Worksheets Pneumatics Basic Level

Contents
Exercises and worksheets
Exercise 1: Pressing cheeses........................................................................................................................... 3

Exercise 2: Run-on brake on a drive shaft ..................................................................................................... 11
Exercise 3: Clamping boards on a saw machine ............................................................................................ 17
Exercise 4: Loading packages ....................................................................................................................... 23
Exercise 5: Stopping milk bottles .................................................................................................................. 33
Exercise 6: Opening and closing a supply pipe ............................................................................................. 39
Exercise 7: Shutting off using a quick power lockout .................................................................................... 47
Exercise 8: Actuating a shut-off device ......................................................................................................... 53
Exercise 9: Expanding a control system to enable cheese pressing .............................................................. 61
Exercise 10: Clamping a workpiece ............................................................................................................... 69
Exercise 11: Loading mesh baskets .............................................................................................................. 77
Exercise 12: Actuating a sliding door ............................................................................................................ 83
Exercise 13: Feeding in wooden boards ........................................................................................................ 91
Exercise 14: Pressing drinks cans ................................................................................................................. 97
Exercise 15: Stamping valve housings ........................................................................................................ 105
Exercise 16: Mounting locking clips ............................................................................................................ 113
Exercise 17: Labeling paint buckets ............................................................................................................ 121
Exercise 18: Cleaning workpieces ............................................................................................................... 129
Exercise 19: Pressing product labels into place .......................................................................................... 137
© Festo Didactic 541088 1

Contents
2 © Festo Didactic 541088

Exercise 1:
Pressing cheeses
Training aims
After completing this exercise, you will:
• Be familiar with the setup and function of a single-acting cylinder.
• Be able to calculate the piston force of a single-acting cylinder.
• Be familiar with the setup and function of a 3/2-way valve, normally closed.
• Be able to recognize and sketch the various types of actuation used for directional control valves.
• Be able to explain and set up direct actuation.
Description of the problem

In cheese manufacturing, pneumatic cylinders are used to press the cheese into molds. Develop a control
system that can be used to carry out this process.
Layout
Cheese manufacturing – press

Exercise 1: Pressing cheeses
Description of the process

1. The cheese is inserted in the press by hand.
2. When a pushbutton actuator is pressed, the piston rod on the cylinder advances and presses the lid
onto the mold.
3. The pushbutton actuator is held down until the pressing procedure is complete.
4. When the pushbutton actuator is released, the piston rod retracts again, allowing access to the mold.
5. The cheese can then be removed.
Parameters
• Use a single-acting cylinder.
• The cylinder must be pneumatically controlled using a manually operated valve.
Work assignments
1. Describe the setup and function of a single-acting cylinder.
2. Calculate the piston force of a single-acting cylinder.
3. Describe the setup and function of a 3/2-way valve, normally closed.
4. Complete the pneumatic circuit diagram for the press.
5. Create an equipment list.
6. Set up the control system.
7. Check the setup of the control system.
8. Describe the working sequence for the control system.
Work aids
• Books of tables
• Textbook: Fundamentals of pneumatics and electropneumatics
• Component data sheets
• FluidSIM® P design and simulation software
• WBT: Pneumatics
Safety instructions
• For this exercise, limit the pressure on the filter regulating valve (service unit)
to max. 350 kPa (3.5 bar).
• If tubing slips off: switch off the compressed air supply immediately.
4 Name: __________________________________ Date: ____________ © Festo Didactic 541088

1. Setup and function of a single-acting cylinder
Single-acting cylinder – circuit symbol and cutaway view
a) Compare the circuit symbol shown above with the schematic diagram of the single-acting cylinder.
Determine whether or not the two diagrams match.
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b) Assign the corresponding number to each component in the drawing above.
Component Designation
Cylinder barrel
End cap
Bearing cap
Piston rod
Piston
Ring magnet
Piston seal
Spring return
Compressed air supply port
Guide bushing
Exhaust hole
© Festo Didactic 541088 Name: __________________________________ Date: ____________ 5

c) Describe the setup and function of a single-acting cylinder.
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2. Calculating the piston force of a single-acting cylinder
Information
The theoretical piston force is calculated using the following formula:
Fth = A ∙ p
Fth Theoretical piston force (N) A Useful piston area (m2)

D2 ⋅ π
( )
4
p Working pressure (Pa) D Cylinder diameter (m)
In practice, it is the effective piston force Feff that is important. When calculating this, the frictional
resistance must be taken into consideration. Under normal operating conditions (pressure range:
400 to 800 kPa/4 to 8 bar), the friction forces (FR) can be assumed as being approx. 10% of the
theoretical piston force.
The effective piston force of a single-acting cylinder is calculated as follows:

Feff = A ( p – (FR + FF)
Feff Effective piston force (N) FR Friction force (approx. 10% of Fth) (N)
FF Spring return force (N)

– Calculate the effective piston force during the forward stroke for the cylinder in question at a working
pressure of 600 kPa (6 bar).
Calculating the piston area and piston force
Note
Consult the cylinder data sheet for the necessary data.
3. How a 3/2-way valve, normally closed, works
a) Complete the circuit symbol of a manually operated, normally closed 3/2-way valve with spring return.
3/2-way valve, manually operated, with spring return, normally closed – circuit symbol and cutaway view

b) Describe how the 3/2-way valve works.
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4. Completing the pneumatic circuit diagram
– Complete the pneumatic circuit diagram for the press. Add any incomplete circuit symbols. Label the
individual components and enter the missing port designations.

5. Creating the equipment list
– Create the equipment list. Enter the quantity, identification and designation of the required components
in the table below.
Quantity Identification Designation
1 Distributor block
1 On-off valve with filter regulating valve
1 — Compressed air source
6. Setting up the control system

Observe the following points when setting up the control system:
• Use the circuit diagram.
• Designate the components.
• Lay the compressed air tubing using the shortest routes possible.
• Push the compressed air tubing into the push-in connector as far as it will go.
• Mark the connected compressed air tubing on the circuit diagram.
7. Double-checking the control system setup

Observe the following points when commissioning the control system:
• Check all the tubing connectors.
• For the first test run, reduce the pressure on the filter regulating valve
(service unit) to 350 kPa (3.5 bar).
• Switch on the compressed air supply at the service unit.
• Check that the control system is working correctly.
• Increase the pressure to the level specified in the exercise instructions.
• Allow the control system to run through several complete cycles.

