Ob Exercise PDF

Learning System for Automation and Technology
Electropneumatics
Workbook Advanced level
094467
Authorised applications and liability
The Learning System for Automation and Technology has been devel-
oped and prepared exclusively for training in the field of automation and
technology. The training organization and / or trainee shall ensure that
the safety precautions described in the accompanying Technical docu-
mentation are fully observed.
Festo Didactic hereby excludes any liability for injury to trainees, to the
training organization and / or to third parties occurring as a result of the
use or application of the station outside of a pure training situation,
unless caused by premeditation or gross negligence on the part of Festo
Didactic.
Order no.: 094467

Description: TEACHW.E-PNEUM.
Designation: D.S202-C-SIBU-GB
Edition: 05/2002
Layout: 06.05.2002, OCKER Ingenieurbro
Graphics: OCKER Ingenieurbro
Authors: D. Waller, H. Werner, Th. Ocker
Copyright by Festo Didactic GmbH & Co., D-73770 Denkendorf 2002

The copying, distribution and utilization of this document as well as the
communication of its contents to others without expressed authorization
is prohibited. Offenders will be held liable for the payment of damages.
All rights reserved, in particular the right to carry out patent, utility model
or ornamental design registrations.
Parts of this training documentation may be duplicated, solely for training
purposes, by persons authorised in this sense.
3
Preface
The Festo Didactic Learning System for Automation and Technology has
been formulated according to various prerequisites and vocational
requirements. It has been divided into the following categories of training
packages:
Basic packages which convey basic knowledge spanning a wide
range of technologies
Technology packages which deal with important subjects of open and
closed-loop control technology
Function packages to explain the basic functions of automated sys-
tems
Application packages to facilitate practice-orientated vocational and
further training
The technology packages deal with the technologies of pneumatics,

electropneumatics, programmable logic controllers, hydraulics, electro-
hydraulics, proportional hydraulics and handling technology.
Mounting frame
Profile plate
U = 230V~
Storage tray
TP202 Festo Didactic

4
The modular design of the Learning System permits applications beyond

the scope of the individual packages. It is, for instance, possible to
design PLC controlled systems with pneumatic, hydraulic and electrical
actuators.
All training packages are based on an identical structure:

Hardware
Teachware
Software
Seminars
The hardware consists of industrial components and systems which

have been adapted for didactic purposes.
The courseware has been designed in line with didactic methods and
coordinated for use with the training hardware. The courseware com-
prises:
Textbooks (with exercises and examples)
Workbooks (with practical exercises, explanatory notes, solutions and
data sheets)
Transparencies and videos (to create a lively training environment)
The training and learning media is available in several languages, which
has been designed for use in the classroom as well as for self-tuition.
The software sector serves as a basis for providing computer training
program, simulation program and programming software for program-
mable logic controllers.
A comprehensive range of seminars on the subject of the various tech-
nology packages completes our program of vocational and further train-
ing.

5
Latest information about the technology package pneumaticTP 202

New in Pneumatic 2000:
Industrial components on the profile plate.
Fostering of key qualifications:
Technical competence, personal competence and social competence
form professional competence.
Training of team skills, willingness to co-operate, willingness to learn,
independence and organisational skills.
Aim Professional competence
Content
Part A Course Exercises
Part B Fundamentals Reference to the text book
Part C Solutions Function diagrams, circuits, descriptions of
solutions and quipment lists
Part D Appendix Storage tray, mounting technology
and datasheets

6
Table of contents
Introduction 9
Notes on safety and operation 11
Training contents of basic level and advanced level 13
Equipment set for the basic level (TP201) 15
Equipment set for the advanced level (TP202) 18
Component and exercise allocation (table) 20
Methodical structure of the exercises 21
Designation of components 22

7
Part A Course
Basic exercises
Exercise 1: Bench drill A-3

Exercise 2: Feed unit for sheet metal strip A-5
Exercise 3: Filling device A-7
Exercise 4: Stamping device A-9
Exercise 5: Drilling jig A-11
Exercise 6: Clamping unit for grinding A-15
Exercise 7: Forming press A-19
Consolidating exercises
Exercise 8: Embossing device A-21

Exercise 9: Handling device A-23
Exercise 10: Drilling and reaming machine A-25
Exercise 11: Loading station A-29
Exercise 12: Internal grinding machine A-33
Exercise 13: Assembly unit A-37
Exercise 14: Moulding press A-41
Exercise 15: Pick-and-place unit A-45
Exercise 16: Galvanising process A-49
Exercise 18: Rotary indexing station A-57
Exercise 19: Checking station A-63
Part B Fundamentals

8
Part C Solutions
Solution 1: Bench drill C-3
Solution 2: Feed unit for sheet metal strip C-9
Solution 3: Filling device C-17
Solution 4: Stamping device C-21
Solution 5: Drilling jig C-27
Solution 6: Clamping unit for grinding C-35
Solution 7: Forming press C-41
Solution 8: Embossing device C-45
Solution 9: Handling device C-49
Solution 10: Drilling and reaming machine C-55
Solution 11: Loading station C-59
Solution 12: Internal grinding machine C-63
Solution 13: Assembly unit C-69
Solution 14: Moulding press C-75
Solution 15: Pick-and-place unit C-81
Solution 16: Galvanising process C-87
Solution 18: Rotary indexing station C-103
Solution 19: Checking station C-111
Part D Appendix
Storage tray D-2
Mounting technology D-3
Plastic tubing D-5
Data sheets ...

9
Introduction
This workbook forms part of Festo Didactics Learning System for Auto-
mation and Technology. The system provides a solid basis for practice-
orientated vocational and further training. Technology package TP200 is
concerned exclusively with electro-pneumatic control systems.
The basic level TP201 is suitable for basic training in electro-pneumatic
control technology. It conveys knowledge concerning the physical fun-
damentals of electropneumatics as well as the function and use of
electro-pneumatic components. The equipment set permits the construc-
tion of simple electro-pneumatic control systems.
The advanced level TP202 is intended for further training in electro-
pneumatic control technology. The equipment set permits the construc-
tion of a wide range of combinatorial circuits with logic operations of the
input and output signals as well as program controls.
Prerequisites for assembling control circuits are a fixed workstation and
a Festo Didactic profile plate. The profile plate has 14 parallel T-grooves
arranged at intervals of 50 mm. A short-circuit proof power supply unit
provides a constant power supply (Input: 230 V, 50 Hz, Output: 24 V,
max. 5 A). A mobile, silenced compressor may be used for compressed
air supply (230 V, maximum 8 bar = 800 kPa).
Working pressure should be a maximum of p = 6 bar (= 600 kPa)
Optimum operational safety is achieved by operating the control system

with unlubricated air at a pressure of p = 5 bar = 500 kPa.
The training hardware of both equipment sets (TP201 and TP202) will
be required for the practical assembly of the controls documented here.
The theoretical fundamentals required to understand this book of exer-
cises can be found in the following textbook:
Learning System for Control Technology
Introduction to Electropneumatics
Also available are data sheets on the various components (cylinders,
valves, measuring devices, etc.).

10

11
Notes on safety and operation

In the interests of your own safety, the following advice should be ob-
served:
Pressurised air lines that become detached can cause accidents.
Switch off supply immediately.
Lines must be connected up and secured before the compressed air
is switched on.
Warning!
Cylinders may advance or retract as soon as the compressed air is
switched on.
Do not operate the electrical limit switches manually during fault
finding (use a suitable tool).
Observe general safety regulations (DIN 58126 and VDE 100).
Distinction is to be made between the two different designs of the
electrical limit switches
Actuation from the left
Actuation from the right
Limit switches should be placed so that they contact only the side of
the trip cam and never the front at high piston speeds.
In the pneumatic circuits cylinders are shown without magnetic pis-
tons, since these are only required when magnetic end-position
switches are used. Festo Didactic training sets only contain cylinders
with magnetic pistons.
Do not exceed permissible operating pressure (observe data sheets).
Only use extra-low voltage 24 V.
All components are provided with 4 mm safety sockets respectively
safety plugs. For electical connections use only electrical cable with
safety plugs.
Pneumatic circuit design:
Components are to be connected by means of the silver-metallic
plastic tubing with a 4 mm external diameter. Insert the tubing into the
QS push-in fitting up to the stop; no further securing necessary!
Releasing of the QS straight push-in fitting:
The tubing can be released by simply pressing the clamping collet
(blue ring). (Cannot be disconnected under pressure!)
Switch off the pressure and power supply prior to disconnecting the
circuit.

12
The profile plate for the assembly of components is equipped for

mounting variants A to D:
Variant A, Detent system
Light, non load-bearing components (e.g. directional control valves).
Simply clip the components into the groove of the profile plate. The
components can be released by pressing the blue lever.
Variant B, Rotational system
Medium-weight, load-bearing components (e.g. actuators). These
components are clamped onto the profile plate by means of T-head
bolts. The components are clamped or released by means of the blue
triple grip nut.
Variant C, Screw-in system
For heavy, load-bearing components, i.e. components which are
rarely removed from the profile plate (such as start-up valves with fil-
ter regulator). The components are secured by means of cheese
head screws and T-head nuts.
Variant D, Plug-in system
Light, non load-bearing components with locating pins (e.g. signalling
device). These components are secured by means of plug-in adapt-
ers.
Please observe the data sheets in Part D for information regarding

the individual components.

13
Training contents of basic level and advanced level

Basic level (TP201)
Physical fundamentals of electricity and pneumatics

Function and application of electropneumatic components
Designation and drawing of electropneumatic symbols
Representation of motion sequences and switching statuses
Drawing pneumatic and electrical circuit diagrams
Assembly of control systems with relays
Direct and indirect manual control systems
Direct and indirect stroke-dependent control systems
Logical AND/OR functions of the input signals
Electrical latching circuits
Using a magnetic proximity switch
Using a pressure switch
Fault finding in simple electropneumatic control systems
Advanced level (TP202)
Function and use of electro-pneumatic components

Stroke-dependent control systems with sensors
Stroke-dependent control systems with preselect counter
Control systems with marginal conditions
(e.g. Single/continuous cycle, EMERGENCY-STOP)
Position-scheduled control/process orientated sequence controls
Timing controls/time orientated sequence controls
Program control systems with latching and resetting sequence
Fault finding in extensive electro-pneumatic control systems

14
List of training aims Exercise Training aim
1 To teach the student the principle of the latching sequence.

2 To teach the student the principle of the resetting sequence
(with reliable switching reversal).
3 To familiarise the student with the procedure for skipping program steps
and with the use of a timer.
4 To teach the student how to realise a stroke-dependent sequence
control with resetting sequence.
5 To teach the student how to realise multiple movements of a cylinder
and monitor service life using a preselect counter.
6 To familiarise the student with the use of a pneumatic/electric converter
To teach the student how to construct a control system using single and
double solenoid valves (resetting sequence with extension).
7 To teach the student how to realise a control system with specified
EMERGENCY-STOP conditions and how to realise a two-hand safety
start-up control via a timer with switch-on delay.
8 To teach the student how to incorporate step repetitions and manual
step mode into a sequence.
9 To teach the student how to incorporate EMERGENCY-STOP and
marginal conditions in a latching sequence.
10 To teach the student how to realise a control system with an alternative
program by means of program switching.
11 To teach the student to program repetition using an additional move-
ment.
12 To familiarise the student with step repetition using the preselect coun-
ter.
13 To teach the student how to set up manual activation of the cylinder with
protection against collision.
To familiarise the student with automatic setting conditions.
14 To teach the student how to construct a two-handed safety start-up with
relay. To familiarise the student with restart before the end of the cycle.
15 To teach the student how to develop a latching sequence with marginal
conditions.
16 To teach the student how to realise program branchings.
To teach the student how to make multiple use of time relays.
To familiarise the student with program section repetitions using the
preselect counter.
17 Consolidating the students knowledge. Program section repetition.
18 To familiarise the student with parallel program division.
19 To familiarise the student with the use of a timer with delayed switch-on
as a delayed starting element.
20 Familiarisation with an alternative solution to electropneumatics.

