Beruflich Dokumente
Kultur Dokumente
vacuum technology
Workbook
TP 230
CD-ROM included
V1
1V4
1
V2
1Z1
2
1Z2
1V1
1V2
1M1
1V3
1A2
1A1
24 V
13
S1
12
14
K1
14
22
24
K1
11
21
31
S2
32
A1
K1
A2
0V
11
12
14 .2
21
22
24 .3
31
32
34
41
42
44
1M1
Festo Didactic
567258 EN
Order No.:
Edition:
Authors:
Editor:
Graphics:
Layout:
567258
09/2011
Ralph-Christoph Weber
Frank Ebel
Ralph-Christoph Weber
01/2011, Susanne Durz, Frank Ebel
Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2013
Internet: www.festo-didactic.com
E-mail: did@de.festo.com
The purchaser shall receive a single right of use which is non-exclusive, non-time-limited and limited
geographically to use at the purchaser's site/location as follows.
The purchaser shall be entitled to use the work to train his/her staff at the purchaser's site/location and
shall also be entitled to use parts of the copyright material as the basis for the production of his/her own
training documentation for the training of his/her staff at the purchaser's site/location with
acknowledgement of source and to make copies for this purpose. In the case of schools/technical colleges
and training centres, the right of use shall also include use by school and college students and trainees at
the purchaser's site/location for teaching purposes.
The right of use shall in all cases exclude the right to publish the copyright material or to make this available
for use on intranet, Internet and LMS platforms and databases such as Moodle, which allow access by a
wide variety of users, including those outside of the purchaser's site/location.
Entitlement to other rights relating to reproductions, copies, adaptations, translations, microfilming and
transfer to and storage and processing in electronic systems, no matter whether in whole or in part, shall
require the prior consent of Festo Didactic GmbH & Co. KG.
Contents
Use for intended purpose __________________________________________________________________ IV
Preface _________________________________________________________________________________ V
Introduction ____________________________________________________________________________ VII
Safety precautions and work instructions ____________________________________________________ VIII
Technology package for electro-pneumatics (TP 200) ____________________________________________X
Learning objectives for the advanced level (TP 230) _____________________________________________ XI
Allocation of learning objectives per exercise _________________________________________________ XII
Equipment set for the advanced level (TP 230) ________________________________________________ XIII
Allocation of equipment per exercise ________________________________________________________ XVI
Tools for the trainer _____________________________________________________________________ XVII
Structure of the exercises ________________________________________________________________ XVII
Component designations _________________________________________________________________ XVII
CD-ROM contents _______________________________________________________________________ XVIII
III
Contents
IV
1
1.1
1.2
2
2.1
2.2
2.3
2.4
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
I-17
I-17
I-17
I-18
I-19
I-20
I-21
I-23
VI
Preface
Festo Didactics learning system for automation technology is geared towards various educational
backgrounds and vocational requirements. The learning system is therefore broken down as follows:
Technology oriented training packages
Mechatronics and factory automation
Process automation and control technology
Robotino training and research with mobile robots
Hybrid learning factories
The technology packages deal with various technologies including pneumatics, electropneumatics,
hydraulics, electrohydraulics, proportional hydraulics, programmable logic controllers, sensor technology,
electrical engineering and electric drives.
The modular design of the training system allows for applications which go above and beyond the
limitations of the individual packages. For example, PLC actuation of pneumatic, hydraulic and electric
drives is possible.
VII
VIII
Introduction
This workbook is part of the learning system for automation technology from Festo Didactic GmbH & Co. KG.
The system provides a solid basis for practice-oriented training and vocational education. Training package
TP 230 deals with the subject of Fundamentals of vacuum technology.
Topics including vacuum generation, system design, the selection of suction grippers and typical circuits
with suction grippers are dealt with in depth. In addition, reducing compressed air consumption in vacuum
systems is also addressed.
A permanent workstation equipped with a Festo Didactic profile plate is a prerequisite for setting up the
controllers. The profile plate has 14 parallel T-slots at 50 mm intervals. A power supply unit with shortcircuit protection is used as a direct voltage source (input: 230 V, 50 Hz, output: 24 V, max. 5 A). A portable
compressor with silencer (230 V, approx. 50 litres per minute, max. 800 kPa = 8 bar) can be used for
compressed air supply.
Working pressure should not exceed 600 kPa (6 bar). Ideal control sequence reliability can be achieved by
operating the controller at a working pressure of 500 kPa (5 bar) without oil.
In addition to equipment set TP 230, youll also need components from equipment set TP 201 in order to
complete the 6 exercises. The theoretical fundamentals for understanding this workbook are included in the
textbook entitled
Pneumatics/electropneumatics,
as well as in the appendix to this workbook.
Technical data for the individual components are also available (vacuum generators, suction cups, vacuum
switches etc.).