Risk of injury when switching on the compressed air!

Cylinders may advance and retract automatically.
Risk of injury if compressed air tubing slips off!

If compressed air tubing slips off, shut off the compressed air supply immediately.
8. Describing the control system sequence
– Describe the individual steps of the control system sequence.
Initial position
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Step 1-2
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Step 2-3
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Exercise 2:
Run-on brake on a drive shaft
Training aims
• Be familiar with the setup and function of a 3/2-way valve, normally open.

An older engine plant has been retrofitted with a brake. The brake is designed to reduce the length of time
for which the drive shaft runs on when the engine comes to a stop after the clutch is disengaged. The brake
force is generated by the spring return in the cylinder. The brake is actuated via a pushbutton actuator on
the machine control console.
Layout
Run-on brake

Exercise 2: Run-on brake on a drive shaft

1. When the pushbutton actuator is pressed, the piston rod on the cylinder retracts due to the force of the
spring return.
2. The pushbutton actuator is held down for as long as the drive shaft needs to be braked.
3. When the pushbutton actuator is released, the piston rod advances again, releasing the brake.
Parameters
• Use a single-acting cylinder.
• The cylinder must be pneumatically controlled using a manually operated valve.
Work assignments
1. Answer the questions on the 3/2-way valve with pushbutton actuator, normally open.
2. Complete the pneumatic circuit diagram for the run-on brake control system.
3. Change the equipment list.
Work aids
• Books of tables
• WBT: Pneumatics
Safety instructions

1. How a 3/2-way valve works
a) Complete the circuit symbol for the 3/2-way valve. It must possess the following functions: manually
operated, spring return, normally open.
3/2-way valve, manually operated, with spring return, normally open – circuit symbol and cutaway view
b) Explain how a 3/2-way valve, normally open, works.
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– Complete the pneumatic circuit diagram for the run-on brake. Add any incomplete circuit symbols. Label
the individual components and enter the missing port designations.
Note
Control systems can be shown in their initial positions.

3. Changing the equipment list
– Change the equipment list below to match the requirements for this control system.
1 -MM1 Cylinder, single-acting
1 -SJ1 3/2-way valve with pushbutton actuator, normally closed
1 -XM1 Distributor block
1 -AZ1 On-off valve with filter regulating valve
Equipment list, template
Modified equipment list






Initial position
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Step 1-2
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Step 2-3
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Exercise 3:
Clamping boards on a saw machine
Training aims
• Be able to analyze and evaluate control systems.

A circular saw is used to cut boards to length. They are inserted in the saw machine by hand. The awing
process itself is controlled using a dedicated control console. To this end, the boards are clamped on the
saw table. For the test build, the control system will be set up with only one cylinder.
Layout
Saw machine

Exercise 3: Clamping boards on a saw machine

1. A board is placed on the saw table by hand.
2. When a switch is pressed, the cylinder's piston rod advances to hold the board in place.
3. The piston rod remains in this position when the switch is released.
4. When the switch is reset, the piston rod moves to the retracted end position and remains there until the
switch is pressed again.
Parameters
• Use the control system from one of the previous tasks and adapt it to deal with this problem.
• For example, you could use just one single-acting cylinder to develop the control system.
Work assignments
1. Read about the different types of actuation used for directional control valves.
2. Complete the pneumatic circuit diagram for the clamping device.
3. Change the equipment list.
Work aids
• Books of tables
• WBT: Pneumatics
Safety instructions

1. Types of actuation used for directional control valves
Information
The type of actuation used for the directional control valves depends on the system requirements.
The following types of actuation are possible:
• Manually operated • Mechanically actuated
• Pneumatically actuated • Combined types of actuation
A complete description of a directional control valve in the pneumatic circuit diagram includes:
• The basic type of actuation method • The return control
used for the valve
• The pilot control (where applicable) • Additional types of actuation
(where applicable)
Each actuation symbol is drawn on the side of the switching position that corresponds to its
direction of action.
Function Symbol
Manual operation
Pressing
Turning
Lever operation
Mechanical actuation
With plunger
With roller plunger
With roller lever
Pneumatic actuation
Using compressed air
Pneumatic spring return
Mechanical components
Spring return

a) Complete the circuit diagrams below by entering the required type of actuation for the directional
control valve in question.

b) Select the right control system and explain your choice.
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3. Changing the equipment list
– Change the equipment list. Enter the quantity, identification and designation of the required
components in the table below.
Modified equipment list





Initial position
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Step 1-2
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Step 2-3
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Exercise 4:
Loading packages
Training aims
• Be familiar with the setup and function of a double-acting cylinder.
• Be able to calculate the piston force of a double-acting cylinder for the forward and return strokes.
• Be familiar with the setup and function of a 5/2-way valve.

On a loading station, packages are separated out and sorted into transport containers by hand. When the
containers are full, they are shipped out and replaced with new, empty containers. During the changeover,
the flow of materials needs to be paused, though the conveyor belt keeps running. The packages are
stopped from moving by a mechanical block (locking blade). This needs to be operated from the loading
station.
Layout
Loading station

Exercise 4: Loading packages

1. When the selector switch is pressed, the piston rod on the cylinder advances and pushes the locking
blade into the flow of materials.
2. The piston rod remains in this position when the selector switch is released, so the flow of materials
cannot continue.
3. When the selector switch is released, the piston rod moves to the retracted end position, allowing the
flow of materials to continue. The piston rod remains retracted until the selector switch is actuated
again.
Parameters
• Since work needs to be carried out on both the forward and the return strokes, you will need to use a
double-acting cylinder.
Work assignments
1. Describe the setup and function of a double-acting cylinder.
2. Calculate the piston force of a double-acting cylinder for the forward and return strokes.
3. Describe how a 5/2-way valve works.
4. Complete the pneumatic circuit diagram for the loading station.
5. Complete the equipment list.
Work aids
• Books of tables
• WBT: Pneumatics
Safety instructions