15
Equipment set for the basic level (TP201)

This equipment set is designed for basic training in electro-pneumatic
control technology. It contains all the components required to achieve
the specified training aims and may be extended as required with the
addition of other equipment sets. To construct fully operational controls,
it is also necessary to have a profile plate, a power supply unit and a
compressed air supply.
Designation Order No. Quantity Equipment set for the

basic level (TP201)
Relay, 3-off* 162241 1
(Order No.: 080243)
Signal input plate, electrical * 162242 1
Indicator/distributor plate, electrical * 162244 2
Plastic tubing, 10 m, silver metallic 151496 1
Single-acting cylinder 152887 1
Double-acting cylinder 152888 2
On/off valve with filter regulator 152894 1
Manifold 152896 1
Proximity sensor, with cylinder mounting 167060 2
Limit switch, electrical, actuation from the left 183322 1
Limit switch, electrical, actuation from the right 183345 1
Pneumatic-electric converter 177459 1
3/2-way solenoid valve, normally closed 167073 1
5/2-way solenoid valve 167074 2
5//2-way double solnoid valve 167076 1
* These components can be attached to the profile plate by means of 4 adapters (Order
No. 323571).

16
Symbols of the Signal input plate, electrical

equipment set
Indicator/distributor, electrical Relay, 3-off
Single-acting cylinder Double-acting cylinder
On/off valve with filter regulator Manifold

17
Proximity sensor with cylinder mounting Pneumatic-electric converter Symbols of the

equipment set
Limit switch, electrical, 3/2-way solenoid valve,

Actuation from left or right* normally closed
5/2-way solenoid valve 5/2-way double solenoid valve

18
Equipment set for the advanced level (TP202)

This equipment set for the advanced level is designed for further training
in electro-pneumatic control technology. The two equipment sets (TP201
and TP202) contain all the components required to achieve the specified
training aims and may be extended as required with the addition of other
equipment sets from the Learning System for Automation and Technol-
ogy.
Equipment set for Designation Order No. Quantity

the advanced level
Relay, 3-off* 162241 4
(TP202)
(Order No: 184461) Signal input plate, electrical* 162242 1
Time relay, 2-off* 162243 1
Preselect counter, electrical, incrementing* 162355 1
5/2-way double solenoid valve 167076 2
Proximity sensor, inductive 178574 1
Proximity sensor, capacitive 178575 1
Proximity sensor, optical 178577 1
EMERGENCY-STOP button 183347 1
* These components can be attached to the profile plate by means of 4 adapters (Order
No. 323571).

19
Signal input plate, electrical Symbols of the

equipment set
advanced level
Relay, 3-off
Time relay, 2-off

with switch-on delay with switch-off delay
Preselect counter, electrical, incrementing EMERGENCY-STOP button
Proximity sensor, inductive Proximity sensor, capacitive
Proximity sensor, optical 5/2-way double solenoid valve

20
Component and exercise allocation (table)

Exercise
Designation 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Relay, 3-off* 2 3 3 4 5 5 2 2 5 3 4 5 5 5 6* 6* 6* 6* 6* 6*
Signal input module,
electrical * 1 1 1 1 2 2 1 2 2 1 1 2 2 1 2 1 1 2 1 2
Time relay, 2-off 1 1 1 1 1 1 1

Preselet counter, electrical,
incrementing 1 1 1 1 1 1 1
Distributor plate, electrical 1 2 1 1 2 1 1 1 1 1 2 2 2 2 2 1 2 2 2 2

Single-acting cylinder 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Double-acting cylinder 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 3* 3* 3* 3*
On-off valve with
filter regulator 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Manifold 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
EMERGENCY-STOP button 1 1 1 1
Proximity sensor, inductive 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Proximity sensor, capacitive 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Proximity sensor, optical 1 1 1 1 1 1 1 1
Proximity sensor with
cylinder mounting 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
Limit switch, electrical,

Actuation from the left 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2* 2* 2*
Limit switch, electrical,

Actuation from the right 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Pneumatic-electric converter 1 1 1
3/2-way solenoid valve,
normally closed 1 1 1 1 1 1 1 1 1 1 1 1
5/2-way solenoid valve 2 2 2 2 2 2 2 2 2 2 2 1 2 2 2 2

5/2-way double solenoid
valve 2 3 2 3 2 3 1 2
* Components which are not available in full quantity in equipment sets 201 and 202.

21
Methodical structure of the exercises

All 20 exercises in part A are of the same methodical design.
The two exercise sheets are divided into:
- Subject
- Title
- Training aim
- Exercise
sowie
- Problem description
- Positional sketch
- Displacement-step diagram
The proposed solutions in part C cover a minimum of four pages and are
divided into:
- Circuit diagram, pneumatic
- Circuit diagram, electrical
- Solution description
- Component list

22
Designation of components
The components in the circuit diagrams are designated in accordance
with ISO 1219-2. All components within a circuit have the same main
code. Letters are assigned dependent on the component. If there are
several components within a circuit, these are numbered consecutively.
Pressure lines are identified with the designation P and are numbered
separately.
Actuators: 1A, 2A1, 2A2, ...
Valves: 1V1, 1V2, 1V3, 2V1, 2V2, 3V, ...
Signal detecter: 1S1, 1S2, ...
Accessories: 0Z1, 0Z2, 1Z, ...
Electrical sensors: 1B1, 1B2, ...
Pressure lines: P1, P2, ...

A-1
Part A Course
Basic exercises
Exercise 1: Bench drill A-3

Exercise 2: Feed unit for sheet metal strip A-5
Exercise 3: Filling device A-7
Exercise 4: Stamping device A-9
Exercise 5: Drilling jig A-11
Exercise 6: Clamping unit for grinding A-15
Exercise 7: Forming press A-19
Consolidating exercises
Exercise 8: Embossing device A-21

Exercise 10: Drilling and reaming machine A-25
Exercise 12: Internal grinding machine A-33
Exercise 13: Assembly unit A-37
Exercise 14: Moulding press A-41
Exercise 15: Pick-and-place unit A-45
Exercise 16: Galvanising process A-49
Exercise 18: Rotary indexing station A-57
Exercise 19: Checking station A-63

A-2

A-3
Aufgabe 1
Electropneumatics Subject
Bench drill Title
To teach the student the principle of a latching sequence. Training aim
Drawing the pneumatic and electrical circuit diagrams. Exercise

Construction of the pneumatic and electrical circuits.
Checking the circuit sequence.

A-4
Aufgabe 1
Problem description Workpieces are inserted into the clamping device by hand. Clamping
cylinder 1A is to extend when the start button is pressed. When the
workpiece is clamped, it is to be drilled via feed unit 2A and the drill
retracted once again. At the same time, the swarf is to be blown away by
an air jet 3Z. Then, the clamping cylinder 1A is to release the workpiece.
Fig. 1/1:
Positional sketch
2A
3Z
1A
Fig. 1/2: 1 2 3 4 5=1

Displacement-step diagram
1 1S2
1A
0 1S1
1 2B2
2A
0 2B1

A-5
Aufgabe 2
Feed unit for sheet metal strip Title
To teach the student the principle of a resetting sequence Training aim

(with reliable switching reversal).


A-6
Aufgabe 2
Problem description A sheet metal strip is to be fed from a drum towards the cutting tool. The
feed unit may only start when the punch-tool is in the upper position (this
signal must be simulated by a push button S3). Cylinder 1A holds the
sheet metal strip and cylinder 2A retracts. Cylinder 1A releases the strip
and cylinder 2A returns to the forward end position.
Operating condition The sheet metal strip feed unit must be provided with a main switch S1.
When cylinder 2A has retracted and cylinder 1A has released the strip, a
signal (optical indicator) is to be passed on to the press for the next part
to be punched out.
Fig. 2/1:
Positional sketch
1A
2A
Fig. 2/2: 1 2 3 4 5 6=1

1 1B2
1A
0 1B1
1 2S2
2A
0 2S1

A-7
Exercise 3
Filling device Title
To familiarise the student with the procedure for skipping program Training aim
steps.
To familiarise the student with the use of a timer with switch-on delay.


A-8
Exercise 3
Problem description Bottles are transported along a conveyor belt to a rotary table. Cylinder
1A is to retract only when a bottle has arrived on the conveyor belt
(position 1) and the START signal (continuous/single cycle) has been
given. The table is then to continue indexing (2A+), when the signal
bottle on indexing table (position 2) has been sent. When a bottle has
reached the filling station (position 3), cylinder 3A is to open the filling
valve, remain it open for approx. 2 seconds and then reclose it.
Operating condition If no bottle is reported as present at the filling station (position 3), the
installation must be indexed manually until a bottle is present for filling.
Sensing of the bottles is to be simulated by push button.
Fig. 3/1:
Positional sketch
1 2
1A 3 3A
2A

A-9
Aufgabe 4
Stamping device Title
To teach the student how to realise a stroke-dependent sequence Training aim

control with a resetting sequence.
Drawing the displacement-step diagram and the pneumatic and Exercise

electrical circuit diagram.

A-10
Aufgabe 4
Problem description Cylinder 1A is to push parts out of the gravity feed magazine and clamp
them. Only then can cylinder 2A stamp the part and retract once again.
Next, clamping cylinder 1A is to unclamp. The part is to be ejected by
cylinder 3A, which then returns to the retracted end position.
Fig. 4/1:
Positional sketch
Fig. 4/2: 1 2 3 4 5 6 7=1

1 1S2
1A
0 1S1
1 2B2
2A
0 2B1
1 3B2
3A
0 3B1

A-11
Exercise 5
Drilling jig Title
To teach the student how to realise multiple movements of a cylinder. Training aim
To familiarise the student with the use of an incrementing preselect
counter.

