Didactic GmbH & Co. KG 541090 A-65
Exercise 7: Sorting of packages

Positional sketch

Conveyor belt for packages


1. The piston rod of a cylinder is to advance automatically as soon as pushbutton
S1 is actuated.
2. If the pushbutton is no longer actuated, the piston rod is to assume the retracted
end position.

A-66 Festo Didactic GmbH & Co. KG 541090
Exercise 7: Sorting of packages
Exercise 7: Sorting of packages
Name: Date:
Fundamentals: Calculation of piston force Sheet 1 of 3

The piston of a double-acting cylinder has a diameter of 16 mm and the piston rod a
diameter of 8 mm. The frictional losses within the cylinder are 10 %.

The following applies for double-acting cylinders:

Advance stroke F
eff

= (A p) F
F

Return stroke F
eff

= (A' p) F
F

F
eff

= Effective piston force (N)
A = Effective piston surface (m
2
)
= )
4
D
(
2


A' = Effective annular surface (m
2
)
=
4
) d (D
2 2


p = Working pressure (Pa)
F
F

= Friction force (approx. 10% of F
th

) (N)
D = Cylinder diameter (m)
d = Piston rod diameter (m)

Calculate the effective piston force in the advance and return stroke at an
operating pressure of 6 bar (600 kPa).

To be calculated Solution approach
Advance stroke




Return stroke







Festo Didactic GmbH & Co. KG 541090 A-67
Exercise 7: Sorting of packages
Exercise 7: Sorting of packages
Name: Date:
Fundamentals: Calculation of electrical characteristic values Sheet 2 of 3

A relay in an electropneumatic circuit is designated as follows: 580 , 1 W.

Calculate the permissible operating voltage which ensures that no overload
occurs on the relay.

To be calculated Solution approach
Max. Operating
voltage






A-68 Festo Didactic GmbH & Co. KG 541090
Exercise 7: Sorting of packages
Exercise 7: Sorting of packages
Name: Date:
Fundamentals: Sheet 3 of 3

Triggering of the advancing movement of the piston rod of a cylinder is to be
achieved by means of two pushbuttons S1 and S2. The valve coil 1M1 is energised if
both pushbuttons are actuated simultaneously and the solenoid valve 1V1 switches
into the actuated position causing the piston rod to advance. If at least one of the
two pushbuttons is released, the valve switches into the initial position and the
piston rod retracts.

Create an appropriate function table and the logic symbol.

Note
0 means: Pushbutton not actuated, i.e. piston rod not advancing
1 means: Pushbutton actuated, i.e. piston rod advances

S1 S2 1M1 1V1





Function table




Logic symbol


Festo Didactic GmbH & Co. KG 541090 A-69
Exercise 7: Sorting of packages
Exercise 7: Sorting of packages
Name: Date:
Completing the pneumatic and electrical circuit diagrams Sheet 1 vof 2

Configure the pneumatic circuit diagram and design the electrical circuit diagram
for the feeding device.

1M1 1M2
1A1
1V1
2 4
3 5
1
1V2 1V3
1B1 1B2
1 1
2 2


Pneumatic circuit diagram


A-70 Festo Didactic GmbH & Co. KG 541090
Exercise 7: Sorting of packages
Exercise 7: Sorting of packages
Name: Date:
Completing the pneumatic and electrical circuit diagram Sheet 2 of 2

K3 1M2
1 2 +24 V
0 V
K1 K2
3 4
A1 A1
A2 A2
12
22
32
42
14
24
34
44
11
21
31
41
12
22
32
42
14
24
34
44
11
21
31
41
12
22
32
42
14
24
34
44
11
21
31
41
5
1M1


Electrical circuit diagram


Festo Didactic GmbH & Co. KG 541090 A-71
Exercise 7: Sorting of packages
Exercise 7: Sorting of packages
Name: Date:
Compiling the equipment list Sheet 1 of 1

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



A-72 Festo Didactic GmbH & Co. KG 541090
Exercise 8: Actuation of a sliding platform
To familiarise yourself with logic functions and to be able to design these Training aims
To be able to explain and design electrical latching circuits with dominant switch-
off signal

Problem definition Wooden boards are to be manually placed onto a sliding platform. The boards are to
be pushed under a belt sanding machine by means of a pneumatic drive.