IX
General
Trainees should only work with the controllers under the supervision of a trainer.
Observe specifications included in the technical data for the individual components and in particular all
safety instructions!
Mechanical setup
Mount all of the components securely onto the profile plate.
Limit switches should not be actuated frontally.
Danger of injury during troubleshooting!
Use a tool to actuate the limit switches, for example a screwdriver.
Only reach into the setup when its at a complete standstill.
Electrical setup
Electrical connections must only be established and interrupted in the absence of voltage!
Only use connecting cables with safety plugs for electrical connections.
Only use low voltage (max. 24 V DC).
Pneumatic setup
Do not exceed the maximum permissible pressure of 600 kPa (6 bar).
Do not activate compressed air until all the tubing connections have been completed and secured.
Do not disconnect tubing while under pressure.
Danger of injury when switching compressed air on!
Cylinders may advance and retract automatically.
Danger of accident due to tubing slipping off!
Use shortest possible tubing connections.
Wear safety glasses.
In the event that tubing slips off:
Switch compressed air supply off immediately.
Pneumatic circuit setup:
Connect the components with plastic tubing with an outside diameter of 4 or 6 mm. Push the tubing into
the push-in connector as far as it will go.
Switch compressed air supply off before dismantling the circuit.
Dismantling the pneumatic circuit:
Press the blue release ring down, after which the tubing can be pulled out.
The mounting boards for the devices are equipped with mounting variants A through D:
Variant A, snap-in system
Lightweight components that are not load-bearing (e.g. directional control valves). Simply clip the device
into the slot on the profile plate. Release the components from the slots by turning the blue lever.
Variant B, bolt system
Components with medium load capacity (e.g. actuators). These components are clamped onto the profile
plate using T-head bolts. The blue, knurled nut is used for clamping and loosening.
Variant C, screw system
For components with high load capacity and components which are seldom removed from the profile plate
(e.g. on-off valve with filter regulator). The elements are secured with socket head screws and T-head bolts.
Variant D, plug-in system
Lightweight components with lock pins which cannot be subjected to loads (e.g. indicators). These are
mounted using plug adapters.
Observe the specifications in the technical data for the individual components.
XI
Pneumatics/electropneumatics
Fundamentals of pneumatic control technology
Maintenance of pneumatic components and systems
Workbooks
Optional teachware
Seminars
P111
P121
P-OP
IW-PEP
P-AL
P-AZUBI
VUU
P-KOMPAKT
Please refer to the current seminar schedule for locations, dates and prices.
Youll find further training materials in our catalogue and on the Internet. The learning system for
automation technology is continuously updated and expanded. Transparency sets, videos, CD-ROMs and
DVDs, as well as textbooks, are available in several languages.
XII
XIII
Learning objectives
Be able to generate a partial vacuum.
workpieces.
XIV
Order no.
Quantity
573043
573044
573045
573046
573047
573057
Vacuum generator 05 H
573258
Vacuum generator 05 L
573259
Air reservoir
152912
Non-return valve
153462
193972
Vacuum gauge
573042
Vacuum switch
548624
540715
Order no.
Quantity
567198
162242
Relay, 3-way
162241
Distributor block
152896
Push-in T-connector
153128
540691
XV
Symbol
Relay, 3-way
A1
12 14
22 24
32 34
42 44
11
21
31
41
12 14
22 24
32 34
42 44
11
21
31
41
12 14
22 24
32 34
42 44
11
21
31
41
A2
A1
A2
A1
A2
13
21
14
22
13
21
14
22
13
21
14
22
13
21
14
22
12
1M1
1
1M1
XVI
Designation
Symbol
Air reservoir
Vacuum switch
Non-return valve
2
1
Vacuum generator
1
3
2
Suction cup
1 21
XVII
Component
Vacuum generator 05 L
Vacuum generator 05 H
Air reservoir
Non-return valve
Flow control valve
Vacuum gauge
(1)
1
Vacuum switch
1
1
The following components from the TP 201 equipment set are also required.
Exercise
Pressure regulator
Relay, 3-way
Distributor block
Component
Push-in T-connector
XVIII
Component designations
Pneumatic components are designated in circuit diagrams in accordance with ISO 1219-2. All the
components included in any given circuit have the same primary identifying number. Letters are assigned
depending on each respective type of component. Consecutive numbers are assigned if several components
of the same type are included within a single circuit. Pressure lines are designated with a P and are
numbered separately.
Drives:
Valves:
Sensors:
Signal inputs:
Accessories:
Pressure lines:
XIX
CD-ROM contents
The workbook is included on the CD-ROM as a PDF file. The CD-ROM also provides you with additional
media.
The CD-ROM contains the following folders:
Circuit diagrams
Demo
Festo catalogue
Industrial applications
Operating instructions
Product information
Software_Component-Selection
Data sheets
The data sheets for the components included in the technology package are available as PDF files. Data
sheets are part of the equipment set.