Drawing the pneumatic and electrical circuits.

A-12
Exercise 5
Problem description Rectangular castings are to be drilled in 4 positions. Castings are in-
serted by hand and clamped by an eccentric cam.
Feed unit 3A with hydraulic cushioning cylinder is aligned vertically (Z-
axis). Positioning cylinders 1A and 2A move the table in X- and Y-
direction so that drilling positions (1), (2), (3) and (4) can be approached
consecutively.
The first hole is drilled by means of feed unit 3A after the START button
has been pressed. Next, double-acting cylinder 1A retracts and the
second drilling process takes place. After double-acting cylinder 2A has
retracted, feed unit 3A carries out the third double stroke. When cylinder
1A has once again reached its forward end position, the fourth hole is
drilled. In the 12th step, cylinder 2A extends once again and the initial
position is obtained.
Operating condition To ensure that the service life of the drill is not exceeded, it is to be
monitored via a counter. This is to emit a signal and interrupt the cycle
once a predetermined number of drilling operations has taken place.
Once the drill has been replaced and the counter has been reset by
hand, the cycle is to continue again.

A-13
Exercise 5
Fig. 5/1:
Positional sketch
4
2
Fig. 5/2:
1 2 3 4 5 6 7 8 9 10 11 12 13=1
1 1B2
1A
0 1B1
1 2B2
2A
0 2B1
1 3S2
3A
0 3S1

A-14
Exercise 5

A-15
Exercise 6
Clamping unit for grinding Title
To familiarise the student with the use of a pneumatic/electric con- Training aim
verter.
To teach the student how to construct a control system using single
and double solenoid valves (Resetting sequence with extension).


A-16
Exercise 6
Problem description Semi-finished flanges of workpieces are to be placed manually in a

clamping and grinding unit, pneumatically clamped and ground on the
right and lefthand flanges.
Once single-acting clamping cylinder 1A has reached its forward end
position and the clamping pressure has built up in the piston chamber,
feed unit 2A performs a double stroke. The righthand flange is ground.
Double-acting cross-feed cylinder 3A extends prior to feed unit 2A
carrying out the second double stroke and grinding the lefthand flange.
Clamping cylinder 1A releases the workpiece when cylinder 3A has
reached its retracted end position.
Operating condition Clamping cylinder 1A, single-acting, controlled via a solenoid valve.
Feed cylinders 2A and cross feed cylinder 3A are both double-acting
and each controlled via a double solenoid valve.
Monitoring of clamping pressure.

A-17
Exercise 6
Fig. 6/1:
Positional sketch
1A
2A
3A
1 2 3 4 5 6 7 8 9=1 Fig. 6/2:

1 1S2
1A
0 1S1
1 2B2
2A
0 2B1
1 3B2
3A
0 3B1

A-18
Exercise 6

A-19
Aufgabe 7
Forming press Title
To teach the student how to realise a control system with specified Training aim
EMERGENCY-STOP conditions.
To teach the student how to realise a two-hand safety control via a
timer with switch-on delay.


A-20
Aufgabe 7
Problem description A metal plate is inserted by hand into the forming press. A profile is to be
stamped into the metal plate by means of a two-handed operation.
When the operation is complete, the formed metal part is to be ejected
by means of ejecting cylinder 2A.
Operating condition The START signal is obtained through a two-hand safety control with
delayed switch-on timer. When the EMERGENCY-STOP button is
pressed, the two cylinders must return immediately to their initial posi-
tions.
Fig. 7/1:
Positional sketch
1A
Fig. 7/2: 1 2 3 4 5=1

1 1S2
1A
0 1S1
1 2B2
2A
0 2B1

A-21
Exercise 8
Embossing device Title
To teach the student how to incorporate step repetitions and manual Training aim
step mode into a sequence.
Drawing the pneumatic and electrical circuits. Exercise


A-22
Exercise 8
Problem description Workpieces to be embossed are inserted manually into a retainer and
pushed under the embossing stamp by cylinder 1A. Cylinder 2A extends
and embosses the workpiece. Then, cylinder 2A retracts again followed
by cylinder 1A.
Operating condition It must be possible to carry out the individual movements step by step
via a push button (manual step mode). In addition, steps 2A+/2A- must
be repeatable to enable adjustment of the embossing cylinder. Cylinder
2A+ is to be moved in manual step mode, meaning that the 2A- move-
ment must be effected via an additional push button. Step repetition and
manual step mode should only be possible when no START signal is
present.
Fig. 8/1:
Positional sketch
Fig. 8/2: 1 2 3 4 5=1

1 1B2
1A
0 1B1
1 2S2
2A
0 2S1

A-23
Exercise 9
Handling device Title
To teach the student how to incorporate EMERGENCY-STOP and Training aim

marginal conditions in a latching sequence.

Checking the circuits sequence.

A-24
Exercise 9
Problem description Round parts are to be fed by a handling device from the outlet channel
of processing station I to the inlet channel of processing station II. As an
additional start condition, the outlet channel is to be interrogated for
round parts.
Operating condition Separate push buttons for SINGLE/CONTINUOUS CYCLE. EMER-

GENCY-STOP: Linear drive 2A must be unpressurised. Gripper 1A must
remain closed or open according to status. When EMERGENCY-STOP
is no longer being actuated, pressing a push button is to bring the linear
drive back into the initial position. A second push button is then to re-
lease the gripper (if this was closed in the EMERGENCY-STOP status).
This push button must also simultaneously latch the start button (after
the EMERGENCY-STOP), so that it is only possible to restart via the
START button after this button has been pressed.
Fig. 9/1:
Positional sketch
Fig. 9/2: 1 2 3 4 5=1

1 1S2 open
1A Gripper
0 1S1 closed
1 2B2
2A Linear drive
0 2B1

A-25
Exercise 10
Drilling and reaming machine Title
To teach the student how to realise a control system with an alterna- Training aim
tive program by means of program switching step jump.


A-26
Exercise 10
Problem description Program 1: - Drilling

Parts, which only need to be drilled, are clamped by hand. The part is
drilled when the START button is actuated. (Cylinder 1A).
Program 2: - Drilling and reaming
Parts, which also need to be reamed, are also clamped by hand. Then,
upon actuation of a PROGRAM SELECTOR button and the START
button, cylinder 1A starts the drilling process. When the drilling process
is completed, positioning cylinder 2A extends and transfers the drilled
part to the reaming station (cylinder 3A). When reaming of the part has
taken place, positioning cylinder 2A retracts and the part can be re-
moved. The PROGRAM SELECTOR button must be actuated before the
START button in order to start up program 2. If these buttons remain
unactuated, then program 1 is to automatically run.

A-27
Exercise 10
Fig. 10/1:
Positional sketch
Fig. 10/2:
Program 1 Program 2
1 2 3=1 1 2 3 4 5 6 7=1
1 1S2 1 1S2
1A 1A
0 1S1 0 1S1
1 2B2 1 2B2
2A 2A
0 2B1 0 2B1
1 3B2 1 3B2
3A 3A
0 3B1 0 3B1

A-28
Exercise 10

A-29
Exercise 11
Loading station Title
To teach the student to program repetition using an additional move- Training aim
ment.
To familiarise the student with the use of an incrementing preselect
counter.


A-30
Exercise 11
Problem description A plate on a conveyor belt is fitted with two steel parts.
The parts advanced via a rail are centred by a spigot and held by an
electromagnet whilst being transferred.
The motion sequence towards position 1 is to be executed via cylinders
1A and 2A.
Position 2 is to be reached by means of the same sequence as that
employed for position 1, with the addition of cylinder 3A (see displace-
ment-step diagram).
Operating condition Sensing of steel parts is to be realised via a push button S2.
When the conveyor belt has passed on the next plate for loading and
transmitted a signal to the loading unit (simulated by push button S1),
the machine is to proceed automatically.
The functioning of the electromagnet is to be simulated by means of a
lamp H1.

A-31
Exercise 11
Fig. 11/1:
Positional sketch
Conveyor belt
Plate
Position 2 Position 1
Fig. 11/2:
1 2 3 4 5 6 7 8 9 10 11 12 13=1
1 1S2
1A
0 1S1
1 2B2
2A
0 2B1
1 3B2
3A
0 3B1
Position 1 Position 2

A-32
Exercise 11

A-33
Exercise 12
Internal grinding machine Title
To familiarise the student with step repetition using the preselect Training aim
counter.

Construction of the pneumatic and electrical circuit diagrams.

A-34
Exercise 12
Problem description Workpieces are fed along a conveyor belt. The forwardmost workpiece
is pushed against the stop by the following one. When a workpiece is
present, it is signalled by a sensor (switch) and the clamping stop is
raised (cylinder 1A).
Next, cylinder 2A is to clamp the part and signal when the clamping
pressure has been reached so that the grinding process can commence.
Cylinder 3A is to advance and the grinding wheel switched on simulta-
neously (simulation by means of visual indicator). Then cylinder 3A is to
travel up and down ten times (half strokes) and then return to the initial
start position. Next, cylinders 1A and 2A are are to retract simultane-
ously.
Cylinder 2A now is to extend once again and push the part onto the
conveyor belt which is to carry it away (only a minimal section of the
stroke was required for the clamping operation). When cylinder 2A has
returned once again and another workpiece has reached the stop, the
cycle is to be repeated.
Operating condition START and STOP at the end of each cycle are each controlled by one
push button.

A-35
Exercise 12
Fig. 12/1:
Positional sketch
3A
2A
1A
Fig. 12/2:
1 2 3 4 5 6 22 23 24 25 26=1
1 1B2
1A
0 1B1
1 2S2
2A
0 2S1
1 3B3
3A 3B2
0 3B1

A-36
Exercise 12

A-37
Exercise 13
Assembly unit Title
To teach the student how to set up manual activation of a cylinder Training aim
including precautions with protection against collision.
To familiarise the student with automatic setting conditions.


A-38
Exercise 13
Problem description Bushes which are placed ready for assembly in a gravity feed magazine
are pressed into metal blocks which are also introduced in a similar
manner.
Cylinder 1A pushes a metal block from the magazine to a stop and
clamps it. Then, cylinder 2A extends and presses the first bush into
place. Next, cylinder 3A is activated, pressing the second bush into
place. Then cylinders 1A and 3A retract simultaneously, followed by
cylinder 2A retracting. The assembled metal block drops onto a con-
veyor belt.
Operating condition The installation is to operate in a continuous cycle.

It must be possible to select between manual and automatic operating
mode.
Manual operation is to be indicated by a lamp H1.
Separate push buttons are to actuate each of the cylinders. This installa-
tion may only be run in manual mode; only one cylinder is to extend at a
time.