A double-acting cylinder is to be used. Parameters
The cylinder control is to be effected indirectly.

1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
Project task
2. Design the pneumatic and electrical circuit diagrams.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile the equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.

Festo Didactic GmbH & Co. KG 541090 A-73
Exercise 8: Actuation of a sliding platform

Positional sketch

Sliding platform


1. The piston rod of a cylinder is to advance if pushbutton S1 is actuated.
2. Actuation of pushbutton S2 is to cause the piston rod to retract.


A-74 Festo Didactic GmbH & Co. KG 541090
Exercise 8: Actuation of a sliding platform
Exercise 8: Actuation of a sliding platform
Name: Date:
Fundamentals: Signal storage Sheet 1 of 3

The actuation of the pushbutton must be stored if the piston rod of a cylinder is to
also advance if the pushbutton is only briefly actuated. This signal storage can be
effected either in the power section or in the signal control section of a circuit.

Describe how signal storage is devised in the power section or in the signal
control section respectively.

Place of signal storage Description: Signal storage
Signal storage in the
power section




Signal storage in the
signal control section






Festo Didactic GmbH & Co. KG 541090 A-75
Exercise 8: Actuation of a sliding platform
Exercise 8: Actuation of a sliding platform
Name: Date:
Fundamentals: Analysing circuits Sheet 2 of 3

Describe the behaviour of the circuit specified (pilot actuated, spring-return
5/2-way solenoid valve with manual override, double-acting cylinder) in the
event of
Power failure
Pressure failure.



Power failure Pressure failure










A-76 Festo Didactic GmbH & Co. KG 541090
Exercise 8: Actuation of a sliding platform
Exercise 8: Actuation of a sliding platform
Name: Date:
Fundamentals: Logic functions Sheet 3 of 3

The lamp P1 is to be illuminated whenever pushbutton S1 is not actuated.

Draw up the appropriate function table and the logic symbol(s).
0 means: Pushbutton S1 not actuated, i.e. lamp P1 off
1 means: Pushbutton S1 actuated, i.e. P1 illuminated

S1 P1





Function table




Logic symbol


Festo Didactic GmbH & Co. KG 541090 A-77
Exercise 8: Actuation of a sliding platform
Exercise 8: Actuation of a sliding platform
Name: Date:
Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

Design the pneumatic and electrical circuit diagrams for the sliding platform.

2 4
3 5
1


Pneumatic circuit diagram


A-78 Festo Didactic GmbH & Co. KG 541090
Exercise 8: Actuation of a sliding platform
Exercise 8: Actuation of a sliding platform
Name: Date:
Completing the pneumatic and electrical circuit diagrams Sheet 2 of 2

12
22
32
42
14
24
34
44
11
21
31
41
1
K1 1M1
+24 V 3 2
0 V
A1
A2


Electrical circuit diagram


Festo Didactic GmbH & Co. KG 541090 A-79
Exercise 8: Actuation of a sliding platform
Exercise 8: Actuation of a diverting device
Name: Date:
Compiling the equipment list Sheet 1 of 1

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



A-80 Festo Didactic GmbH & Co. KG 541090
Exercise 9: Expanding a diverting device
To familiarise yourself with different types of end position control and to be able
to select a suitable type.
Training aims
To familiarise yourself with latching circuits of different characteristics.

Problem definition Packages are to be transferred from one conveyor belt to another via a diverting
device using reciprocating strokes. Once switched on, the device is to run
continuously and only be switched off via a stop signal.

The latching circuit used is to exhibit a dominant Off behaviour.

Parameters
1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
Project task
2. Design the pneumatic and electrical circuit diagram.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile the equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.