XX
Exercise 1
Generating vacuum
Learning objectives
After completing this exercise:
Youll be able to generate a partial vacuum.
Youll be familiar with the function of a venturi nozzle.
Youll be familiar with the effects of system pressure on the degree of vacuum achieved and on the
evacuation time with different vacuum generators.
Youll be familiar with the effects of throttle points on vacuum generation.
Youll be able to control and adjust vacuum.
Problem description
A handling unit for different workpieces needs to be developed. Your job is to examine various components
and investigate the possible use of vacuum technology. First of all, youll have to examine components used
for vacuum generation.
1.
2.
3.
4.
5.
6.
Parameters
Use the vacuum generators included in the equipment set.
Project assignment
Describe the mode of operation of a vacuum generator.
Set up the test circuit.
Measure the vacuum generated and the evacuation time with various vacuum generators.
Draw characteristic curves for both vacuum generators.
Compare the two vacuum generators and describe their differences.
List any possible negative effects on vacuum generation.
Name the various components and ports of the vacuum generator shown below. Enter the
corresponding designations to the right of the numbers in the table.
Exhaust port, supply port, collector nozzle, jet nozzle, vacuum port
2
5
Vacuum generator
Number
Designation
Supply port
Jet nozzle
Collector nozzle
Exhaust port
Vacuum port
Describe the mode of operation of the vacuum generator based on the venturi principle.
Compressed air flows from the supply port (1) through a restriction, i.e. the vacuum generators jet
nozzle (2). Air flow velocity is increased at this restriction to ultrasonic speeds. After the air exits the
jet nozzle, it expands and flows through the collector nozzle (3) and out of the exhaust port (4). Partial
vacuum occurs in the chamber around the jet nozzle during this process. As a result, air is drawn in
through the vacuum port.
Measuring the degree of partial vacuum generated with various vacuum generators
Set up the controller in accordance with the circuit diagram shown below. Measure the degree of partial
vacuum achieved with the vacuum generator at different system pressures. Compare the two vacuum
generators included in the equipment set.
+24 V
1V3
1
3
2
13
12
S1
14
K1
14
22
24
11
1Z1
1V2
K1
21
2
31
S2
32
1V1
A1
K1
1M1
1M1
1
A2
0V
11
12
14 .2
21
22
24 .3
31
32
34
41
42
44
System
pressure
1 bar
-0.08
2 bar
-0.34
-0.14
3 bar
-0.54
-0.2
4 bar
-0.7
-0.3
5 bar
-0.77
-0.38
6 bar
-0.8
-0.42
Enter the characteristic curves of both vacuum generators for the degree of partial vacuum achieved in
the diagram below (pu = partial vacuum, p = system pressure).
-1,0
pU
-0,8
VN-05-H-T3-PQ2-VQ2-RQ2
-0,7
-0,6
-0,5
VN-05-L-T3-PQ2-VQ2-RQ2
-0,4
-0,3
-0,2
-0,1
1
Note:
The reservoir is required in order to ensure that the amount of time required for evacuation is actually
measurable, and thus simulates evacuation of a larger vacuum system. Use a clock or a stopwatch to
measure elapsed time.
+24 V
1V3
1
3
2
13
S1
12
14
K1
14
22
1Z2
24
1V2
K1
11
21
2
31
S2
1Z1
32
1V1
A1
K1
1M1
1M1
1
A2
0V
11
12
14 .2
21
22
24 .3
31
32
34
41
42
44
Measure evacuation time for all the listed values and enter the evacuation time for both vacuum
generators in the table included below. Set system pressure to 6 bar for this exercise.
Partial
vacuum
(bar)
-0.1 bar
0.4
-0.2 bar
0.8
0.4
-0.3 bar
1.0
0.8
-0.4 bar
1.8
2.0
-0.5 bar
2.4
-0.6 bar
3.5
-0.7 bar
5.8
-0.8 bar
10.0
Enter the determined evacuation times in the graphic shown below, and draw characteristic curves for
both vacuum generators.
10
VN-05-H-T3-PQ2-VQ2-RQ2
t (s)
VN-05-L-T3-PQ2-VQ2-RQ2
-0,2
-0,4
pU
-0,8
Describe the differences between the two vacuum generators used and their respective advantages for
vacuum generation.
This vacuum generator achieves relatively low levels of vacuum in comparison with the other
(approx. 50%).
High system pressure is required in order to reach maximum achievable vacuum.
On the other hand, it needs only minimal evacuation time in order to generate a partial vacuum.
This vacuum generator is used when a large vacuum system has to be evacuated quickly. Type L
vacuum generators are used especially where minimal vacuum and/or short cycle times are required.