A-39
Exercise 13
Fig. 13/1
Positional sketch
1 2 3 4 5 6=1 Fig. 13/2:

1 1S2
1A
0 1S1
1 2B2
2A
0 2B1
1 3B2
3A
0 3B1

A-40
Exercise 13

A-41
Exercise 14
Moulding press Title
To teach the student how to construct a two-handed safetystart-up Training aim

control with relay.
To familiarise the student with restart before the end of the cycle.


A-42
Exercise 14
Problem description Plastic plates are to be formed from duroplastic pellets. The pellets are
inserted manually into the lower part of the mould.
When the START button is pressed (two-handed safety control), the
upper part of the mould is guided into the lower part of the mould.
When the forward end position is reached, pressure must be sustained
for approximately ten seconds to guarantee hardening of the formed
part. Then, the plates are removed from the mould tool by the extractor
unit and stacked next to the press.
Operating condition The START signal must continue until cylinder 1A has assumed its
forward end position.
The press cylinder may extend immediately the extractor unit has been
removed from the working area (half return stroke of cylinder 2A).
The two-handed safety control using a relay.
The function of the vacuum generator 4Z is to be represented by a lamp.

A-43
Exercise 14
Fig. 14/1:
Positional sketch
1 2 3 4 5 6 7=1 Fig. 14/2:

1 1B2
1A
0 1B1
1 2B3
2A 2B2
0 2B1
1 3S2
3A
0 3S1

A-44
Exercise 14

A-45
Exercise 15
Pick-and-place unit Title
To teach the student how to develop a latching sequence with mar- Training aim
ginal conditions.
Drawing the pneumatic and electrical circuit diagrams.. Exercise


A-46
Exercise 15
Problem description A triple-axis unit is used for insertion of parts from position 2 into posi-
tions 3 and 4 of a gear housing. The vacuum gripper 4Z is to be simu-
lated by a lamp (gripper suction = lamp on, no gripper suction = lamp
off). The start position is to be position 1, where the gripper is raised
(Z-axis) and there is no suction. When the START button is pressed,
position 2 is to be approached and a part picked up from the feed hop-
per and then deposited in position 3. Another part is then picked up from
position 2 and deposited in position 4. The gripper then returns to initial
position 1.
Operating condition Sensing of the magazine (simulated by a switch and indicated via a
lamp):
When the magazine is empty, the control system is to remain in position
1 or position 2 and must only proceed or restart when the magazine has
been filled and the start button pressed.
Sensing of the gear housing:
This is to guarantee that a gear housing which is inserted into a device
is removed after processing (switch and lamp off). The initial start posi-
tions of the double-acting cylinders are: 1A+, 2A+, 3A-.

A-47
Exercise 15
Fig. 15/1:
Positional sketch
2A
1A
3A
Fig. 15/2:
down
up
Vaccuum Vaccuum Vaccuum Vaccuum

generator on generator off generator on generator off

A-48
Exercise 15

A-49
Exercise 16
Galvanising process Title
To teach the student how to realise program branchings. Training aim

To teach the student how to make multiple use of time relays.
To familiarise the student with program section repetitions using the
preselect counter.
To teach the student how to realise a pressure-dependent control
system.


A-50
Exercise 16
Problem description An overhead trolley beam transports the parts to be galvanised from a
work surface across the three baths and back again. A doubleacting
cylinder positions the basket on the work surface or else lowers it into
the baths. It remains in the forward end position (bath 2) or swings the
basket up and down in the bath (baths 1 and 3). Partial strokes are
sensed by three limit switches.
If the trolley has approached a horizontal position, a control lamp is
illuminated (bath 1 lamp H1, bath 2 lamp H2, bath 3 lamp H3 and work
surface lamp H4).
In the initial position, the basket hangs above the work surface. When
the up/down switch S2 is actuated, the cylinder extends and the basket
is deposited on the work surface for loading. When the initial start posi-
tion has once more been reached, the cylinder can be actuated via start
button S. The movements of the trolley (from work surface to bath 1,
from bath 1 to bath 2, from bath 2 to bath 3 and from bath 3 back to the
work surface) are simulated by four identical time periods t1 = 2 seconds.
Once the basket has been dipped into bath 1 (and bath 3), the piston
extends four half strokes in the forward stroke area. The basket remains
in bath 2 in the forward stroke area t2 = 3 seconds.
Operating condition When the main power supply has been switched on, the control is to be
activated via the SET button S1 and the time interval t1 started simulta-
neously.
During this time period, the cylinder is to be brought into the initial posi-
tion (as it would have moved into the forward end position by leakage
losses when the installation was stopped).
When the time t1 has expired, the positioning lamp H4 is illuminated.
The installation can only be started once a pneumatic-electrical con-
verter has signalled the supply of compressed air.

A-51
Exercise 16
Fig. 16/1:
Positional sketch
Bath 1 Bath 2 Bath 3
Fig. 16/2:
START Bath 1 Bath 2 Bath 3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17=1
t2
1 1B3
1A 1B2
0 1B1
t1 t1 t1
S1
t1

A-52
Exercise 16

A-53
Exercise 17
Loading station Title
Consolidating the students knowledge. Training aim

Program section repetition.


A-54
Exercise 17
Problem description A loading station is used for loading boxes. Empty boxes which are
supplied via a conveyor belt must be placed onto the transfer unit by
hand. Transfer unit 1A moves underneath the swivel device 4M, which
then fills the box with containers row by row. The motion sequence can
be seen in displacement-step diagram 1. Indicate on the diagram the
step which has been reached by the installation shown in the positional
sketch.
Operating condition The functioning of the suction cups is to be simulated by lamp. The
motion sequences which recur (see displacement-step diagram 1, steps
3....21), should be brought together in a subroutine which is to be re-
peated itself a number of times (see displacement-step diagram 2).
Fig. 17/1:
Positional sketch
4M
3A
1A
2A
The loading station shown here is not in the initial position.

A-55
Exercise 17
1B2
1B1
2B2
2B1
3S2
3S1
Fig. 17/2:
4B
4S
25=1 Displacement-step
diagram 1
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
1
0
4M
1A
2A
3A
1A+ 3A+ 4M+ 4M- 3A- 2A+ 3A+ 4M+ 4M- 2A- 3A- 2A+ Abbreviated notation
3A+ 4M+ 4M- 2A- 3A- 2A+ 3A+ 4M+ 4M- 3A- 1A-

A-56
Exercise 17
1B2
2B2
3S2
1B1
2B1
3S1
Fig. 17/3:
4B
4S
Displacement-step
25=1
diagram 2
24
23
22
21
21
3
3
2
1
1
0
1
0
1A
3A
4M
2A
Abbreviated notation 1A+ 3A+ 4M+ 4M- 2A- 3A- 2A+ 3A+ 4M+ 4M- 3A- 1A-
Main program 3 x Subroutine Main program

A-57
Exercise 18
Rotary indexing station Title
To familiarise the student with parallel program division. Training aim
Drawing the pneumatic and electrical circuit diagram. Exercise


A-58
Exercise 18
Problem description Workpieces are drilled vertically and horizontally on an eight-station

rotary indexing table. Six feed units are used for the various machining
operations. Two each for drilling, counterboring and countersinking.
Two transferring units load and unload the machine respectively.
Lifting cylinders 1A and 3A descend onto the workpieces. These are
picked up by suction (functioning of the vacuum generator is to be
indicated by a lamp) and then lifted.
The stroke of cylinder 5A then causes the table to index on by one
position. At the same time, transfer cylinders 2A and 4A approach the
positions for placing on the indexing table and depositing via the con-
veyor belt 2.
Then, cylinder 5A latches the rotary indexing table and the two lifting
cylinders 1A and 3A deposit the parts.
At the same time as the lifting cylinder retracts, processing via feed units
6A to 11A begins.
When these have reached their forward end positions, the feed units and
the transfer cylinders return to their initial positions.
Operating condition Choice between manual and automatic operating modes.

Separate push buttons for START and STOP (continuous cycle).
The start signal must be maintained until the machine has been supplied
with lubricant via a centralised lubrication system (the pump motor is to
be simulated by a lamp). Then, the start signal is to be stored and indi-
cated by a lamp.
Workpiece sensing on conveyor belt 1 is simulated by a switch.
The air blast for swarf removal is to be simulated using a solenoid valve.

A-59
Exercise 18
EMERGENCY-STOP
The electrical power to the control must be switched off.
The feed units are to retract.
The transfer units and the cylinder of the indexing table are to complete
their movements.
When the vacuum generators are active, they must continue to remain
active until, after the RESET and a renewed START, the controller gives
the command to deposit.
RESET
If, after indexing on, processing can no longer take place because the
EMERGENCY-STOP has been actuated, processing must be carried
out in RESET mode via a time control.
All cylinders must be brought into their initial position. In the case of the
transport units, cylinders 1A and 3A must retract before cylinder 2A and
4A.
Note regarding solution

For the purpose of simulation, this exercise can be solved using four
cylinders:
The transer units are to be represented by double-acting cylinders.
Cylinders 1A and 2A are sufficient for this as the movements of the two
units are synchronised.
Cylinder 5A for indexing of the table is also represented by a double-
acting cylinder.
All feed units are to be represented by a single-acting cylinder.
Only the limit switches of the four cylinders are to be drawn in the elec-
trical circuit diagram.

A-60
Exercise 18
Fig. 18/1:
Positional sketch
Discharge
Conveyor 2
9A
Counter 2
8A
1A Counter 1
Rotary indexing table

Conveyor 1
7A
Drilling 1

A-61
Exercise 18
1 2 3 4 5 6 7=1 Fig. 18/2:

Transfer 1 1 1S2 (1B2)
1A
0 1S1 (1B1)
1 2S2 (2B2)
2A
0 2S1 (2B1)
1 2 3 4 5 6 7=1
Transfer 2 1 3S2
3A
0 3S1
1 4S2
4A
0 4S1
1 2 3 4 5 6 7=1
Rotary indexing 1 5S2

table 5A
0 5S1
1 2 3 4 5 6 7=1
Drilling 1 1 6S2 (6B)

6A
0 6S1 (6S)
Drilling 2
1 7S2
7A
0 7S1
Counter-
1 8S2
boring 1 8A
0 8S1
Counter- 1 9S2
boring 2 9A
0 9S1
1 10S2
Deburring 1
10A
0 10S1
Deburring 2
1 11S2
11A
0 11S1

A-62
Exercise 18

A-63
Exercise 19
Checking station Title
To familiarise the student with the use of a timer with delayed switch- Training aim
on as a delayed starting element.