1. Setup and function of a double-acting cylinder
Double-acting cylinder – circuit symbol and cutaway view
a) Match up the numbers from the schematic drawing to the individual components of the double-acting
cylinder.
Component Designation
Cylinder barrel
End cap
Bearing cap
Piston rod
Piston
Ring magnet
Piston seal
Compressed air supply port for piston chamber
Compressed air supply port for piston rod chamber
Seal
Seal and dirt wiper
Guide bushing
Damping piston
Adjustable end-position cushioning

b) Compare the circuit symbol shown above with the schematic diagram of the double-acting cylinder.
Determine whether or not the two diagrams match.
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c) Write down the similarities and differences between single-acting and double-acting cylinders.
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d) Describe how a double-acting cylinder works.
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Forward stroke
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Return stroke
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e) What requirements must a directional control valve fulfill in order to be able to actuate a double-acting
cylinder?
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f) Explain why the actuation function for the directional control valve needs to be performed by a switch.
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2. Calculating the piston force of a double-acting cylinder for the forward and return strokes
Information
The theoretical piston force is calculated using the following formula:
Fth = A ⋅ p
For double-acting cylinders, the following applies:

Forward stroke Feff = (A ⋅ p) – FR Return stroke Feff = (A' ⋅ p) – FR
Feff Effective piston force (N)

A Useful piston area (m2) A' Useful piston ring area (m2)
D2 ⋅ π (D2 − d 2 ) ⋅ π
( )
4 4
p Working pressure (Pa) FR Friction force (approx. 10% of Fth) (N)
D Piston diameter (m) d Piston rod diameter (m)

– Calculate the effective piston force during the return stroke for the cylinder in question at a working
pressure of 600 kPa (6 bar).
Calculating the piston area Calculating the piston ring area
Calculating the piston force, forward stroke Calculating the piston force, return stroke
Note
Consult the cylinder data sheet for the necessary data.

3. How a 5/2-way valve works
a) Complete the circuit symbol of a manually operated 5/2-way valve with locking function and spring
return, designating the ports.
5/2-way valve, manually operated, with locking function and spring return – circuit symbol and cutaway view
b) Describe how a 5/2-way valve works when port 2 of the valve is connected to the piston rod side of a
double-acting cylinder and port 4 to the piston side.
How a 5/2-way valve, unactuated, works
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How a 5/2-way valve, actuated, works
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Actuation with a switch
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– Complete the pneumatic circuit diagram for the loading station. Label the individual components and
enter the missing port designations.

5. Completing the equipment list
– Complete the equipment list. Enter the quantity, identification and designation of the required





Initial position
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Step 1-2
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Step 2-3
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Exercise 5:
Stopping milk bottles
Training aims
• Be able to explain and set up indirect actuation.
• Be familiar with the function of a pneumatically activated 5/2-way valve.
• Be familiar with the difference between a signaling element and a control element.

A bottling system is used to fill bottles with milk. The bottles are fed in and stopped under the bottling
machine by a conveyor belt. This task is performed with the aid of a pneumatic cylinder. A test setup of the
stopping system will be used to check the positioning accuracy of the stopping process. The stopping
procedure needs to be started from the system's control console.
Layout
Bottling system for milk

Exercise 5: Stopping milk bottles

1. When a selector switch is actuated, the piston rod on the cylinder advances and pushes the locking
blade into the flow of materials, stopping the milk bottles in place.
2. When the selector switch is released, the piston rod moves to the retracted end position, allowing the
flow of materials to continue.
3. The piston rod remains retracted until the selector switch is actuated again.
Parameters
• It must be possible to stop the flow of materials from a central control console.
• Since the control console can be used to access compressed air, a pneumatic solution is required.
• The control valve for the cylinder should be actuated pneumatically.
Work assignments
1. Complete the pneumatic circuit diagram for the materials blocking system.
Additional exercise
• Explain the term "indirect actuation."
Work aids
• Books of tables
• WBT: Pneumatics
Safety instructions

– Complete the pneumatic circuit diagram for the stopping system. Add any incomplete circuit symbols.
Label the individual components and enter the missing port designations.
1 -MM1 Cylinder, double-acting
1 -QM1 5/2-way valve, pneumatic, with spring return






Initial position
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Step 1-2
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Step 2-3
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6. Additional exercise: "Indirect actuation"
– Explain the term "indirect actuation."
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Exercise 6:
Opening and closing a supply pipe
Training aims
• Be able to measure the pressure in pneumatic control systems.
• Be familiar with the setup and function of a one-way flow control valve.
• Be able to distinguish between flow control methods and use them in accordance with specifications.

Find a way to open and close the locking blade in a pipe. Use a valve with a selector switch for the actuation.
Use a double-acting cylinder as the drive.
Layout
Shut-off device with spool valve

Exercise 6: Opening and closing a supply pipe

1. When the selector switch is actuated, the piston rod on the cylinder advances to allow the air to flow
through.
2. When the selector switch is reset, the piston rod returns to its normal position and the locking blade
closes.
Parameters
• The locking blade must open and close slowly in order to ensure that the pipe is not subjected to
excessive loads (there should be no wave formation).
• The speed of the forward and return strokes must be equal.
• Each forward and return stroke should take 1 s.
Work assignments
1. Describe how a pressure gauge works.
2. Describe how a one-way flow control valve works.
3. Complete the pneumatic circuit diagram.
Work aids
• Books of tables
• WBT: Pneumatics
Safety instructions

1. How a pressure gauge works
Bourdon pressure gauge – circuit symbol and cutaway view
– Describe how a Bourdon pressure gauge works.
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2. How a one-way flow control valve works
One-way flow control valve – circuit symbol and cutaway views
a) Describe how a one-way flow control valve works.
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b) Describe the two types of flow control used in a double-acting cylinder.
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a) Complete the circuit diagram for the shut-off device. Complete any incomplete circuit symbols, and add
any that are missing. Label the individual components and enter the missing port designations.
Note
The on-off valve with filter regulating valve and the distributor block are not shown. These
components are required to set up the control system.

b) What type of flow control does this control system provide?
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1 -SJ1 5/2-way valve with selector switch



• Set the one-way flow control valve to match the specified retraction and advancing times. Use a
stopwatch to do this.



Initial position
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Step 1-2
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Step 2-3
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Exercise 7:
Shutting off using a quick power lockout
Training aims
• Be able to set the advancing and retracting speeds of cylinders.
• Be able to distinguish between flow control methods and use them accordingly.