Which other influences, in addition to changing system pressure and the size of the system to be
evacuated, might have negative effects on the generation of a partial vacuum by means of a vacuum
generator? Write them down.
Long or restricted tubing connections between the ejector and the suction cup.
Long or restricted compressed air supply line to the ejector.
Contaminated or clogged silencer.
Branch TEEs and angle connectors in the vacuum lines.
Simulate the influences listed in the table with regard to degree of partial vacuum and evacuation time.
Influence
Contaminated silencer
Evacuation time:
Evacuation time:
Max. vacuum
Max. vacuum
If theres a kink at either of these places, If theres a kink at either of these places,
10 cm
15 seconds
3 seconds
100 cm
22 seconds
5 seconds
10
Contents
Exercises and worksheets
Exercise 1: Generating vacuum _______________________________________________________________3
Exercise 2: Selecting suction cups for various workpieces _______________________________________ 11
Exercise 3: Maintaining vacuum when using more than one suction cup ____________________________ 21
Exercise 4: Monitoring partial vacuum _______________________________________________________ 29
Exercise 5: Reducing compressed air consumption in a vacuum system ____________________________ 37
Exercise 6: Controlled release of workpieces retained by a vacuum ________________________________ 43
Contents
Exercise 1
Generating vacuum
Learning objectives
After completing this exercise:
Youll be able to generate a partial vacuum.
Youll be familiar with the function of a venturi nozzle.
Youll be familiar with the effects of system pressure on the degree of vacuum achieved and on the
evacuation time with different vacuum generators.
Youll be familiar with the effects of throttle points on vacuum generation.
Youll be able to control and adjust vacuum.
Problem description
A handling unit for different workpieces needs to be developed. Your job is to examine various components
and investigate the possible use of vacuum technology. First of all, youll have to examine components used
for vacuum generation.
1.
2.
3.
4.
5.
6.
Parameters
Use the vacuum generators included in the equipment set.
Project assignment
Describe the mode of operation of a vacuum generator.
Set up the test circuit.
Measure the vacuum generated and the evacuation time with various vacuum generators.
Draw characteristic curves for both vacuum generators.
Compare the two vacuum generators and describe their differences.
List any possible negative effects on vacuum generation.
Name the various components and ports of the vacuum generator shown below. Enter the
corresponding designations to the right of the numbers in the table.
Exhaust port, supply port, collector nozzle, jet nozzle, vacuum port
2
5
Vacuum generator
Number
Designation
1
2
3
4
5
Describe the mode of operation of the vacuum generator based on the venturi principle.
Measuring the degree of partial vacuum generated with various vacuum generators
Set up the controller in accordance with the circuit diagram shown below. Measure the degree of partial
vacuum achieved with the vacuum generator at different system pressures. Compare the two vacuum
generators included in the equipment set.
+24 V
1V3
1
3
2
13
12
S1
14
K1
14
22
24
11
1Z1
1V2
K1
21
2
31
S2
32
1V1
A1
K1
1M1
1M1
1
A2
0V
11
12
14 .2
21
22
24 .3
31
32
34
41
42
44
System
pressure
1 bar
2 bar
3 bar
4 bar
5 bar
6 bar
Enter the characteristic curves of both vacuum generators for the degree of partial vacuum achieved in
the diagram below (pu = partial vacuum, p = system pressure).
-1,0
pU
-0,8
-0,7
-0,6
-0,5
-0,4
-0,3
-0,2
-0,1
Note:
The reservoir is required in order to ensure that the amount of time required for evacuation is actually
measurable, and thus simulates evacuation of a larger vacuum system. Use a clock or a stopwatch to
measure elapsed time.
+24 V
1V3
1
3
2
13
S1
12
14
K1
14
22
1Z2
24
1V2
K1
11
21
2
31
S2
1Z1
32
1V1
A1
K1
1M1
1M1
1
A2
0V
11
12
14 .2
21
22
24 .3
31
32
34
41
42
44
Measure evacuation time for all the listed values and enter the evacuation time for both vacuum
generators in the table included below. Set system pressure to 6 bar for this exercise.
Partial
vacuum
(bar)
-0.1 bar
-0.2 bar
-0.3 bar
-0.4 bar
-0.5 bar
-0.6 bar
-0.7 bar
-0.8 bar
Enter the determined evacuation times in the graphic shown below, and draw characteristic curves for
both vacuum generators.
10
t (s)
-0,2
-0,4
pU
-0,8
Describe the differences between the two vacuum generators used and their respective advantages for
vacuum generation.
Which other influences, in addition to changing system pressure and the size of the system to be
evacuated, might have negative effects on the generation of a partial vacuum by means of a vacuum
generator? Write them down.
Simulate the influences listed in the table with regard to degree of partial vacuum and evacuation time.
Influence
Contaminated silencer
Throttle point between the vacuum generator
and the silencer
10