A-64
Exercise 19
Problem description Transfer cylinder 1A is to push a container onto the scales. Then, cylin-
der 2A is to release the scales and cylinder 1A is to return to its initial
position.
After a waiting time of approx. 3 seconds, cylinder 2A is to block the
scales again. If the container is within the weight tolerance (switch S4 is
activated), cylinder 3A is to push it onto the conveyor belt to move it on
and then to retract once again. However, if the tolerance limit is not
maintained (switch S4 not activated), cylinder 4A is to transfer the con-
tainer to the outlet chute and then to retract again. Then, the container is
to be transferred on by the conveyor belt (simulated by a lamp H1).
Operating conditions The installation is to operate in continuous mode and started by a push
button S1 and stopped at the end of the cycle by a second push button
S6.
The good parts are to be counted.
As the sensor for the containers is not attached directly to transfer
cylinder 1A, for technical reasons, the run-time of the conveyor belt must
be controlled as follows:
The conveyor belt continues running until a sensor (push button S4)
outside the transfer area, signals the presence of a container and uses
this to control a timer. When the time has expired, the conveyor belt can
stop and cylinder 1A then commences the cycle once again.

A-65
Exercise 19
Fig. 19/1:
Positional sketch
1A
3A
4A
1 2 3 4 5 6=1 Fig. 19/2:

1 1B2
1A
0 1B1
1 2B2
2A
0 2B1
1 3B1
3A
0 3S1
1 4S2
4A
0 4S1

A-66
Exercise 19

A-67
Exercise 20
Handling device Title
Familiarisation with an alternative solution to Electropneumatics. Training aim


A-68
Exercise 20
Problem description Cylindrical parts are to be distributed evenly from outlet channel 1 onto
the two inlet channels 2 and 3 (see displacement-step diagram)
Operating condition The unit is to be operated in continuous cycle only. START and STOP
AT END OF CYCLE are each to be effected by one push button.
Sensing of parts at channel 1 is to be simulated by a switch. If this
switch is not activated, the unit is to stop at the end of the cycle.
After the swivel movement to inlet channels 2 and 3 has been carried
out, the gripper is not to open until a short delay time has expired.
After actuation of the EMERGENCY-STOP switch, cylinders 1A, 2A and
3A are to retract and cylinder 4M switched to an unpressurised condi-
tion.
When the EMERGENCY-STOP has been unlatched, the reset button is
to return cylinder 4M to the initial position.
It must be possible to limit the number of cycles using a preselect
counter.

A-69
Exercise 20
Fig. 20/1:
Positional sketch
Fig. 20/2:
1 2 3 4 5 6 7 8 9 10 11 12 13=1
1 1S2
1A
0 1S1
1 2B2
2A
0 2B1
1 3B2
3A
0 3B1
1 4B
4A
0 4S

A-70
Exercise 20

B-1
Part B - Fundamentals
The theoretical fundamentals for the training package Electropneumatics
are summarised in the textbook
Learning System for Automation and Technology
Introduction to
Electropneumatics.
Basic Level TP201

B-2

C-1
Part C Solutions
Solution 1: Bench drill C-3
Solution 2: Feed unit for sheet metal strip C-9
Solution 3: Filling device C-17
Solution 4: Stamping device C-21
Solution 5: Drilling jig C-27
Solution 6: Clamping unit for grinding C-35
Solution 7: Forming press C-41
Solution 8: Embossing device C-45
Solution 10: Drilling and reaming machine C-55
Solution 12: Internal grinding machine C-63
Solution 13: Assembly unit C-69
Solution 14: Moulding press C-75
Solution 15: Pick-and-place unit C-81
Solution 16: Galvanising process C-87
Solution 18: Rotary indexing station C-103
Solution 19: Checking station C-111

C-2

C-3
Solution 1
Bench drill
Fig. 1/3:
Circuit diagram, pneumatic
**
* For the purposes of this exercise, feed unit 2A is replaced by a

double-acting cylinder.
** Detailed representation of the on/off valve with filter regulator.

C-4
Solution 1
Fig. 1/4
Circuit diagram, electrical
24 V- 1 2 3 4 5 6 7 8 9 10 11 12
13 13 1 13 13 33 33 33
S K1 1S2 K2 2B2 K3 2B1 K1 K2 K3
14 14 4 14 BN 14 BN 34 34 34
1
1S1 BK BK
4 BU BU
41 23 23 23 41
K4 K1 K2 K3 K3
42 24 24 24 42
A1 A1 A1 A1
K1 K2 K3 K4 1Y 2Y 3Y
A2 A2 A2 A2
1A+ 2A+ 3Z
2 4 11 7 1
3 5 9
10 11

Ausblasen
C-5
Solution 1
Since in this case the memory function is via a relay, single solenoid Solution description
valves are generally activated using a latching sequence. It should be
remembered that the coil circuit should be interrupted by a second
contact for the return motion, for example, in order to achieve spring
return of the valve to the initial position. (The final step represents an
exception to this since it is possible to dispense with a normally closed
contact as all valves are returned to their initial positions through inter-
ruption of all the circuits). This is why a latching sequence is used since
in the case of power failure all cylinders will return to an accurately
defined initial position. This is important for accident prevention, al-
though it is important to watch out for overlapping of movements which
may occur on reaching the initial position.
24 V- 1 2 10 Fig. 1/5:
Step 1, Cylinder 1A+
13 13 33
S K1 K1
14 14 34
1
1S1
4
41
K4
42
A1
K1 1Y
A2
1A+
When START button S is actuated and normally open contact 1S1 is

activated via cylinder 1A, the circuit to relay K1 is closed via the normally
closed contact of K4, which then goes into self-holding (latching) via the
parallel contact of K1.
A further normally open contact of K1 switches the circuit to solenoid coil
1Y. This in turn switches the solenoid valve and cylinder 1A travels into
the forward end position.

C-6
Solution 1
Fig. 1/6: 24 V- 1 2 3 4 10 11
Step 2, Cylinder 2A+
13 13 1 13 33 33
S K1 1S2 K2 K1 K2
14 14 4 14 34 34
1
1S1
4
41 23 41
K4 K1 K3
42 24 42
A1 A1
K1 K2 1Y 2Y
A2 A2
1A+ 2A+
When cylinder 1A has reached its forward end position, it actuates limit
switch 1S2. Then, the circuit for relay K2 is closed via S2 and the setting
condition K1, this then goes into self-latching via a parallel normally
open contact.
A second normally open contact of K2 switches the current to solenoid
coil 2Y via normally closed contact K3; this switches the valve and
cylinder 2A extends.
The principle of the latching sequence is to interrogate the preceding
step and its acknowledgement (limit switch) and then to set a new mem-
ory for the next step. Finally, the complete sequence (the self-latching
circuits) is reset by the last step (or cycle) no self-latching is required
for the last step.

C-7
Solution 1
Quantity Designation Components list
2 Relay, 3-off
1 Signal input plate, electrical
1 Indicator/distributor plate, electrical
2 Double-acting cylinder
1 On/off valve with filter regulator
1 Manifold
2 Proximity sensor with cylinder mounting
1 Limit switch, electrical, actuation from the left
1 Limit switch, electrical, actuation from the right
1 3/2-way solenoid valve, normally closed
2 5/2-way solenoid valve
1 Cable set with safety plug
1 Electrical power supply unit, 24 V

C-8
Solution 1

C-9
Solution 2
Feed unit for sheet metal strip
Fig. 2/3:
1B1 1B2
2S1 2S2 Circuit diagram, pneumatic
1A 2A
4 2 4 2
1Y1 1Y2 2Y1 2Y2

5 3 5 3
1 1
0Z2
0Z1
1 2
Simplified representation of on/off valve with filter regulator

Solution 2
C-10
(1)
Fig. 2/4:
24 V- 1 2 3 4 5 6 7 8 9 10
13 13 23 13 23 1 13 23
S1 K1 K1 K3 K3 2S1 K5 K5
14 14 22 1B1 BN 14 24 4 14 24
13 13
S2 K4
BK
14 14
1 BU 13
2S2 K2
4 14
11
K8
14
41 41 21
K4 K6 K8
42 42 22
A1 A1 A1 A1 A1 A1
K1 K2 K3 K4 K5 K6
A2 A2 A2 A2 A2 A2
2 12 5 6 1 8 9 5 12
3 17 7 18 10 16
19

24 V- 11 12 13 14 15 16 17 18 19 20
11 SET 13 21 23 23 23 33 31
K7 K7 K6 K2 K4 K6 K8
1B2 14 14 24 24 24 24 34 34

BN
BK
BU 13
K6
14
41
K2
42
A1 A1
K7 K8 H1 1Y1 2Y1 1Y2 2Y2
A2 A2
1A- 2A- 1A+ 2A+

13 8 1
15 20
(2)
Fig. 2/5:
Solution 2
C-11
C-12
Solution 2
Solution description When the SET button is pressed, relay K7 goes into self-latching and
switches relay K8, which represents the start condition.
If appropriate, the SET button should be latched in such a way that it can
only be active at the time when the main current supply is applied, in
order to safeguard the circuit sequence.
Once the feed has been initiated with S1 and S2, K1 goes into self-
latching and K2 switches, self-latching at K7 is cancelled via a normally
closed contact of K2.
A further possibility is to replace the SET key by a relay (see exer-
cise 13).
Fig. 2/6:
24 V- 1 2 3 17
Step 1, Cylinder 1A-
13 13 23 23
S1 K1 K1 K2
14 14 22 24
13
S2
14
1
2S2
4
11
K8
14
41
K4
42
A1 A1
K1 K2 1Y1
A2 A2
1A-
When START button S1 is actuated, the circuit for relay K1 is closed via
the signal from pressing S2, the limit switch S22, the setting signal for
relay K8 and the normally closed contact K4. The relay goes into self-
latching via the parallel normally open K1. At the same time, a further
normally open contact of K1 switches the circuit for the relay K2.
A normally open contact of K2 switches the circuit in the power section
to solenoid coil 1Y1. The valve switches and cylinder 1A travels into the
retracted end position and there actuates limit switch 1B1.

C-13
Solution 2
Fig. 2/7:
Step 2, Cylinder 2A-
24 V- 1 2 3 4 5 6 7 17 18
13 13 23 13 23 23 23
S1 K1 K1 K3 K3 K2 K4
14 14 22 1B1 BN 14 24 24 24
13
S2
BK
14
1 BU 13
2S2 K2
4 14
11
K8
14
41 41
K4 K6
42 42
A1 A1 A1 A1
K1 K2 K3 K4 1Y1 2Y1
A2 A2 A2 A2
1A- 2A-
Now sensor 1B1 emits a signal which closes the circuit for relay K3 via
the normally open contact K2 and the normally closed contact K6. This
goes into self-latching via the parallel normally open contact K3. At the
same time, relay K4 is switched via a further normally open contact K3.
Only now, when self-latching of K3 has been established, is the setting
condition K1 or K2 reset by normally closed contact K4 and in the power
section, the normally open contact K4 switches the circuit to solenoid
coil 2Y1, which in turn switches the valve, cylinder 2A retracts and
activates 2S1 in the end position.
Owing to its additional switching time, relay K4 serves as a delay be-
tween the build-up of self-latching of K3 and the reset of setting condi-
tion K2. This guarantees that K3 is in self-latching before the setting
signal is set.
Then, the next step is activated (K5, K6) by 2S1 via K4. The principle of
the latching sequence is based on the interrogation of the preceding
step and its acknowledgement (limit switch). The next step is activated
on the basis of these conditions; when this happens, the preceding step
is reset.
The reset sequence is particularly suitable for the control of double
solenoid valves, since here the memory behaviour is assumed by the bi-
stable solenoid valve.