A bottling system is used to fill bottles with milk. The pipes through which the milk flows are opened and
closed using a knife gate valve. In order to prevent the milk from spilling over at the start of the filling
process, the opening process needs to be executed slowly.
The closing process needs to be executed quickly.
Layout
Filling milk bottles

Exercise 7: Shutting off using a quick power lockout

1. When a selector switch is actuated, a knife gate valve is opened slowly.
2. When the selector switch is reset, the knife gate valve closes quickly.
Prerequisites
• The speed regulation should allow the valve to open at an even speed.
Work assignments
1. Select the appropriate flow control method.
2. Complete the pneumatic circuit diagram for the shut-off device.
Work aids
• Books of tables
• WBT: Pneumatics
Safety instructions

1. Selecting the flow control method
– Decide whether supply air flow control or exhaust air flow control is most appropriate for solving this
problem.
Write down the reasoning behind your decision.
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– Complete the circuit diagram below. Observe the specified parameters.
Note
The on-off valve with filter regulating valve
and the distributor block are not shown.
These components are required to set up the
control system.

1 -SJ1 5/2-way valve with selector switch





Note
This control system uses exhaust air flow control. Use a stopwatch to set the required time. The
setting can be fixed using a lock nut.
Initial position
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Step 1-2
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Step 2-3
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Exercise 8:
Actuating a shut-off device
Training aims
• Be familiar with a way of storing signals in pneumatic control systems.
• Be able to set the advancing and retracting speeds of cylinders.

The ball valve of a filling system for plastic granulate needs to be closed quickly, but opened slowly.
Layout
Shut-off device with ball valve

Exercise 8: Actuating a shut-off device

1. When a pushbutton actuator is pressed, a shut-off device (ball valve) is opened slowly.
2. When a second pushbutton actuator is pressed, the shut-off device closes quickly.
Parameters
• Use a double-acting cylinder.
• The closing process should be carried out using the return stroke of the cylinder.
Work assignments
1. Describe how a quick-exhaust valve works.
2. Describe how a 5/2-way bistable valve works.
3. Complete the pneumatic circuit diagram for the shut-off device.
Work aids
• Books of tables
• WBT: Pneumatics
Safety instructions

1. How a quick-exhaust valve works
Quick-exhaust valve – circuit symbol and cutaway views
– Describe how a quick-exhaust valve works.
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2. How a 5/2-way bistable valve works
5/2-way bistable valve – circuit symbol and cutaway view
a) Describe how the 5/2-way bistable valve works.
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b) Describe how the valve shown above behaves when port 14 is briefly pressurized with compressed air.
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a) Complete the circuit diagram below for the shut-off device. Add any incomplete circuit symbols. Label
Note
The on-off valve with filter regulating valve and the distributor block are not shown. These
components are required to set up the control system.
b) How do you set the speed of the advancing movement?
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1 -PG1 Pressure gauge
1 -RZ1 One-way flow control valve
1 -QM1 5/2-way bistable valve




• Set the one-way flow control valve to maintain an advancing time of approx. 1 s. Use a stopwatch to do
this.


Initial position
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Step 1-2
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Step 2-3
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Advancing time
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Exercise 9:
Expanding a control system to enable cheese pressing
Training aims
• Be able to expand an existing control system.
• Be able to analyze a proposed solution.
• Be able to implement an OR operation.

In cheese manufacturing, pneumatic cylinders are used to press the cheese into molds. The pressing
procedure is operated using a pushbutton actuator. You now need to implement a system that also allows
operation to be carried out using 2 pushbutton actuators so that the pressing procedure can be operated
from the loading side or the unloading side. A solution variant for this purpose exists, but it does not
possess the piston force required to press the cheese.
Layout
Cheese manufacturing – press

Exercise 9: Expanding a control system to enable cheese pressing

1. The cheese is inserted in the press by hand.
2. When a pushbutton actuator on either the loading or the unloading side of the system is pressed, the
piston rod on the cylinder advances and presses the lid onto the device.
3. The pushbutton actuator is held down until the pressing procedure is complete.
4. When the pushbutton actuator is released, the piston rod retracts again, allowing access to the device.
5. The cheese can then be removed.
Parameters
• The cylinder must be pneumatically controlled using a second manually operated valve.
• It should be possible to operate the process using either of the two valves.
Work assignments
1. Analyze the proposed solution variants for the pneumatic circuit diagram.
2. Describe how an OR valve works.
3. Complete the pneumatic circuit diagram for the press.
4. Update the equipment list.
Work aids
• Books of tables
• WBT: Pneumatics

1. Analyzing the pneumatic circuit diagram

The control system shown below has been used to expand the function as required. However, we have
determined that it does not possess the piston force required to press the cheese. The piston force was only
sufficient when both pushbuttons were pressed at the same time.
Proposed solution – pneumatic circuit diagram
2 -SJ1, -SJ2 3/2-way valve with pushbutton actuator, normally closed
Equipment list for proposed solution
– Analyze the control system above and explain why it was not able to provide the required piston force.
______________________________________________________________________________________
______________________________________________________________________________________

2. How an OR valve works
OR valve – circuit symbol and cutaway views
– Describe how an OR valve works.
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________

– Complete the circuit diagram below for the press. Add any incomplete circuit symbols. Enter the missing
port designations.
4. Updating the device list
a) The device list for the original control system (see Exercise 1) must be changed in order to document the
current status of the control system.
Existing equipment list

b) Update the equipment list. Enter the quantity, identification and designation of the required
Updated equipment list


• Increase the pressure to 600 kPa (6 bar).



Initial position
______________________________________________________________________________________
______________________________________________________________________________________
Step 1-2
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Step 2-3
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______________________________________________________________________________________


Exercise 10:
Clamping a workpiece
Training aims
• Be able to implement an AND operation.
• Be familiar with a way of sensing the end positions of cylinders.
• Be able to draw the displacement-step diagram.

