Learning System for Automation and Communications Hydraulics Workbook Advanced Level 094015 Authorised applications and liability The Learning System for Automation and Communication has been de- veloped and prepared exclusively for training in the field of automation and communication. The training organization and / or trainee shall en- sure that the safety precautions described in the accompanying Techni- cal documentation are fully observed. Festo Didactic hereby excludes any liability for injury to trainees, to the training organization and / or to third parties occurring as a result of the use or application of the station outside of a pure training situation, un- less caused by premeditation or gross negligence on the part of Festo Didactic.S502-C-GB Edition: 06/1999 Layout: 14.1999, OCKER Ingenieurbüro Graphics: OCKER Ingenieurbüro Author: Th. Ocker © Copyright by Festo Didactic GmbH & Co., D-73770 Denkendorf 1999 The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited.
Offenders will be held liable for the payment of damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design registrations. Parts of this training documentation may be duplicated, solely for train- ing purposes, by persons authorised in this sense. TP502 • Festo Didactic 3 Preface Festo Didactic’s Learning System for Automation and Communications is designed to meet a number of different training and vocational re- quirements.
The Festo Training Packages are structured accordingly: Basic Packages provide fundamental knowledge of a wide range of technologies. Technology Packages deal with important areas of open-loop and closed-loop control technology. Function Packages explain the basic functions of automation sy- stems. Application Packages provide basic and further training closely orien- ted to everyday industrial practice.
Technology Packages deal with the technologies of pneumatics, elec- tropneumatics, programmable logic controllers, automation with PCs, hydraulics, electrohydraulics, proportional hydraulics and application technology (handling). 1: Mounting frame Hydraulics 2000 – i. mobile workstation U = 230V~ Profile plate p = 6 MPa Storage tray TP502 • Festo Didactic 4 The modular structure of the Learning System permits applications to be assembled which go beyond the scope of the individual packages. It is possible, for example, to use PLCs to control pneumatic, hydraulic and electrical actuators.
All training packages have an identical structure: Hardware Courseware Software Courses The hardware consists of industrial components and installations, adapted for didactic purposes. The courseware is matched methodologically and didactically to the training hardware. The courseware comprises: Textbooks (with exercises and examples) Workbooks (with practical exercises, explanatory notes, solutions and data sheets) OHP transparencies and videos (to bring teaching to life) Teaching and learning media are available in several languages. They have been designed for use in classroom teaching but can also be used for self-study purposes.
In the software field, computer-based training programs and program- ming software for programmable logic controllers are available. Festo Didactic’s range of products for basic and further training is com- pleted by a comprehensive selection of courses matched to the contents of the technology packages. TP502 • Festo Didactic 5 Latest information about the technology package TP502. New in Hydraulic 2000: Industrial components on the profile plate.
Exercises with exercise sheets and solutions, leading questions. Fostering of key qualifications: Technical competence, personal competence and social competence form professional competence. Training of team skills, willingness to co-operate, willingness to learn, independence and organisational skills. Aim – Professional competence Content Part A Course Exercises Part B Fundamentals Reference to the text book Part C Solutions Function diagrams, circuits, descriptions of solutions and quipment lists Part D Appendix Storage tray, mounting technology and data sheets TP502 • Festo Didactic 6 TP502 • Festo Didactic 7 Table of contents Introduction 9 Notes on safety 11 Notes on operation 11 Standard method of representation used in circuit diagrams 12 Technical notes 13 Training contents of “Hydraulics, Advanced Level” TP502 16 Hydraulic equipment set 18 Component/exercise table for TP502 22 Section A – Course Exercise 1: Hose-reel drive system for tanker truck Hydraulic motor A-3 Exercise 2: Table feed for a rough-grinding machine Bypass with 2-way flow control valve A-7 Exercise 3: Lifting device with two cylinders Flow divider A-11 Exercise 4: Rapid-traverse feed device for a drilling machine Rapid-traverse feed circuit A-15 Exercise 5: Control system for a scrap press Differential circuit A-21 Exercise 6: Clamping a gearbox casing Accumulator A-27 Exercise 7: Plastic injection-moulding machine Dual pressure circuit A-31 Exercise 8: Pipe-bending machine Rectifier circuit A-35 Exercise 9: Single-column press Flow control valves in inlet and outlet lines A-39 Exercise 10: Machining centre Sequence control with two cylinders A-45 Exercise 11: Magnetic crane Tractive load A-49 TP502 • Festo Didactic 8 Exercise 12: Folding machine Pressure regulator A-53 Exercise 13: Earth drill Rapid-traverse circuit with accumulator A-59 Exercise 14: Machining centre Electrical sequence control A-65 Section B – Fundamentals Section C – Solutions Solution 1: Hose-reel drive system for tanker truck C-3 Solution 2: Table feed for a rough-grinding machine C-7 Solution 3: Lifting device with two cylinders C-13 Solution 4: Rapid-traverse feed device for a drilling machine C-17 Solution 5: Control system for a scrap press C-21 Solution 6: Clamping a gearbox casing C-27 Solution 7: Plastic injection-moulding machine C-31 Solution 8: Pipe-bending machine C-35 Solution 9: Single-column press C-39 Solution 10: Machining centre C-43 Solution 11: Magnetic crane C-47 Solution 12: Folding machine C-51 Solution 13: Earth drill C-57 Solution 14: Machining centre C-63 Section D – Appendix Storage tray D-3 Mounting systems D-4 Sub-base D-6 Coupling system D-7 Data sheets.