C-14
Solution 2
This can be very important in the case of power failure, in respect of

accident prevention.
To be able to start up again after power failure or switch off the main
power supply (circuit dead), relays K7 and K8 must be switched. This
happens here via the SET key. The principle of reversal of the latched
sequence which is shown here is completely reliable owing to the use of
an additional relay per step and can be used for every type of relay.
Where there is a late opening or early closing relay, it may be possible to
get by without an additional one. (Normally, only contactors have this
type of switching behaviour). In such a case, the circuit up to step 2
would look as follows. Compare this simplified circuit diagram with the
electrical circuit diagram.
Fig. 2/8 24 V-
Circuit diagram, simplified
13 13 13 23 23
S1 K1 K2 K1 K2
14 14 1B1 BN 14 24 24
13
S2
BK
14
1 BU 23
2S2 K1
4 24
11
K8
14
41 41
K2 K4
42 42
A1 A1
K1 K3 1Y1 2Y1
A2 A2
1A- 2A-

C-15
Solution 2
3 Relay, 3-off
1 Manifold
2 5/2-way double solenoid valve

C-16
Solution 2

C-17
Solution 3
Filling device
Fig. 3/2:
2B1 2B2
1S1 1S2 3A 3B1 3B2
1A 2A
4 2 4 2 2
1Y 2Y 3Y
5 3 5 3 1 3
1 1
0Z2
0Z1
1 2

Solution 3
C-18
(1)
Fig. 3/3:
24 V- 1 2 3 4 5 6 7 8 9 10 11
3B1 13 1 13 1 13 2B2 13
BN BN
K1 1S1 K2 1S2 K3 K4
14 4 14 4 14 14
BK 13 BK
S1 13 S2
BU BU
14 14
S1 = Single cycle
S3 13 13
S4
S2 = Continuous cycle
14 14
35
K6
st
36
41 23 23 23
K7 K1 K2 K3
42 24 24 24
A1 A1 A1 A1
S3 = 1 interrogation
S4 = 2nd interrogation
K1 K2 K3 K4
A2 A2 A2 A2
4 18 6 8 19 11
5 7 10 13
18 19 17

24 V- 12 13 14 15 16 17 18 19 20
2B1 13 2B2 13 33 33 33
BN BN
K5 S6 K1 K3 K5
14 14 34 34 34
BK 13
BK

BU BU
rd
S5 14
S5 = 3 interrogation
S6 = Idle cycle without filling
23 23 33 41 41
K4 K5 K4 K2 K4
24 24 34 42 42
A1 A1 A1
K5 K6 K7 1Y 2Y 3Y
A2 A2 A2
1A- 2A+ 3A+

14 2 2
16
20
(2)
Fig. 3/4:
Solution 3
C-19
C-20
Solution 3
Solution description When S1 or S2 and S3 are activated, the control system is started up.
Cylinder 1A retracts and the bottles move along. If S4 is actuated, the
cylinder extends again. Then, the indexing table (cylinder 2A) inches
round one position. Once a bottle has reached the filling station, it is
filled until the time delay closes the container (cylinder 3A), and the
control system is brought back into the initial start position. If no bottle is
reported as being present at the filling station, the control can be re-
turned to the initial start position via S6. Then the indexing table can be
supplied with bottles until a signal is received from S7.
Components list Quantity Designation
3 Relay, 3-off
1 Time relay, 2-off
1 Single-acting cylinder
1 Manifold
1 Proximity sensor, capacitive
1 Proximity sensor, optical

C-21
Solution 4
Stamping device
2B1 2B2 Fig. 4/3:

2A
1A 1S1 1S2 3A 3B1 3B2
4 2
2Y1 2Y2
5 3
1
4 2 4 2
1Y1 1Y2 3Y1 3Y2

5 3 5 3
1 1
0Z2
0Z1
1 2

Solution 4
C-22
(1)
Fig. 4/4:
24 V- 1 2 3 4 5 6 7 8 9 10
13 23 13 13 23 13
3B1 2B2 BN
K1 K1 K2 K3 K3 K5
14 24 14 14 24 14
BK
11 1 BU
K12 1S2
14 4
13 13
S K4
14 14
41 41 11
K4 K6 K8
42 42 12
A1 A1 A1 A1 A1
K1 K2 K3 K4 K5
A2 A2 A2 A2 A2
3 20 5 6 2 9 10
4 23 7 24 11

24 V- 11 12 13 14 15 16 17 18
23 11 21 1 11 21
2B1 BN
K5 K7 K7 1S1 K9 K9
24 14 24 4 14 24

BK
BU 13 21
K6 K8
14 24
11 21
K10 K12
12 24
A1 A1 A1 A1 A1
K6 K7 K8 K9 K10
A2 A2 A2 A2 A2
5 13 14 6 2 9 2 9
25 15 7 24 24
(2)
Fig. 4/5:
Solution 4
C-23
Solution 4
C-24
(3)
Fig. 4/6:
24 V- 19 20 21 22 23 24 25 26 27 28
11 SET 13 21 23 23 23 31 31 31
K11 K11 K2 K4 K6 K8 K10 K12
3B2 14 14 24 24 24 24 34 34 34
21
K10
22
41
K2
42
A1 A1
K11 K12 1Y1 2Y1 2Y2 1Y2 3Y1 3Y2
A2 A2
1A+ 2A+ 2A- 1A- 3A+ 3A-

20 16 2
22 20

C-25
Solution 4
This solution corresponds to a reset sequence of 6 steps with single Solution description
cycle operation. Only when the last step has been set via the SET
button, can another single cycle be started. The signal generators are
directly switched to limit the number of relays.
4 Relay, 3-off
1 Manifold

C-26
Solution 4

C-27
Solution 5
Drilling jig
Fig. 5/3:
1B2 1B1 2B1 2B2 * 3S1 3S2

3A
1A 2A
4 2 4 2 4 2
1Y 2Y 3Y
5 3 5 3 5 3
1 1 1
0Z2
0Z1
1 2
* For the purposes of this exercise, feed unit 3A is replaced by a single-acting cylinder.
A 3/2-way solenoid valve may also be used as a final control element.
Fig. 5/4:
3A 3S1 3S2
Part of circuit diagram,
pneumatic
3Y
1 3

Solution 5
C-28
(1)
Fig. 5/5:
24 V- 1 2 3 4 5 6 7 8 9
13 1 11 13 1 11 13
2B2
K1 3S2 K2 K3 3S1 K4 K5
14 4 14 14 4 14 14
13 11
S K16
14 12
11 23 23
K14 K1 K3
12 24 24
A1 A1 A1 A1 A1
K1 K2 K3 K4 K5
A2 A2 A2 A2 A2
3 5 35 6 8 9
5 13 8 15 11
35 20 22 33
27 29

24 V- 10 11 12 13 14 15 16 17 18 19
13 21 13 21 13 11
1B1 2B1 BN
K6 K2 K7 K4 K8 K9
14 24 14 24 14 14

BK
21 BU
K16
22
23 23 23 23
K5 K6 K7 K8
24 24 24 24
A1 A1 A1 A1
K6 K7 K8 K9
A2 A2 A2 A2
12 36 14 16 19
13 15 18 20
36 34 37
(2)
Fig. 5/6:
Solution 5
C-29
Solution 5
C-30
(3)
Fig. 5/7:
24 V- 20 21 22 23 24 25 26 27 28 29 30
31 11 31 11 11 41 11 41
1B2 BN
K2 K10 K4 K11 K12 K2 K13 K4
34 14 34 14 14 44 14 44
BK
31 BU 41
K16 K16
32 42
21 21 21 21 21
K9 K10 K11 K12 K13
24 24 24 24 24
A1 A1 A1 A1 A1 A1
K10 K11 K12 K13 K14 K15
A2 A2 A2 A2 A2 A2
37 21 33 23 26 38 28 2 31
22 25 27 29
38

24 V- 31 32 33 34 35 36 37 38
11 33 33 33 33 31 31
K15 K5 K8 K1 K6 K9 K12
14 34 34 34 34 34 34

41 41 31 31
K3 K7 K10 K13
42 42 32 32
31
K11
32
A1
K16 H 1Y 2Y 3Y
A2
1A- 2A- 3A+

8
15
22
29
(4)
Fig. 5/8:
Solution 5
C-31
C-32
Solution 5
Solution description The preselect counter receives pulses from 3S2. When the preselect
figure or the end of the drill life has been reached, the sequencer is
stopped. It will not continue running until the drill has been changed
(counter reset).
Signal generators 3S1 and 3S2 must be switched indirectly to ensure
reliable sensing. Otherwise, self-latching would supply a continuous
signal (see example) when a latching sequence is being used.
Example Kn+1 can be set without acknowledgement 3S1 being activated since
current can flow via the self-latching of K3 and Kn.
Fig. 5/9: 24 V-
3S1 K3 Kn+1
K2 Kn
K3 Kn+1

C-33
Solution 5
The signal generators indirectly switched (as in the solution to the exer-
cise).
24 V- Fig. 5/10:
Alternative circuit (1)
3S1 K1 K3 K1 Kn+1
K2 Kn
K1 K3 Kn+1
As the connection is interrupted here by K4 via K3, Kn+1 may only be

set if Kn and 3S1 are activated.
24 V- Fig. 5/11:
Alternative circuit (2)
3S1 K3 3S2 K4 Kn+1
K4
K2 K3 Kn
K3 K4 Kn+1

C-34
Solution 5
5 Relay, 3-off
1 Preselect counter, electrical, incrementing
1 Manifold
1 Proximity sensor, inductive

C-35
Solution 6
Clamping unit for grinding
Fig. 6/3:
*
2A 2B1 2B2
1A 1S1 1S2 3A 3B1 3B2
1B
P1
4 2
2Y1 2Y2
5 3
1
2 4 2
1Y 3Y1 3Y2
1 3 5 3
1
0Z2
0Z1
1 2
* For the purposes of this exercise, feed unit 2A is replaced by a double-acting cylinder.