In a production plant, an automatic rotary indexing machine is used to feed in workpieces. The workpieces
must be clamped in the individual workholders for machining. A test setup needs to be built to develop and
test a clamping device.
Layout
Rotary indexing machine

Exercise 10: Clamping a workpiece

1. The piston rod on the double-acting clamping cylinder must only advance when a pushbutton actuator
is pressed AND the piston rod is in the retracted end position, otherwise it will not be possible to insert
a workpiece for machining.
2. The clamping cylinder needs to remain in the advanced end position until the machining of the
workpiece is complete. The machining time can vary.
3. The workpiece is released again when a second pushbutton actuator is pressed.
Parameters
• The clamping process must not begin unless the cylinder's piston rod is in the retracted end position.
• When a second pushbutton actuator is pressed, the piston rod returns to the retracted end position and
releases the workpiece.
• The retracting and advancing times for the piston rod should be approx. 1 s each.
• A pressure gauge should be mounted between the one-way flow control valve and the cylinder at each
port to allow the operator to read the pressure.
Work assignments
1. Describe how an AND valve works.
2. Describe how a 3/2-way roller-actuated valve works.
8. Create the displacement-step diagram.
Additional exercise
• What effect does moving the 3/2-way roller-actuated valve have on the system?
Work aids
• Books of tables
• WBT: Pneumatics

1. How an AND valve works
AND valve – circuit symbol and cutaway views
– Describe how an AND valve works.
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________

2. How a 3/2-way roller-actuated valve works
3/2-way roller-actuated valve – circuit symbol and cutaway views; left: unactuated, right: actuated
a) Describe how a 3/2-way roller-actuated valve works.
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
b) Describe how the pilot stage works.
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________

a) Complete the circuit diagram below for the clamping device. Add any incomplete circuit symbols. Label
b) Describe how the 3/2-way roller-actuated valve needs to be mounted in order to ensure that the control
system works correctly.
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________

1 -BG1 3/2-way roller-actuated valve, normally closed
1 -PG1, -PG2 Pressure gauge
1 -RZ1, -RZ2 One-way flow control valve


• Align the 3/2-way roller-actuated valve and check that the control system is working properly.

• Set the one-way flow control valves to match the specified retraction and advancing times of approx.
1 s. Use a stopwatch to do this.


Initial position
______________________________________________________________________________________
______________________________________________________________________________________
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Step 1-2
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______________________________________________________________________________________
______________________________________________________________________________________

Step 2-3
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
8. Creating the displacement-step diagram
– Draw the displacement-step diagram with signal lines for the process described above.
9. The effect of moving the 3/2-way roller-actuated valve
– Describe the effect that moving the 3/2-way roller-actuated valve has on the control system.
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________

Exercise 11:
Loading mesh baskets
Training aims
• Be able to build a latching circuit with an OR operation.

In a loading station, mesh baskets are loaded with packages. In order to ensure that the continuous flow of
materials does not need to be paused at any time, the mesh baskets are placed at two output points on a
conveyor. When a mesh basket is full, the packages are directed to the opposite output point by a deflector
so that they can be transported away and a new mesh basket can be moved into position.
Layout
Loading station

Exercise 11: Loading mesh baskets

1. When the pushbutton actuator is pressed, the piston rod on the cylinder advances and pushes the
deflector into the flow of materials.
2. The piston rod remains in this position when the pushbutton actuator is released, and the flow of
materials is redirected.
3. When a second pushbutton actuator is pressed, the piston rod moves back to the retracted end
position, allowing the flow of materials to return to the original output point.
4. The piston rod remains in this position until the first pushbutton actuator is pressed again.
Parameters
• The flow of materials needs to be controlled by two valves with pushbutton actuators: one pushbutton
actuator each for blocking and one pushbutton actuator each for allowing flow.
• Since the signals from the pushbutton actuators are only issued for a short time, a control system the
stores the signal statuses is required.
Work assignments
5. Describe how the latching circuit works.
Work aids
• Books of tables
• WBT: Pneumatics

– Develop the latching circuit required for the task and add it to the circuit diagram below. Label the
individual components.

1 5/2-way valve, pneumatic, with spring return





5. How a latching circuit works
– Describe how the latching circuit works.
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________


Exercise 12:
Actuating a sliding door
Training aims
• Be able to combine logic operations.
• Be familiar with the setup and function of a pneumatic proximity sensor.
• Be able to distinguish between 5/2-way valves, and select and use them in accordance with
specifications.

It needs to be possible to open and close a pneumatically driven sliding door from two different rooms using
pushbutton actuators. In order to prevent operational errors in emergencies, there must be only one
pushbutton actuator on each side of the door.
Layout
Sliding door

Exercise 12: Actuating a sliding door

1. When the sliding door is in a defined end position, it can be moved to the other end position by pressing
the pushbutton actuator. This opens or closes the door.
2. If the sliding door is not in one of the end positions, it is not possible to begin the opening or closing
procedures.
Parameters
• It must not be possible to start either of the processes unless the door is in one of the end positions.
• For safety reasons (to prevent risk of crushing), the pressure must be restricted to 300 kPa (3 bar).
Work assignments
1. Describe how a pneumatic proximity sensor works.
2. Complete the pneumatic circuit diagram for the sliding door control system.
Additional exercise
• What happens if the compressed air supply fails during a forward or return movement?
Work aids
• Books of tables
• WBT: Pneumatics

1. How a pneumatic proximity sensor works
Pneumatic proximity sensor – circuit symbol and cutaway view
– Describe how the pneumatic proximity sensor works.
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
Information
Aligning the pneumatic proximity sensor
1. Move the cylinder to its end position.
2. Supply compressed air to port 1 until the pressure reaches 200 to 600 kPa (2 to 6 bar).
3. Move the proximity sensor until it reaches the switching point
(compressed air signal at port 2).
4. Attach the proximity sensor to the cylinder.

– Complete the circuit diagram below for the sliding door. Add any missing circuit symbols. Label the
individual components and enter the port designations.

2 -BG1, -BG2 Proximity sensor, pneumatic


• On the service unit, set the pressure to the level specified in the exercise instructions and switch on the
compressed air supply.
• Align the pneumatic proximity sensor and check that the control system is working properly.



Initial position
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Step 1-2
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Step 2-3
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______________________________________________________________________________________
______________________________________________________________________________________

7. Additional exercise: Malfunction due to compressed air failure
Information
The control system's compressed air supply fails during a forward or return movement of the sliding
door. What happens next? How can the control system be made operational again?
– Describe the results of the compressed air failure.

How can the control system be made operational again?
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________


Exercise 13:
Feeding in wooden boards
Training aims
• Be familiar with the NOT logic operation.
• Be able to combine logic operations.
• Be able to develop existing control systems further.