Festo Didactic GmbH & Co. KG 541090 A-81
Exercise 9: Expanding a diverting device

Positional sketch

Diverting device for packages


1. Actuation of the pushbutton is to cause a reciprocating movement of the cylinder
piston rod to drive the diverting device via a latching drive.
2. The packages are to be deflected and transported in the opposite direction.
3. Pressing of a second pushbutton is to switch off the drive.


A-82 Festo Didactic GmbH & Co. KG 541090
Exercise 9: Expanding a diverting device
Exercise 9: Expanding a diverting device
Name: Date:
Fundamentals: Latching circuits Sheet 1 of 4

A latching relay circuit is required in order to store a signal in the signal control
section.

The relay K1 is energised by actuating pushbutton S1. Complete the electrical
circuit diagram below so that the relay latches after the pushbutton S1 is
released.

12
22
32
42
14
24
34
44
11
21
31
41
1
S1
K1
+24 V
0 V
A1
A2
13
14


Electrical circuit diagram


Festo Didactic GmbH & Co. KG 541090 A-83
Exercise 9: Expanding a diverting device
Exercise 9: Expanding a diverting device
Name: Date:
Fundamentals: Latching circuits Sheet 2 of 4

An additional normally closed contact is required in order to cancel a set self-
latching loop.
Differentiation is made between two groups depending on the configuration of this
normally closed contact:
Dominant setting self-latching loop
Dominant resetting self-latching loop

Complete the electrical circuit diagram below so that the self-latching loop is
reliably cancelled via the actuation of a pushbutton S2.

12
22
32
42
14
24
34
44
11
21
31
41
1
S1
K1
+24 V
0 V
A1
A2
13
14


Electrical circuit diagram

A-84 Festo Didactic GmbH & Co. KG 541090
Exercise 9: Expanding a diverting device
Exercise 9: Expanding a diverting device
Name: Date:
Fundamentals: Latching circuits Sheet 3 of 4

The various circuits for signal storage exhibit different behaviour:
with simultaneously applicable set and reset conditions
in the event of power failure or cable fracture

Complete the table and enter the behaviour of the respective valve.
Valve position unchanged/valve is actuated/valve switches to normal position

Signal storage via electrical latching circuit
combined with spring-return valve
Signal storage via
double solenoid
valve
Dominant setting Dominant resetting
Set and reset signal shared
Power failure


Festo Didactic GmbH & Co. KG 541090 A-85
Exercise 9: Expanding a diverting device
Exercise 9: Expanding a diverting device
Name: Date:
Fundamentals: Limit switches and proximity sensors Sheet 4 of 4

The function of limit switches and proximity sensors is to acquire information and to
transmit this for signal processing.

These include:
Mechanical position switches (limit switches), magnetic proximity sensors (reed
switches), optical proximity sensors, capacitive proximity sensors, inductive
proximity sensors

Allocate the designations to the corresponding symbols in the table.

Designation Symbol

BN
BU
BK


BN
BU
BK


BN
BU
BK


4 2
1


BN
BU
BK


A-86 Festo Didactic GmbH & Co. KG 541090
Exercise 9: Expanding a diverting device
Exercise 9: Expanding a diverting device
Name: Date:
Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

Design the pneumatic and electrical circuit diagram for the diverting device.

1M1 1M2
1V1
2 4
3 5
1
1V2 1V3
1A1
1 1
2 2


Pneumatic circuit diagram


Festo Didactic GmbH & Co. KG 541090 A-87
Exercise 9: Expanding a diverting device
Exercise 9: Expanding a diverting device
Name: Date:
Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

12
22
32
42
14
24
34
44
11
21
31
41
K1
14 12
11
1
S1
K1 1M1 1M2
+24 V 3 5 7 8 2 4 6
0 V
A1
A2
S2
31
13
32
14


Electrical circuit diagram


A-88 Festo Didactic GmbH & Co. KG 541090
Exercise 9: Expanding a diverting device
Exercise 9: Expanding a diverting device
Name: Date:
Compiling the equipment list Sheet 1 of 1

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


Festo Didactic GmbH & Co. KG 541090 A-89
Exercise 9: Expanding a diverting device



A-90 Festo Didactic GmbH & Co. KG 541090
Exercise 10: Designing a stamping device
To be able to design a pressure-dependent reversal control. Training aims
To familiarise yourself with the design and mode of operation of magnetic
proximity sensors.

