Learning System for Automation and Communications Electrohydraulics Workbook Basic Level 094470 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.S601-C-SIBU-GB Edition: 11/1998 Layout: 10.1998, OCKER Ingenieurbüro Graphics: OCKER Ingenieurbüro Author: D. Werner © Copyright by Festo Didactic GmbH & Co., D-73770 Denkendorf 1998 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. TP601 • 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 Training Packages are structured accordingly: Basic Packages provide fundamental knowledge which is not limited to a specific technology. Technology Packages deal with the important areas of open-loop and closed-loop control technology. Function Packages explain the basic functions of automation sys- tems. Application Packages provide basic and further training closely ori- ented 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 Example of Hydraulics 2000: Mobile laboratory trolley U = 230V~ Profile plate p = 6 MPa Storage tray TP601 • 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, electronic transparencies for PCs 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, CAD programs, computer-based training programs and programming software for programmable logic controllers are avail- able.
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. TP601 • Festo Didactic 5 Latest information about the technology package TP601. 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 datasheets TP601 • Festo Didactic 6 TP601 • Festo Didactic 7 Table of contents Introduction 11 Notes on safety 13 Notes on operation 14 Technical notes 15 Training contents 21 Training aims/exercise table (Table 1) 22 Equipment set for Basic Level TP 601 23 Equipment set for Advanced Level TP 602 26 List of additional components for TP600 27 Component/exercise table (Table 2) 28 Methodological structure of exercises 29 Part A – Course Simple control circuits without limit switches Exercise 1: Sorting device Double-acting cylinder, directly actuated, manually A-3 Exercise 2: Component selection on conveyor belt Double-acting cylinder, indirectly actuated, manually A-13 Exercise 3: Lifting station Single-acting cylinder, indirectly actuated, manually A-23 Exercise 4: Bending device Double-acting cylinder, latching A-29 Exercise 5: Press-fitting device Double-acting cylinder, latching, return stroke using pressure switch A-33 TP601 • Festo Didactic 8 Exercise 6: Stamping machine Double-acting cylinder, differential circuit A-39 Exercise 7: Door control Double-acting cylinder, interlock, INCHING operation A-43 Control circuits with limit switches Exercise 8: Machining unit Differential circuit return stroke using limit switch A-49 Exercise 9: Feed for drilling machine Rapid-traverse feed circuit, speeds controlled by limit switch A-53 Exercise 10: Press Pressure control circuit with limit switch and pressure switch A-59 Exercise 11: Feed device Pressureless pump bypass with limit switch A-63 Control circuits with two actuators Exercise 12: Assembly device Pressure-dependent sequence control with cylinder and hydraulic motor A-69 Exercise 13: Lifting device for packages Position-dependent sequence control with two cylinders A-75 TP601 • Festo Didactic 9 Part B – Fundamentals Teil C – Solutions Solution 1: Sorting device C-3 Solution 2: Component selection on conveyor belt C-7 Solution 3: Lifting station C-11 Solution 4: Bending device C-15 Solution 5: Press-fitting device C-19 Solution 6: Stamping machine C-23 Solution 7: Door control C-27 Solution 8: Machining unit C-33 Solution 9: Feed for drilling machine C-39 Solution 10: Press C-45 Solution 11: Feed device C-49 Solution 12: Assembly device C-55 Solution 13: Lifting device for packages C-61 Part D – Appendix Storage tray D-2 Mounting systems D-3 Sub-base D-5 Coupling system D-6 Data sheets. TP601 • Festo Didactic 10 TP601 • Festo Didactic 11 Introduction This workbook forms part of Festo Didactic’s Learning System for Auto- mation and Communications.
The Training Package TP 600 is designed to provide an introduction to the fundamentals of electrohydraulic control technology. This package comprises a basic level and an advanced level. The basic level package TP 601 teaches basic knowledge of electrohydraulic control technology. The equipment sets TP 601 and TP 602 (for the advanced level) provide the student with the key qualifica- tion “Technical competence”.