Wooden boards need to be fed into a machining process from a magazine. If the removal area is not clear,
the system must prevent further wooden boards from being pushed out.
Layout
Stacking magazine

Exercise 13: Feeding in wooden boards

1. The pushing out process can be started with a pushbutton actuator when the cylinder is in the retracted
end position. The pushing cylinder only pushes a wooden board out of the magazine if the roller-
actuated valve in the removal area signals that the removal position is NOT occupied.
2. If the removal area is clear, the piston rod on the cylinder moves to the advanced end position with
controlled exhaust air, pushes the wooden board out and then immediately moves back to the retracted
end position, again with controlled exhaust air.
Parameters
• A roller-actuated valve is used to check mechanically whether there is a wooden board in the removal
area.
• The cylinder's exhaust air is controlled during advancing and retraction.
Work assignments
Additional exercise
• What changes would you need to make to the control system if it were only permitted to start the
pushing out process when there is at least one wooden board in the magazine AND the removal position
is clear?
Work aids
• Books of tables
• WBT: Pneumatics

– Complete the circuit diagram below for the stacking magazine. Add any missing circuit symbols. Label
the individual components and enter the port designations.






Initial position
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Step 1-2
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Step 2-3
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______________________________________________________________________________________
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Step 3-1
______________________________________________________________________________________
______________________________________________________________________________________
6. Additional exercise: Adapting the control system
– The control system needs to be modified so that the pushing out process can only start when there are
wooden boards in the magazine AND the removal position is clear at the same time.
Describe the modifications required to the control system in order to fulfill this requirement.
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________

Exercise 14:
Pressing drinks cans
Training aims
• Be familiar with the setup and function of a pressure sequence valve.
• Be able to set up pressure-dependent control systems.

At a recycling plant, drinks cans are pressed into small packages to save on storage space. The pressing
process is triggered by a pushbutton actuator. The return stroke can be triggered by another pushbutton
actuator. The pressing process should only begin if there is sufficient pressure in the system.
Layout
Can press
Note
Protective grilles that are required in actual practice are not shown here.

Exercise 14: Pressing drinks cans

1. The drinks cans are inserted in the press by hand.
2. When the preset pressure is reached, a pressure sequence valve switches and releases the compressed
air into the control system. The control system must not be able to function at pressures below 450 kPa
(4.5 bar).
3. It must be impossible to start the pressing process unless the pressing cylinder is in the top end
position. When this is the case, it must be possible to start the pressing process using a start button.
The piston rod on the pressing cylinder moves to the advanced end position, or up to the stop point
defined by the material.
4. The return stroke is triggered by either another proximity sensor or a pushbutton actuator.
5. The pressed drinks cans are pushed out of the system at the side by a second cylinder.
Parameters
• The initial position of the pressing cylinder is the retracted end position.
• The pushing cylinder for the pressed packages is not taken into account.
• The pressing procedure should not start until the system pressure exceeds 450 kPa (4.5 bar).
• The return stroke can be triggered by hand if the pressing cylinder cannot reach its advanced end
position due to the number of drinks cans it has pressed.
Work assignments
1. Describe how a pressure sequence valve works.
2. Complete the pneumatic circuit diagram for the can press.
Work aids
• Books of tables
• WBT: Pneumatics

1. How a pressure sequence valve works
Pressure sequence valve – circuit symbol and cutaway view
a) Describe how a pressure sequence valve works.
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
b) What applications is the pressure sequence valve used for?
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________

– Complete the circuit diagram below for the can press. Add any incomplete circuit symbols.

– Complete the equipment list. Enter the quantity and designation of the required components in the
table below.
-KH1
-KH2


• Align the pneumatic proximity sensors.
• Set the pressure sequence valve so that it switches at the required operating pressure.



Initial position
______________________________________________________________________________________
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______________________________________________________________________________________
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Step 1-2
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Step 2-3
______________________________________________________________________________________
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______________________________________________________________________________________
______________________________________________________________________________________
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______________________________________________________________________________________


Exercise 15:
Stamping valve housings
Training aims
• Be familiar with the setup and function of a pressure regulator.

Prototypes of aluminum valve housings need to be stamped with identification codes. The housings are
inserted in the stamping machine by hand. The operating pressure must be at least 400 kPa (4 bar) in order
to ensure that the identification codes are easily legible. However, the pressure at the stamping cylinder
must not exceed 500 kPa (5 bar) otherwise the housing may be damaged during stamping.
There is one pushbutton actuator each to actuate the forward and return strokes. The stamping cylinder's
retracted end position is sensed by a pneumatic proximity sensor.
Layout
Note
Safety devices that are required
in actual practice are not
shown.
Stamping machine

Exercise 15: Stamping valve housings

1. The valve housing is inserted in the stamping machine by hand.
2. When the preset pressure is reached, a pressure sequence valve switches and releases the compressed
air into the control system.
3. The stamping procedure begins when the stamping cylinder is in the retracted end position and a
pushbutton actuator is pressed. The cylinder’s piston rod advances and remains in this position.
4. The procedure is ended by pressing a second pushbutton actuator, after which the piston rod on the
cylinder moves back to the retracted end position.
5. The stamped valve housing is removed by hand.
Parameters
• The procedure can only begin if the cylinder's piston rod is in the retracted end position.
• In addition to this, the control system should not start up until the operating pressure exceeds 400 kPa
(4 bar).
• The return stroke is triggered manually.
Work assignments
1. Describe how a pressure regulator works.
2. Complete the pneumatic circuit diagram for the stamping machine.
7. Describe how the one-way flow control valve installed parallel to the pressure regulator works.
Work aids
• Books of tables
• WBT: Pneumatics

1. How a pressure regulator works
Pressure regulator – circuit symbol and cutaway views
– Describe how a pressure regulator works.
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________

– Complete the pneumatic circuit diagram below for the stamping machine. Add any missing circuit
symbols. Label the individual components and enter the port designations.

– Create an equipment list by entering the required devices in the table below.
1 -QN2 Pressure regulator
1 -QN1 Pressure sequence valve



• Align the pneumatic proximity sensor.
• Set the maximum pressure for the stamping cylinder using the pressure regulator.
this.


Initial position
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Step 1-2
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______________________________________________________________________________________

Step 2-3
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
7. How the one-way flow control valve installed parallel to the pressure regulator works
– Describe how the one-way flow control valve installed parallel to the pressure regulator works.
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________


Exercise 16:
Mounting locking clips
Training aims
• Be able to analyze and optimize existing control systems.