Solution 6
C-36
(1)
Fig. 6/4:
24 V- 1 2 3 4 5 6 7 8 9 10 11 12
13 13 23 13 23 2B2 BN 13 23 2B1 BN 13
S K1 K1 K2 K2 K4 K4 K6
14 14 24 14 24 BK 14 24 BK 14
1
BU BU
1S2
4
1 1B BN 13 13
1S1 P1 K3 K5
4 BK 14 14
P2 41
BU K5
42
K7
11 K9 11 11
K14 K7 K9
12 K13 12 12
A1 A1 A1 A1 A1 A1
K1 K2 K3 K4 K5 K6
A2 A2 A2 A2 A2 A2
2 4 7 8 4 11 12
3 5 29 9 31 13
28

24 V- 13 14 15 16 17 18 19 20 21 22
23 3B2 11 21 11 21 11
K6 K8 K8 K10 K10 K12
24 14 24 14 24 14

21 21 21
K7 K9 K11
24 24 24
11 11 21
K11 K13 K14
12 12 24
A1 A1 A1 A1 A1 A1
K7 K8 K9 K10 K11 K12
A2 A2 A2 A2 A2 A2
7 15 16 11 18 19 15 21 27 22
4 33 17 4 30 20 32 23
(2)
Fig. 6/5:
Solution 6
C-37
Solution 6
C-38
(3)
Fig. 6/6:
24 V- 23 24 25 26 27 28 29 30 31 32 33 34
21 3B1 31 23 33 23 31 23 31 31 41
K12 K14 S K1 K3 K9 K5 K11 K7 K13
24 34 24 34 24 34 24 34 34 44
21
K13
24
11 31
K15 K12
12 32
A1 A1 A1
K13 K14 K15 1Y 2Y1 2Y2 3Y1 3Y2
A2 A2 A2
1A+ 2A+ 2A- 3A+ 3A-

18 25 1 26 25
4 34 21

C-39
Solution 6
In this exercise, two problems can be solved with minimal modifications Solution description
to the reset sequence:
Memorising of the start signal (K1) for the movement 1A+,
Resetting of the final step (K14) via START button S.
The pressure switch does not switch over until the clamping pressure
has been reached; consequently the sequencer stops until the required
pressure has built up.
In this exercise, sensor 2B1 and 2B2 can be interrogated directly several
of times without faulty actuation of the control taking place (compare with
exercise 5).
5 Relay, 3-off
1 Manifold
1 Pneumatic-electric converter

C-40
Solution 6

C-41
Solution 7
Forming press
2B1 2B2 Fig. 7/3:

1A 1S1 1S2 Circuit diagram, pneumatic
2A
4 2 4 2
1Y 2Y
5 3 5 3
1 1
0Z2
0Z1
1 2

Solution 7
C-42
(1)
Fig. 7/4:
24 V- 1 2
21 13
ES K1
22 14 3 4 5 6 7
1
11 2B1 BN
K5
12
13 BK
K4 BU
14
13 23
S1
14 24
13 23
S2
14 24
35 41
K3 K2
36 42
A1 A1 A1 A1
K1 K2 K3 = 0,5s K4
A2 A2 A2 A2
2 4 14 3 3

24 V-
8 9 10 11 12 13 14 15
1
1 21 1 11 2B2 13 31
BN

1S2 K5 1S1 K6 K2 K6
4 24 4 14 14 34
BK
BU
41 31 21 41
K7 K5 K6 K5
42 34 24 42
A1 A1 A1
K5 K6 K7 1Y 2Y
A2 A2 A2
1A+ 2A+
3 9 11 8
14 10 13
15
(2)
Fig. 7/5:
Solution 7
C-43
C-44
Solution 7
Solution description If the EMERGENCY-STOP switch ES is not activated, current path (1) is
supplied with current. In order to switch relay K2, the two push buttons
S1 and S2 must be actuated simultaneously (START signal). If one of
the push buttons is pressed before the other, the time relay with switch-
on delay is energised which then switches after 0.5 secs. (For safety
reasons, the switch-on delay must not exceed 0.5 seconds). The result
of this is that the normally closed contact K3 in current path 3 opens
and, thus the connection to K2. If two buttons are actuated simultane-
ously so that the time relay does not switch through, relay K2 is switched
and cylinder 1A extends.
When the EMERGENCY-STOP switch is actuated, the current to path 1
is interrupted and the solenoid coils are no longer supplied with current.
The result of this is that the reset springs reverse the solenoid valves
and the cylinders return to the initial position.
2 Relay, 3-off
1 Time relay, 2-off
1 Manifold
1 EMERGENCY-STOP button

C-45
Solution 8
Embossing device
1A 1B1 1B2 2A 2S1 2S2 Fig. 8/3:

4 2 4 2
1Y 2Y
5 3 5 3
1 1
0Z2
0Z1
1 2

Solution 8
C-46
(1)
Fig. 8/4:
24 V- 1 2 3 4 5 6 7 8 9 10 11 12
13 11 13 11 11
S1 K1 S2 1B1 K3 1B2 K4
14 14 14 14 14
31 11 41 21
K1 K2 K1 K2
34 14 44 24
S1 = START-button
S2 = Manual step mode
11 21
K6 K3
12 24
21 21 11
K1 K7 K7
22 22 12
A1 A1 A1 A1 A1
K1 K1' K2 K3 K4
A2 A2 A2 A2 A2
4 2 18 13 7 8 12
6 16 11 10 13
10 14 19 20
17

24 V- 13 14 15 16 17 18 19 20
1 11 1 13 31 31
2S2 K5 2S1 S3 K3 K4
4 14 4 14 34 34

11 31 21 41
K1' K2 K1' K2
14 34 24 44
S3 = Step repetition
21 21 31 31
K1 K5 K1' K5
24 24 32 32
A1 A1 A1
K5 K6 K7 1Y 2Y
A2 A2 A2
1A+ 2A+
20 15 1 10
16 6
(2)
Fig. 8/5:
Solution 8
C-47
C-48
Solution 8
Solution description By pressing the START button, the program is started in accordance
with the displacement-step diagram.
Manual step mode By pressing push button S2, it is possible to carry out one movement per
actuation in accordance with the program or control sequence.
Step repetition When, after pressing S2, cylinder 1A has advanced via K3 and cylinder
2A via K4, self-latching at K4 can be reset via K7 by means of push
button S3. As a result of this, K4 is de-energised and cylinder 2A re-
tracts. Cylinder 2A is now able to advance again via S2.
2 Relay, 3-off
1 Manifold

C-49
Solution 9
Drilling and reaming machine
2B1 2B2 Fig. 9/3:

1S1 1S2
*
1A 2A
4 2 2 2
1Y 2Y1 2Y2
5 3 1 3 1 3
1
0Z2
0Z1
1 2
* For the purposes of this exercise, linear drive 2A is replaced by a double-acting

cylinder.
2A 2B1 2B2 Fig. 9/4:

Part of circuit diagram,
pneumatic
2 4 2
2Y1 2Y2
1 3 5 3
1

Solution 9
C-50
(1)
Fig. 9/5:
24 V- 7 8
21 11
NA K4
ES
1 2 3 4 5 6 22 14 9 10 11 12
13 13 13 13 23 23 1 11
S1 K1 S2 K2 K1 K2 1S2 1B K6
14 14 14 14 24 24 2 14
S3 = STOP
2B1
11 21 BN
S1 = Single cycle
K5 K5
14 24 BK
S2 = Continuous cycle
BU
13
K3
14
11 31 21
K9 S3 K9
1B = Sensing of parts
12 32 24
A1 A1 A1 A1 A1 A1
ES = EMERGENCY-STOP
K1 K2 K3 K4 K5 K6
A2 A2 A2 A2 A2 A2
2 4 11 19 8 1 12
5 6 25 26 3 13

18 21
24 V- 19 20 21 22
21 11 31 11
K4 K10 K6 K11
13 14 15 16 17 18 22 14 32 14
1 11 11 31
1S1 K7 2B2 K8 K5
BN

4 14 12 34
BK
BU
S4 = RESET linear drive

11
K12
12
21 21 21 31 13
K6 K7 K8 S4 K13
24 24 24 32 14
A1 A1 A1 A1 A1
K7 K8 K9 K10 K11
A2 A2 A2 A2 A2
30 14 17 1 29 20 22
15 18 30 28
29 23
(2)
Fig. 9/6:
Solution 9
C-51
Solution 9
C-52
(3)
Fig. 9/7:
24 V- 23 24 25 26 27 28
31 21 23 23 31 21
K8 K12 K3 K4 S5 K11
34 24 24 24 32 24 29 30
31 41
K7 K7
34 42
21 31
K10 K10
22 32
S5 = RESET gripper
41
K5
42
23
K13
24
A1 A1
K12 K13 1Y 2Y1 2Y2
A2 A2
1A+ 2A+ 3A-

21 24 21
23

C-53
Solution 9
Line 1 is supplied with current via relay K4 (provided the EMERGENCY- Solution description
STOP button has not been pressed). The cycle is started via S1 or S2. A
latching sequence is then constructed for this motion sequence through
current paths 9 to 18.
When the EMERGENCY-STOP switch (ES) has been actuated, the
gripper is to remain in its current position, whether open or closed. The
signal close gripper is acquired via relay K6. This signal must be stored
after actuation of EMERGENCY-STOP to keep the gripper in a closed
position (see current paths 21 and 22). However, this memory must be
erased if, at the time of the EMERGENCY-STOP actuation, the control
had opened the gripper. In this case, the open signal K8 MUST BE
STORED (SEE CURRENT PATHS 23 AND 24). Relay K13 is required
to ensure that the reset button for gripper S5 is only active when the
EMERGENCY-STOP key has already been switched off and the control-
ler has been stopped. This is only released when no start signal or
EMERGENCY-STOP signal is present and push button S5 has been
actuated.
Coil Y2 is actuated by signal K7 and the linear drive proceeds. Self-
latching of relay K10 is required to switch the linear drive to unpressur-
ised on actuation of the EMERGENCY-STOP and to memorise this
status. This is then reset by RESET button S4 and the unit is returned
once again to the initial start position.
A new start signal is not memorised until the gripper has actuated limit
switch 1S2 (K5).
The cycle only starts if parts are present in the outlet channel (sen-
sor 1B) and the initial position of the linear drive (sensor 2B1) is being
signalled.
Owing to multiple sensing, limit switch 1S2 must be switched indirectly
via relay K5.

C-54
Solution 9
5 Relay, 3-off
1 Manifold

C-55
Solution 10
Drilling and reaming machine
Fig. 10/3:
* 2B1 2B2 *
1A 1S1 1S2 3A 3B1 3B2
2A
4 2 4 2 4 2
1Y 2Y 3Y
5 3 5 3 5 3
1 1 1
0Z2
0Z1
1 2
* In order to assemble this control system on the profile plate, feed unit 1A is replaced
by a double-acting cylinder and feed unit 3A by a single-acting cylinder.