Problem definition Small mounting blocks are to be stamped during the production of door frames.
These blocks are to be stamped by means of a stamping device.

The stamping pressure is to be 5.5 bar (550 kPa).

Parameters
1. Answer the questions or carry out the exercises regarding the fundamentals of
the training contents listed.
Project task
2. Design the pneumatic and electrical circuit diagrams.
3. Simulate the electropneumatic circuit diagram and check its correct functioning.
4. Compile an equipment list.
5. Carry out the pneumatic and electrical circuit assembly.
6. Check the circuit operation.

Festo Didactic GmbH & Co. KG 541090 A-91
Exercise 10: Designing a stamping device

Positional sketch

Stamping device


1. The pressing of a pushbutton is to cause the stamping device to advance and the
workpiece to be stamped.
2. The stamping tool is to return into the initial position once the stamping pressure
is obtained.


A-92 Festo Didactic GmbH & Co. KG 541090
Exercise 10: Designing a stamping device
Exercise 10: Designing a stamping device
Name: Date:
Fundamentals: Magnetic proximity sensor Sheet 1 of 5

In contrast with limit switches proximity sensors are switched contactlessly and
without an external mechanical actuating force.

Describe the design and function of a magnetic proximity sensor (reed switch).

Description: Design and function Symbol Schematic representation














BN
BU
BK




Festo Didactic GmbH & Co. KG 541090 A-93
Exercise 10: Designing a stamping device
Exercise 10: Designing a stamping device
Name: Date:
Fundamentals: Magnetic proximity sensors Sheet 2 of 5

As regards polarity there are two different designs of electronic proximity sensors,
i.e. PNP or NPN.

Describe the differences between these two types.

PNP NPN









A-94 Festo Didactic GmbH & Co. KG 541090
Exercise 10: Designing a stamping device
Exercise 10: Designing a stamping device
Name: Date:
Fundamentals: Pressure switches Sheet 3 of 5

Pressure sensitive sensors, so-called PE converters, are used to monitor the
pressure in a system.

Describe the mode of operation of PE converter.

Description of mode of operation






Festo Didactic GmbH & Co. KG 541090 A-95
Exercise 10: Designing a stamping device
Exercise 10: Designing a stamping device
Name: Date:
Fundamentals: Pressure sensors Sheet 4 of 5

Pressure sensors can be divided into two groups whereby differentiation is made
between:
Pressure sensors with mechanical contact (mechanical principle of action)
Pressure sensors with electronic switching
(electronic principle of action)

Describe the purpose and function of the pressure sensor shown below.

Description: Purpose and function Symbol Schematic representation








A-96 Festo Didactic GmbH & Co. KG 541090
Exercise 10: Designing a stamping device
Exercise 10: Designing a stamping device
Name: Date:
Fundamentals: Choice of proximity sensors Sheet 5 of 5

The end positions of a drive cylinder are to be sensed by means of proximity
sensors. The following requirements apply regarding the proximity sensors:
The end positions of the piston rod are to be sensed contactlessly
The proximity sensors are to be insensitive to dust
The piston rod and trip cam of the cylinder are made of metal

Choose which proximity sensors meet the specified requirements and explain
your reasons for this.

Proximity sensor Reason









Festo Didactic GmbH & Co. KG 541090 A-97
Exercise 10: Designing a stamping device
Exercise 10: Designing a stamping device
Name: Date:
Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

Design the pneumatic and electrical circuit diagrams for the stamping device.