An automatic assembly machine is used to mount locking clips on plug connector housings. Up until now,
the pressure has been set using a pressure regulator on the automatic assembly machine. This method
repeatedly caused malfunctions in the mounting process.
A test setup needs to be built to investigate the mounting process. Each mounting procedure is triggered
manually. The control system needs to be modified so that it only works when the pressure exceeds a
certain level.
Layout
Automatic assembly machine for plug connector housings – Feeding in locking clips

Exercise 16: Mounting locking clips

1. The procedure should begin at the push of a pushbutton actuator when the mounting cylinder's piston
rod is in the retracted end position.
2. The piston rod needs to move to the advanced end position with minimal force.
3. When it reaches this position, the piston rod will actuate a limit valve.
4. Once it has done this, the piston rod needs to return to the retracted end position.
Parameters
• The pressure at the working port of the mounting cylinder must be 300 kPa (3.0 bar) in order to ensure
that the locking clips are mounted securely.
• I must be impossible to start the procedure if the pressure is above 400 kPa (4.0 bar).
• The return stroke of the mounting cylinder starts automatically after it has reached its advanced end
position.
Work assignments
1. Analyze the pneumatic circuit diagram for the automated assembly machine.
2. Complete the pneumatic circuit diagram. Take the parameters into consideration.
Work aids
• Books of tables
• WBT: Pneumatics
1. Analyzing the pneumatic circuit diagram
– Analyze the following circuit diagram and check whether it is suitable for the problem described above.
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________

Pneumatic circuit diagram

– Complete the pneumatic circuit diagram for the automated assembly machine. Take all the specified
parameters into consideration. Label the individual components and enter the missing port
designations.

1 -BG1 Proximity sensor, pneumatic
1 5/2-way bistable valve
1 -QN1 Pressure regulator



• Align the pneumatic proximity sensor.
• Set the pressure regulator.
this.


Initial position
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Step 1-2
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Step 2-3
______________________________________________________________________________________
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______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________


Exercise 17:
Labeling paint buckets
Training aims
• Be familiar with the setup and function of a pneumatic timer.
• Be able to set up time-dependent control systems.
• Be able to create and describe the GRAFCET.

A gluing machine is used to label paint buckets. The gluing procedure is triggered when a pushbutton
actuator on the machine is pressed.
The label must be pressed on for 10 seconds in order for the adhesive to take effect. The system is ready to
start when the piston on the pressing cylinder is in the retracted end position.
Layout
Labeling machine

Exercise 17: Labeling paint buckets

1. The procedure should begin at the push of a pushbutton actuator when the cylinder's piston rod is in
the retracted end position.
2. The piston rod needs to move to the advanced end position with minimal force and speed, then remain
there for a set period of time.
3. Once it has done this, the piston rod needs to return quickly to the retracted end position.
4. The advancing pressure needs to be displayed on a pressure gauge.
Parameters
• Since the label needs to be glued to the paint bucket with minimal force, the working pressure needs to
be adjustable.
• The cylinder's piston rod must be retracted as quickly as possible.
• The working pressure must be adjustable within a range of between 300 and 600 kPa (3 and 6 bar).
• The pressure needs to be displayed on a pressure gauge upstream of the cylinder.
Work assignments
1. Describe how a pneumatic timer works.
3. Create an equipment list.
7. Create the GRAFCET for the process.
Work aids
• Books of tables
• WBT: Pneumatics

1. How a pneumatic timer works
Pneumatic time – circuit symbol and photo
– Describe how a pneumatic timer works and enter the most important technical data for it in the table.
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
Technical data
Pressure range
Switch-on pressure
Standard nominal flow rate
Time delay
Setting accuracy
Resetting interval

– Complete the circuit diagram below. Add any incomplete circuit symbols. Enter the missing port
designations.

– Complete the equipment list. Enter the identification of the required components in the table below.
1 Cylinder, double-acting
2 Proximity sensor, pneumatic
1 Pressure gauge
1 Quick-exhaust valve
1 One-way flow control valve
1 5/2-way bistable valve
1 AND valve
1 Timer, pneumatic
1 Pressure regulator
1 3/2-way valve with pushbutton actuator, normally closed
Equipment list



• Set the maximum pressure for the pressing cylinder using the pressure regulator.
• Set the pressing time using the pneumatic timer.
this.


Initial position
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Step 1-2
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Step 2-3
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______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
7. Creating a GRAFCET for the process
a) Create a GRAFCET chart for process described above.

b) Describe the steps and the transition conditions.
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______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
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______________________________________________________________________________________

Exercise 18:
Cleaning workpieces
Training aims
• Be able to set up control systems with oscillating movements.
• Be able to use a time delay valve in accordance with parameters.

A mesh basket of workpieces needs to be raised and lowered in the cleaning bath. The procedure is started
by pressing a pushbutton actuator.
Layout
Automatic washing system

Exercise 18: Cleaning workpieces

1. The procedure begins when a pushbutton actuator is pressed and the lifting cylinder's piston rod is
retracted.
2. The piston rod on the cylinder of the lifting system advances to its advanced end position. The piston
rod then moves back to the mid-position, and then back to the advanced end position. This movement
continues until the pneumatic timer interrupts the procedure.
3. When this happens, the cylinder's piston rod moves back to the retracted end position.
Parameters
• A roller-actuated valve must be used to sense the retracted end position.
• The advancing and retracting speeds of the piston rod must be adjustable.
• The time for the cleaning procedure should be set to 20 seconds.
Work assignments
1. Convert a 5/2-way bistable valve to make a 3/2-way bistable valve.
2. Set the retracting and advancing speeds for the cylinder.
3. Complete the pneumatic circuit diagram for the automatic cleaning system.
Work aids
• Books of tables
• WBT: Pneumatics

1. Converting a 5/2-way bistable valve
Circuit symbol for a 5/2-way bistable valve
– Convert a 5/2-way bistable valve to make a 3/2-way bistable valve.
Describe what you need to do.
______________________________________________________________________________________
______________________________________________________________________________________
2. Setting the retracting and advancing speeds
– The speed of the piston can be adjusted using supply air flow control, exhaust air flow control or a
combination of both. The cylinder in the washing system works with the piston rod moving vertically
downwards; the load is a pulling load.
What type of flow control should you use?
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________

– Complete the circuit diagram below. Add any missing circuit symbols. Label the individual components
and enter the port designations.