The hydraulic components have been designed to provide the following: Easy handling Secure mounting Environmentally-friendly coupling system Compact component dimensions Authentic measuring methods You will require the following for the practical execution of the exercises: A Festo Didactic profile plate or a laboratory trolley An equipment set TP 601 (cylinders, valves, relay plate, .) A hydraulic power pack A number of hydraulic hose lines An electrical power supply unit A set of electrical cables The Training Package TP 601 specifies fundamental training contents. These help develop both technical and methodological competence in electrohydraulics: Physical interrelationships in electrical engineering and hydraulics Drafting, assembly and understanding of basic electrohydraulic cir- cuits Comparison of the use of various valves and other components Development of alternative solutions TP601 • Festo Didactic 12 The technical requirements for safe operation of the components are as follows: A hydraulic power pack to provide an operating pressure between 0.5 and 6 Mpa (5 to 60 bar) and a flow rate of 2 l/min. An electrical power supply for the above of 230 V AC, 50 Hz, with a 10 A fuse. A short-circuit-proof electrical power supply for the electrical compo- nents with an output of 24 V DC and a 3 A fuse.
A profile plate to mount the components The profile plate (1100 x 700 mm) has 14 parallel T-grooves at inter- vals of 50 mm. This workbook has been developed for use in the “Dual system” of vo- cational training. It is, however, equally suitable for use in providing a practical introduction to electrohydraulics for students at universities and technical colleges. The modular design of the hardware allows theoreti- cal questions to be dealt with experimentally in a simple and efficient form.
The theoretical background to facilitate understanding of this workbook is provided in the textbook Learning System for Automation and Communications Electrohydraulics Basic Level Festo Didactic also offers the following further training materials for hy- draulics: Sets of OHP transparencies and electronic transparencies for PCs Linear videos and interactive videos (video discs) Autosketch CAD software and symbol library Hydraulics simulation program for planning, simulation and visualisa- tion (in course of preparation) Sets of magnetic symbols and symbols for OHPs, hydraulic slide rule Transparent models for OHPs, with special hydraulic power pack Equipment sets: BIBB, hand-lever hydraulics, proportional hydraulics, closed-loop hydraulics, measurement kit in case Please see our special brochures for a detailed description of further training materials. TP601 • Festo Didactic 13 Notes on safety Observe the following in the interests of your own safety: Caution! Cylinders may move unexpectedly when the hydraulic power pack is switched on. Do not exceed the maximum permissible hydraulic operating pres- sure. See the relevant data sheets.
Do not operate electrical limit switches directly by hand when carrying out fault-finding. Use a tool for this. Use only an extra-low voltage of 24 to operate the components. Observe all general safety instructions.
TP601 • Festo Didactic 14 Notes on operation Assembly Always work in the following sequence when assembling or dismantling an electrohydraulic 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 or mount- ing frame. Connect up the hydraulic hose lines.
All valves, other components and hose lines are fitted with self- closing quick-acting couplings. Do not exceed the maximum permis- sible pressure of 12 MPa (120 bar). The maximum operating pres- sure is 6 MPa (60 bar). Connect up the electrical cables.
Connect test leads to the component sockets by means of 4 mm plugs. Before commissioning a hydraulic control circuit, check that all return lines are connected and that all connectors are secure. 6 Switch on the electrical power supply first and then the hydraulic power pack. Commissioning the control circuit – Press the START pushbutton – Set components, etc.
– Compare what you have assembled with the description in thebook. Before dismantling the circuit, ensure that pressure in hydraulic com- ponents has been released: Couplings must be disconnected only under zero pressure! 9. Switch off the hydraulic power pack first and then the electrical power supply. TP601 • Festo Didactic 15 Technical notes Observe the following in order to ensure safe operation.
The hydraulic power pack incorporates an adjustable pressure relief valve. In the interests of safety, the pressure is limited to approx. Every time a control circuit is assembled on the pro- file plate, a second pressure relief valve is used. We recommend that this should be set to a maximum pressure of 5 MPa (50 bar).
All valves, cylinders and hose lines are fitted with quick-acting cou- plings which ensure minimum leakage. The maximum pressure for all components in the training package is 12 MPa (120 bar). Thanks to their design, the couplings reduce leakage during connection and disconnection to a minimum. The operating pressure should not exceed 6 MPa (60 bar) 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 6 MPa (60 bar), this increased pressure may be over 10 MPa (100 bar)! 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 relief device can be used to release this pressure.