1M1 1M2
1V1
2 4
3 5
1
1V2 1V3
1A1
1 1
2 2


Pneumatic circuit diagram


A-98 Festo Didactic GmbH & Co. KG 541090
Exercise 10: Designing a stamping device
Exercise 10: Designing a stamping device
Name: Date:
Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

7
K2 K3 K1 1M1 1M2
+24 V 1 3 5 8 2 4 6
0 V
1B1 1B2 1B3
A1 A1 A1
A2 A2 A2
p
12 12 12
22 22 22
32 32 32
42 42 42
14 14 14
24 24 24
34 34 34
44 44 44
11 11 11
21 21 21
31 31 31
41 41 41


Electrical circuit diagram


Festo Didactic GmbH & Co. KG 541090 A-99
Exercise 10: Designing a stamping device
Exercise 10: Designing a stamping device
Name: Date:
Compiling the equipment list Sheet 1 of 1

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



A-100 Festo Didactic GmbH & Co. KG 541090
Exercise 11: Realising a pallet loading station
To familiarise yourself with displacement-step diagrams and to be able to design
these for specified problem definitions.
Training aims
To be able to realise a sequence control using two cylinders.

Problem definition Stacks of roof tiles are to be strapped with a band and then transported to a pallet
loading station, where they are to be transferred onto Euro pallets.

Adjust the one-way flow control valve so that both cylinders retract at identical
speed.

Parameters
1. Design the displacement-step diagram. Project task
2. Draw up the corresponding function diagram and function chart.
3. Design the pneumatic and electrical circuit diagrams.
4. Simulate the electropneumatic circuit diagram and check its correct functioning.
5. Compile an equipment list.
6. Carry out the pneumatic and electrical circuit assembly.
7. Check the circuit operation.

Festo Didactic GmbH & Co. KG 541090 A-101
Exercise 11: Realising a pallet loading station

Positional sketch

Pallet loading station


1. Cylinder 1A1 is to advance when pushbutton S1 is pressed, whereby a single
package arrives at the loading point and sensor 1B2 is actuated.
2. Cylinder 2A1 advances, actuates sensor 2B2, and pushes the package onto the
pallet.
3. If 2B2 is actuated and S1 is unactuated, cylinder 1A1 retracts. 1B2 is therefore no
longer actuated and cylinder 2A1 retracts. Consequently, the overall sequence is:

1A1+ 2A1+ 1A1
2A1


A-102 Festo Didactic GmbH & Co. KG 541090
Exercise 11: Realising a pallet loading station
Exercise 11: Realising a pallet loading station
Name: Date:
Fundamentals: Designing the displacement-step diagram Sheet 1 of 3

If pushbutton S1 is actuated, cylinder 1A1 advances whereby the package reaches
its loading point and sensor 1B2 is actuated. Cylinder 2A1 advances, actuates
sensor 2B2 and pushes the package onto the pallet. If 2B2 is actuated and S1
unactuated, cylinder 1A1 retracts. 1B2 is no longer actuated and cylinder 2A1
retracts. Consequently the overall sequence is:

1A1+ 2A1+ 1A1
2A1

Design the displacement-step diagram for the problem definition described.

1A1
0
1
2A1
0
1
1 2 3 4=1


Displacement-step diagram


Festo Didactic GmbH & Co. KG 541090 A-103
Exercise 11: Realising a pallet loading station
Exercise 11: Realising a pallet loading station
Name: Date:
Completing the pneumatic and electrical circuit diagrams Sheet 1 of 2

Design the pneumatic and electrical circuit diagrams for the pallet loading
station.

1V1
2 4
3 5
1
1V2 1V3
1A1
2V2
2
3 1
2A1
2V1
1 1
2 2
2
1


Pneumatic circuit diagram


A-104 Festo Didactic GmbH & Co. KG 541090
Exercise 11: Realising a pallet loading station
Exercise 11: Realising a pallet loading station
Name: Date:
Completing the pneumatic and electrical circuit diagrams Sheet 2 of 2

1M1 1M2 2M1
+24 V 1 3 5 6 7 8 2 4
0 V
1B2 2B2
A1 A1 A1
A2 A2 A2
12 12 12
22 22 22
32 32 32
42 42 42
14 14 14
24 24 24
34 34 34
44 44 44
11 11 11
21 21 21
31 31 31
41 41 41
BN
BU
BK
BN
BU
BK


Electrical circuit diagram


Festo Didactic GmbH & Co. KG 541090 A-105
Exercise 11: Realising a pallet loading station
Exercise 11: Realising a pallet loading station
Name: Date:
Compiling the equipment list Sheet 1 of 1

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



A-106 Festo Didactic GmbH & Co. KG 541090
Exercise 12: Eliminating a fault on the pallet loading station
To be able to identify and eliminate faults in simple electropneumatic control
systems.