TP502 • Festo Didactic 9 Introduction This workbook forms part of Festo Didactic’s Learning System for Automation and Communications. The Technology Package “Hydrau- lics”, TP500, is designed to provide an introduction to the fundamentals of hydraulic control technology. This package comprises a basic level and an advanced level. The basic level package TP501 teaches basic knowledge of hydraulic control technology, while the advance level package TP502 builds on this.
The basic level hydraulic exercises are designed to be carried out with manual actuation. It is, however, also possible to use electrical actua- tion. The hydraulic components have been designed to provide the fol- lowing: Easy handling Secure mounting Environmentally-friendly coupling system Compact component dimensions Authentic measuring methods We recommend the following for the practical execution of the exer- cises: Hydraulic components: Equipment set TP501 and TP502 One hydraulic power pack A number of hose lines A profile plate or a suitable laboratory trolley A measuring set with the appropriate sensors TP502 • Festo Didactic 10 This workbook provides knowledge of the physical interrelationships and the most important basic circuits in hydraulics. The exercises deal with the following: Plotting of characteristics for individual components Comparison of the use of different components Assembly of various basic circuits Use of basic hydraulics equations The following technical equipment is required for safe operation of the components: A hydraulic power pack providing an operating pressure of 60 bar and a flow rate of 2 l/min An electrical power supply of 230V AC for the hydraulic power pack A power supply unit with an output of 24V DC for solenoid-actuated valves A Festo Didactic profile plate for mounting the components The theoretical background is described in the “Hydraulics Basic Level” textbook TP501.
Technical descriptions of the components used are given in the data sheets in Part D of this workbook. Festo Didactic offers the following further training material for hydraulics: Magnetic symbols Hydraulics slide rule Set of OHP transparencies Transparent models Interactive video Symbol library TP502 • Festo Didactic 11 Notes on safety Observe the following in the interests of your own safety: Exercise care when switching on the hydraulic power pack. Cylinders may advance unexpectedly! Do not exceed the maximum permissible operating pressure (see data sheets). Observe all general safety instructions (DIN 58126 and VDE 100).
Notes on operation Always work in the following sequence when assembling a hydraulic circuit. The hydraulic power pack and electrical power supply must be switched off during the assembly of the circuit. All components must be securely fitted to the profile plate, i. se- curely snap-fitted or bolted down.
Check that all return lines are connected and all hose lines are se- curely fitted. Switch on the electrical power supply first and then the hydraulic power pack. Before dismantling the circuit, ensure that pressure in hydraulic com- ponents has been released: Couplings must be connected and disconnected only under zero pressure! 6. Switch off the hydraulic power pack first and then the electrical power supply.
TP502 • Festo Didactic 12 Standard method of representation used in circuit diagrams The hydraulic circuit diagrams are based on the following rules: Clear representation avoiding crossovers as far as possible Symbols conforming to DIN/ISO 1219 Part 1 Circuit diagrams with several loads are divided into control chains Identification of components in accordance with DIN/ISO 1219 Part 2: • Each control chain is assigned an ordinal number 1xx, 2xx, etc. • The hydraulic power pack is control chain 0xx. • Identification of components by letters: A – Power component B – Electrical sensors P – Pump S – Signal generator V – Valve Z – Other component • The complete code for a component consists of – a digit for the control chain, – a letter for the component, – a digit for the consecutive numbering of components in accor- dance with the direction of flow in the control chain. Example: 1V2 = Second valve in control chain 1.
TP502 • Festo Didactic 13 Technical notes Observe the following in order to ensure safe operation. The hydraulic power pack PN 152962 incorporates an adjustable pressure relief valve. In the interests of safety, the pressure is limited to approx. The maximum permissible pressure for all hydraulic components is 120 bar (12 MPa).
The operating pressure should not exceed 60 bar (6 MPa). In the case of double-acting cylinders, the pressure intensification effect may produce an increased pressure proportional to the area ratio of the cylinder. With an area ratio of 1:1.7 and an operating pressure of 60 bar (6 MPa), this increased pressure may be over 100 bar (10 MPa)! Fig. 2: Pressure intensification If connections are detached under pressure, the non-return valve in the coupling may cause pressure to become trapped in the valve or other component concerned.
The pressure relieving device PN 152971 can be used to release this pressure. Exception: This is not possible in the case of hose lines and non-return valves. All valves, other components and hose lines are fitted with self- closing quick-release couplings. This prevents the accidental spillage of hydraulic fluid.
In the interests of simplicity, these couplings are not shown in circuit diagrams. 3: Simplified drawing of self-closing couplings Throttle valve Hose Shut-off valve TP502 • Festo Didactic 14 It is frequently necessary when assembling a control circuit to modify the given circuit diagram. Within the scope of the equipment set in this Training Package, the following alternative solutions are possible: – Plugs can be used to change the function of directional control valves (Figs. – Directional control valves with different normal positions can be used (Fig.
– Solenoid-actuated valves can be used in place of hand lever valves (Fig. 4: 2/2-way valve 3/2-way valve Circuit diagram Fig. 5: 4/2-way valve 4/2-way valve Practical assembly Fig. 6: Circuit diagram Practical assembly Directional control valves with various normal positions Fig.
7: Solenoid-actuated directional control valve TP502 • Festo Didactic 15 Flow rate sensor The flow rate sensor consists of: A hydraulic motor, which converts the flow rate q into a rotary speed n. A tachogenerator, which produces a voltage V proportional to the rotary speed n.