1 -QM2 5/2-way bistable valve, pneumatic
1 -QM1 3/2-way bistable valve, pneumatic
1 -BG1 3/2-way roller-actuated valve, normally closed
1 -KH1 Time delay valve
1 -KH2 OR valve
Note
A pneumatic 5/2-way bistable valve is converted to make a pneumatic 3/2-way bistable valve.



• Set the cleaning time using the pneumatic timer.


Initial position
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Step 1-2
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______________________________________________________________________________________

Step 2-3
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______________________________________________________________________________________
Step 3-4
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
Step 4-5
______________________________________________________________________________________
Oscillating movement
______________________________________________________________________________________
______________________________________________________________________________________
Steps n-2 to n
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________


Exercise 19:
Pressing product labels into place
Training aims
• Be able to analyze and set up control systems with two cylinders.

Product labels are pressed into valve housings at a machining station. First, the product labels are placed in
recesses in the valve housing. A pressing cylinder then presses them into place.
The valve housing clamping procedure is triggered by a pushbutton actuator. Once clamping is complete,
the pressing procedure begins. Once the pressing cylinder has reached its advanced end position, both
cylinders should return.
Layout
Note
Safety devices that are required
in actual practice are not
shown.
Pressing system for product labels

Exercise 19: Pressing product labels into place

1. A product label is placed in the recess.
2. The clamping and pressing procedure is started by pressing a pushbutton actuator.
3. A limit valve should be used to sense whether the piston rod on the clamping cylinder has reached the
correct position.
4. The piston rod on the pressing cylinder must not advance until the piston rod on the clamping cylinder
has reached its advanced end position and the clamping pressure has built up to the required level.
5. Once the product label has been pressed into place, the piston rods on both cylinders retract.
Parameters
• A single-acting cylinder must be used to clamp the valve housing.
• The clamping pressure must be at least 400 kPa (4 bar).
• A roller-actuated valve must be used to sense whether the piston rod on the clamping cylinder has
reached its advanced end positions.
• A double-acting cylinder must be used as the pressing cylinder.
• The forward stroke speeds of both the clamping and the pressing cylinders must be adjustable.
Work assignments
1. Complete the pneumatic circuit diagram for the pressing system.
6. Describe how the failure of a proximity sensor signal would affect the control system.
Work aids
• Books of tables
• WBT: Pneumatics

– Complete the circuit diagram below. Add any missing circuit symbols. Label the individual components
and enter the port designations.

1 -H1MM1 Cylinder, double-acting
1 -U1MM1 Cylinder, single-acting
2 -U1RZ1, -H1RZ1 One-way flow control valve
1 -H1QM1 5/2-way bistable valve, pneumatic
1 -U1QM1 3/2-way bistable valve, pneumatic
Note
A pneumatic 5/2-way bistable valve is converted to make a pneumatic 3/2-way bistable valve.



• Set the pressure sequence valve.
• Set the one-way flow control valves to an advancing time of approx. 1 s. Use a stopwatch to do this.



Initial position
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Step 1-2
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Step 2-3
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Step 3-4
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Note
The piston rod on the single-acting cylinder -U1MM1 returns slightly earlier than that of the double-
acting cylinder -H1MM1. This is because the control signals at pilot ports 14 and 12 on the 5/2-way
bistable valve -H1QM1 overlap. The 5/2-way bistable valve -H1QM1 cannot switch until the single-
acting cylinder -U1MM1 has left its advanced end position and the 3/2-way roller-actuated valve
-U1BG1 is no longer actuated, because the AND valve -H1KH1 will then no longer switch.
6. Failure of a proximity sensor signal
– What happens if the pneumatic proximity sensor -H1BG2 on the pressing cylinder fails or is knocked out
of alignment?
Write down the results of these events.
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Worksheets Pneumatics Basic Level

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Contents

Exercises and worksheets

Exercise 1: Pressing cheeses........................................................................................................................... 3

© Festo Didactic 541088 1

2 © Festo Didactic 541088

Description of the problem

Cheese manufacturing – press

© Festo Didactic 541088 3

Description of the process

4 Name: __________________________________ Date: ____________ © Festo Didactic 541088

1. Setup and function of a single-acting cylinder

Single-acting cylinder – circuit symbol and cutaway view

b) Assign the corresponding number to each component in the drawing above.

Compressed air supply port

© Festo Didactic 541088 Name: __________________________________ Date: ____________ 5

c) Describe the setup and function of a single-acting cylinder.

2. Calculating the piston force of a single-acting cylinder

Fth Theoretical piston force (N) A Useful piston area (m2)

The effective piston force of a single-acting cylinder is calculated as follows:

6 Name: __________________________________ Date: ____________ © Festo Didactic 541088

Calculating the piston area and piston force

3. How a 3/2-way valve, normally closed, works

© Festo Didactic 541088 Name: __________________________________ Date: ____________ 7

b) Describe how the 3/2-way valve works.

4. Completing the pneumatic circuit diagram

8 Name: __________________________________ Date: ____________ © Festo Didactic 541088

5. Creating the equipment list

Quantity Identification Designation

1 On-off valve with filter regulating valve

1 — Compressed air source

6. Setting up the control system

7. Double-checking the control system setup

© Festo Didactic 541088 Name: __________________________________ Date: ____________ 9

Risk of injury when switching on the compressed air!

Risk of injury if compressed air tubing slips off!

8. Describing the control system sequence

– Describe the individual steps of the control system sequence.

10 Name: __________________________________ Date: ____________ © Festo Didactic 541088

Description of the problem

© Festo Didactic 541088 11

Description of the process

12 Name: __________________________________ Date: ____________ © Festo Didactic 541088

1. How a 3/2-way valve works

b) Explain how a 3/2-way valve, normally open, works.

© Festo Didactic 541088 Name: __________________________________ Date: ____________ 13

2. Completing the pneumatic circuit diagram

14 Name: __________________________________ Date: ____________ © Festo Didactic 541088

3. Changing the equipment list

Quantity Identification Designation

1 -MM1 Cylinder, single-acting

1 -SJ1 3/2-way valve with pushbutton actuator, normally closed

1 -XM1 Distributor block

1 -AZ1 On-off valve with filter regulating valve

1 — Compressed air source

Equipment list, template

Quantity Identification Designation

1 -MM1 Cylinder, single-acting

1 -XM1 Distributor block

1 -AZ1 On-off valve with filter regulating valve

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