Training aims
Problem definition The pallet loading station stops during continuous operation. A fault has occurred
and must be eliminated. Thereafter the pallet loading station is to be re-started.

Only one fault has occurred.

Parameters
1. Describe the behaviour of the control system. Compare this with the correct
control system behaviour. Use the displacement-step diagram to assist you.
Project task
2. Localise potential causes of the fault with the help of the pneumatic and
electrical circuit diagrams.
3. Find the fault in the control system and eliminate it.
4. Re-start the control system.


Festo Didactic GmbH & Co. KG 541090 A-107
Exercise 12: Eliminating a fault on the pallet loading station


Pallet loading station


1. Cylinder 1A1 is to advance if pushbutton S1 is pressed. This causes a single
package to reach its loading point thereby actuating sensor 1B2.
2. Cylinder 2A1 advances, actuates sensor 2B2 and pushes the package onto the
pallet.
3. If 2B2 is actuated and S1 unactuated, cylinder 1A1 retracts, 1B2 is no longer
actuated and cylinder 2A1 retracts. Consequently the overall sequence is:

1A1+ 2A1+ 1A1
2A1


Positional sketch
A-108 Festo Didactic GmbH & Co. KG 541090
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station
Name: Date:
Fault finding in simple electropneumatic circuits Sheet 1 of 4

The following fault occurs in the circuit shown below:
The piston rod of cylinder 1A1 and the piston rod of cylinder 2A1 advance and
remain in the forward end position.

Describe what the potential causes of the fault could be.

1M1 1M2
1V1
2 4
3 5
1
1V2 1V3
1A1
1B2 2B2
2V2
2
2M1
3 1
2A1
2V1
1 1
2 2
2
1


Pneumatic circuit diagram


Festo Didactic GmbH & Co. KG 541090 A-109
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station
Name: Date:
Fault finding in simple electropneumatic circuits Sheet 2 of 4

K3
14 12
11
K2
14 12
11
K1
14 12
11
K2 K1 K3 1M1 1M2 2M1
+24 V 1 3 5 6 7 8 2 4
0 V
1B2 2B2
A1 A1 A1
A2 A2 A2
S1
13
14
12 12 12
22 22 22
32 32 32
42 42 42
.8 .7 .6
14 14 14
24 24 24
34 34 34
44 44 44
11 11 11
21 21 21
31 31 31
41 41 41
BN
BU
BK
BN
BU
BK


Electrical circuit diagram


List of potential causes of faults








A-110 Festo Didactic GmbH & Co. KG 541090
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station
Name: Date:
Fault finding in simple electropneumatic circuits Sheet 3 of 4

A cable break occurs at the areas marked in the circuit shown below.

Describe what the effects of a cable break at these respective points are on the
functioning of the circuit.

K3
14 12
11
K2
14 12
11
K1
14 12
11
K2 K1 K3 1M1 1M2 2M1
+24 V 1 3 5 6 7 8 2 4
0 V
1B2 2B2
A1 A1 A1
A2 A2 A2
S1
13
14
12 12 12
22 22 22
32 32 32
42 42 42
.8 .7 .6
14 14 14
24 24 24
34 34 34
44 44 44
11 11 11
21 21 21
31 31 31
41 41 41
BN
BU
BK
BN
BU
BK


Electrical circuit diagram


Festo Didactic GmbH & Co. KG 541090 A-111
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station
Name: Date:
Fault finding in simple electropneumatic circuits Sheet 4 of 4

Fault Effect of fault
Break in earthing wire of
relay K1 (current path 2)


Break in signal line of
sensor 2B2 (current path 4)


Break in supply line of relay
K3 (current path 5)


Break in supply line of relay
contact 14 at K2 (current
path 7)

Break in earthing wire 2M1
(current path 8)




A-112 Festo Didactic GmbH & Co. KG 541090
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station
Name: Date:
Fault finding: Determining the required status Sheet 1 of 9

Create the displacement-step diagram with the help of the documentation given
out.

Time
Designation Signal Identification
Components
Step
1 2 3 4 5 6 7 8 9 10


Displacement-step diagram


Festo Didactic GmbH & Co. KG 541090 A-113
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault in the pallet loading station
Name: Date:
Fault finding: Setpoint/actual comparison Sheet 2 of 9

Determine the ACTUAL status of the system with the help of the following
documentation:
Positional sketch with problem description
Graphic representation

If the correct function is not given (REFERENCE/ACTUAL comparison), clearly
mark the area in the diagram where the fault occurs.

Time
Designation Signal Identification
Components
Step
1 2 3 4 5 6 7 8 9 10


Displacement-step diagram


A-114 Festo Didactic GmbH & Co. KG 541090
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station
Name: Date:
Fault finding: Description of faults Sheet 3 of 9

You have marked the area where a fault occurs in the diagram of the worksheet
REFERENCE/ACTUAL comparison.

Describe the process up the point where the station or system stops.

_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________


Festo Didactic GmbH & Co. KG 541090 A-115
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station
Name: Date:
Fault finding: Definition of faults - pneumatics Sheet 4 of 9

Once you have established the ACTUAL status of the system, consider what the
causes of the faults could be.

In which pneumatic tubing connections could the fault occur?

Enter all the possibilities and indicate components at the start and end of the
tubing connection in order to ensure clear identification.

Potential fault
No.
Tubing connection
Start

End










Potential faults


A-116 Festo Didactic GmbH & Co. KG 541090
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station
Name: Date:
Fault finding: Definition of faults electrics Sheet 5 of 9

Once you have established the ACTUAL status of the system, consider what the
causes of the faults could be.

In which current paths could the fault be located?
What is the function of the current path?

Enter all the possibilities.

Potential fault
No.
Current path No. Function of current path


























Potential faults


Festo Didactic GmbH & Co. KG 541090 A-117
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station
Name: Date:
Fault finding: Localisation of faults - pneumatics Sheet 6 of 9

Investigate the potential causes of errors you have found in the pneumatics.

Use the same fault numbering that you have used for the worksheet Definition
of faults pneumatic.
Document the procedure used to investigate the tubing connections.

Enter the results of your investigation.

Measuring and test protocol
Potential fault
No.
Tubing connection
Start

End
Inspection Result



















Measuring and test protocol


A-118 Festo Didactic GmbH & Co. KG 541090
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station
Name: Date:
Fault finding: Localisation of faults Sheet 7 of 9

Investigate the potential error causes you have found.

Use the same fault numbering that you have used in the worksheet Definition of
faults - electrics.
Document the procedure you have used to check the line connection.

Enter the result of the investigation.

Measuring and test protocol
Potential fault
No.
Current path
No.
Measuring points

Inspection Result






















Measuring and test protocol


Festo Didactic GmbH & Co. KG 541090 A-119
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station
Name: Date:
Fault finding: Elimination of fault Sheet 8 of 9

Once you have localised the failure location, your procedure for the elimination of
the fault must be documented on this worksheet.

Describe each of the steps carried out in detail.

_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

Note
In the event of the system not fulfilling the intended function return to the first
worksheet and repeat the fault finding.

Ask for new worksheet s to do so.

A-120 Festo Didactic GmbH & Co. KG 541090
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station
Name: Date:
Fault finding: Re-starting Sheet 9 of 9

Once you have identified, localised and eliminated the fault, re-start the system in
accordance with the required status.
Reset the specified required times.

Briefly document the procedure followed in note form.

_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________


Festo Didactic GmbH & Co. KG 541090 A-121
Exercise 12: Eliminating a fault on the pallet loading station


A-122 Festo Didactic GmbH & Co. KG 541090