C-56
Solution 10
(1)
Fig. 10/4:
24 V- 1 2 3 4 5 6 7 8 9 10
13 13 2B1 BN 13 1 1 33 23 11
K1 K2 1S1 1S2 K1 K3 K5
14 14 BK 14 4 4 34 24 14
41 13 21
BU
K2 K3 K4
42 14 24
13
S
14
23
K1
24
11 21
S = START-button
PS = PROGRAM SELECTION button

11 23 31
K4 K8
K8 12 22
K2 K4
12 24 34
A1 A1 A1 A1 A1
K1 K2 K3 K4 K5
A2 A2 A2 A2 A2
2 1 5 4 4 8 10
5 7 9 19 9 12
8 19 20

24 V- 11 12 13 14 15 16 17 18 19 20 21
11 11 33 31 31
2B2 BN 3B2 3B1
K6 K7 K2 K5 K6
14 14 34 34 34

BK
BU
21 21 21 41 31
K5 K6 K7 K4 K7
24 24 24 42 32
A1 A1 A1
K6 K7 K8 1Y 2Y 3Y
A2 A2 A2
1A+ 2A+ 3A+

13 21 16 1
15 18 5
21
(2)
Fig. 10/5:
Solution 10
C-57
C-58
Solution 10
Solution description Relay K1 is switched via the PROGRAM SELECTOR BUTTON PS. This
is only possible prior to actuation of the START button.
If program 2 (drilling and reaming) is selected, the latched sequence
runs through as usual. However, if program 1 (drilling) is required, it is
simply necessary to press the start button. If 1S2 and contact K2 switch
the relay K4, the sequencer is reset by K4 and cylinder 1A retracts.
3 Relay, 3-off
1 Manifold

C-59
Solution 11
Loading station
Fig. 11/3:
* 3B1 3B2
1A 1S1 1S2 2A 2B1 2B2
3A
4 2 4 2 4 2
1Y 2Y 3Y
5 1 3 5 1 3 5 1 3
0Z2
0Z1
1 2
* For the purposes of this exercise, cylinder 1A is replaced by a single-acting cylinder.

C-60
Solution 11
(1)
Fig. 11/4:
24 V- 1 2 3 4 5 6 7 8 9 10 11 12 13
1 11 11 1 11 1 21 21 11
S1 K1 2B1 K2 1S2 K3 1S1 K4 K5 K6
4 14 14 4 14 4 24 24 12
11 11 11
2B2
K9 K4 K5
14 12 12
S1 = START button
21
K1
24
S2 = Sensing of steel parts

1
41
S2
K10 4
42
41 21 21
31 31
K7 K2 K3
42 24 24 K4 K5
34 34
A1 A1 A1 A1 A1 A1 A1
K1 K2 K3 K4 K4' K5 K6
A2 A2 A2 A2 A2 A2 A2
2 5 15 7 6 9 25 8 12 21 13
4 6 22 8 12 13 22 14
15 21 24 23
22

14 15 16 17 18 19 20 21 22 23 24 25
31 13 31 41 41 41 11
K1 K1 3B1 3B2 K2 K2 K5 K4 K8
34 14 BN BN 34 44 44 44 14
BK BK

BU BU
41 11
K5 K4'
42 14
Electromagnet
21 31 31 41
K6 K3 K6 K6
24 32 32 42
A1 A1 R1 A1 A1
K7 K8 K9 K10 H1 1Y 2Y 3Y
A2 A2 R2 A2 A2
Electro- 1A+ 2A+ 3A+

4 25 4 1 16 magnet
(2)
Fig. 11/5:
Solution 11
C-61
C-62
Solution 11
Solution description The cycles of the control are counted to enable cylinder 3A to extend.
Where there is a preselected figure 2, cylinder 3A is extended together
with cylinder 2A on the second cycle of the control system in order to
bring the part past position 2.
If cylinder 3A has extended, start condition K1 is reset via 3B2 (K10) and
the counter is reset to zero.
4 Relay, 3-off
1 Manifold

C-63
Solution 12
Internal grinding machine
Fig. 12/3:
*
3A
1A 1B1 1B2 2A 2S1 2S2 3B1 3B3 3B2
2B
P1
4 2 4 2 4 2
1Y 2Y 3Y
5 3 5 3 5 3
1 1 1
0Z2
0Z1
1 2
* For the purposes of this exercise, cylinder 1A is replaced by a single-acting cylinder

and feed unit 3A by a double-acting cylinder. The inductive proximity sensor 3B2 is
switched to mid-position by the trip cam.

C-64
Solution 12

(1)
Fig. 12/4:
24 V- 1 2 3 4 5 6 7 8 9 10 11 12 13
13 13 1 23 13 13 13
1B2 2B BN 3B3 BN
S1 K1 2S1 K1 K3 K4 K5
p
14 14 4 24 14 14 p1 14
2
13 BK BK
K2 BU BU
14
1
S2
4
S3 = STOP-button
S1 = START-button
S2 = Part of the stop
23
31 11 23
K4
S3 K14 K3
24
32 14 24
A1 A1 A1 A1 A1 A1 A1
K1 K2 K3 K4 K5 K5' K6
A2 A2 A2 A2 A2 A2 A2
2 4 5 8 11 37 20 14
4 29 7 10 14 16
32 33 22
35

C-65
Solution 12
Fig. 12/5:
(2)

C-66
Solution 12
(3)
Fig. 12/6:
24 V- 28 29 30 31 32 33 34 35 36 37
1B1 21 1 33 33 41 41 11
K13 2S2 K3 K4 K13 K5 K5'
24 4 34 34 42 44 14
23 41 31 31
K2 K12 K7 K10
24 42 32 34
21 31 41 11
K12 K12 K11 K12'
24 32 42 12
A1 A1
K13 K14 1Y 2Y 3Y H1
A2 A2
1A+ 2A+ 3A+

17 4
30
31
35
Grinding wheel

C-67
Solution 12
When the installation is started up and the initial position of cylinder 2A Solution description
(2S1) and a workpiece (S2) are signalled, cylinder 1A extends. Then
cylinder 2A extends and clamps the part. When the clamping pressure
has been reached, cylinder 3A is extended via K5. Sensor B5 is acti-
vated in the forward end position. This in turn activates relay K6. Then
feed cylinder 3A retracts again. In addition, K6 passes on a counting
pulse to the preselect counter.
Sensor 3B2 is activated when the cylinder has retracted by a half. This
then reverses the valve via further contacts (K6, K7, K9) and cylinder 3A
extends again. This sequence is carried out until the preselected figure
has been reached. If 3B2 is activated on the return stroke, the valve may
not switch since counter contact K9 interrupts the circuit. The sequence
is switched on via a second counter contact.
5 Relay, 3-off
1 Manifold

C-68
Solution 12

C-69
Solution 13
Assembly unit
Fig. 13/3:
2A 2B1 2B2
* 3B1 3B2
1A 1S1 1S2
3A
4 2
2Y1 2Y2
4 2 5 3 4 2
1
1Y1 1Y2 3Y1 3Y2

5 3 5 3
1 1
0Z2
0Z1
1 2

C-70
Solution 13
(1)
Fig. 13/4:
24 V- 1 2 4
13 23 11
S2 K1
14 24 12
1
3 5 6 7 8 9 10 11 12
2
11 21 1 11 21 2B2 11
K2 K2 1S2 K4 K4 K6
2B1 14 24 4 14 24 14
11
K3
S1 = OFF/ON
13 14
S2 = MAN/AUT
21
S1
K5
14
13 24
K11
14
11 11 11
K5 K7 K9
12 12 12
A1 A1 A1 A1 A1 A1
K1 K2 K3 K4 K5 K6
A2 A2 A2 A2 A2 A2
4 5 19 7 8 4 11 12
32 6 29 9 33 13
36
40

24 V-
13 14 15 16 17 18 19 20 21 22

21 3B2 11 21 13 41 23
BN 3B1 BN
K6 K8 K8 K10 K12 K10
24 14 24 14 42 24
BK BK
BU BU
21 1
K7 1S1
24 4
21
K9
24
41 21
K11 K3
42 22
A1 A1 A1 A1 A1
K7 K8 K9 K10 K11
A2 A2 A2 A2 A2
7 15 16 11 19 20 15 4
37 17 31 22 35
28 39 23
(2)
Fig. 13/5:
Solution 13
C-71
C-72
Solution 13
(3)
Fig. 13/6:
24 V- 32
21
K1
25 26 27 28 30 22
23 24 29 31
33 13 13 31 41 31 13 31 41
K10 K12 S3 K3 K13 K9 K13
34 14 14 32 42 34 14 34 42
31 13 41
S4
32 14 42
31 41 13
S5
32 42 14
A1 A1 A1 A1
K12 K13 K14 K15 H1 1Y1 1Y2
A2 A2 A2 A2
1A+ 1A-
21 24 32 30 36 34 40 38
MAN

24 V- 36 40
31 41
K1 K1
34 32 38 42

33 35 37 39
31 13 23 41 31 13 41 41
K5 K14 K11 K14 K7 K15 K9 K15
34 14 24 42 34 14 42 42
2Y1 2Y2 3Y1 3Y2
2A+ 2A- 3A+ 3A-

(4)
Fig. 13/7:
Solution 13
C-73
C-74
Solution 13
Solution description When the MAN/AUT switch S2 or relay K1 is not actuated, voltage is
applied at line 1 (MANUAL mode). The cylinder can be extended indi-
vidually via push buttons S3, S4 and S5.
Cylinder 1A extends and remains in the extended position for as long as
push button S3 is actuated or an additional push button is pressed.
Movement is prevented if two or three push buttons are pressed simul-
taneously.
To ensure that there is no interference with AUTOMATIC mode, the
lines to the normally closed contacts of relays K13, K14 and K15 are
each interrupted by a normally closed contact of K1.
As soon as line 2 (AUTOMATIC mode) is supplied with current, self-
latching is set via the normally closed contact K12 in current path 12. At
the same time, when K10 goes into self-latching, relay K12 is switched
via a normally open contact K10. This also goes into self-latching and
the normally closed contact K12 in current path 21 opens. Thus, the last
step which is normally required as a start condition can be activated
without the use of a SET button.
5 Relay, 3-off
1 Manifold

C-75
Solution 14
Moulding press
Fig. 14/3:
2B1 2B2 2B3 *

1A 1B1 1B2 3A 3S1 3S2
2A
4 2 4 2 4 2
1Y 2Y 3Y
5 3 5 3 5 3
1 1 1
0Z2
0Z1
1 2
* For the purposes of this exercise, the double-acting cylinder is replaced by a single-
acting cylinder.

C-76
Solution 14
(1)
Fig. 14/4:
24 V- 1 2 3 4 5 6 7 8 9 10 11
13 23 1B2 13 13 23 17 13
S1 K4 K5 K4 K6 K7
14 24 14 14 24 18 14
13 23 13
S2 K3
S1, S2 = START-button
14 24 14
11
K14
14
41
K5
42
41 13 41 11 23
K3 K1 K2 K11 K5
42 14 42 12 24
A1 A1 A1 A1 A1 A1 A1
K1 K2 K3 K4 K5 K6 K7
A2 A2 A2 A2 A2 A2 A2
3 4 1 7 24 7 4 8 10 31 11
30 9 10 13
31

24 V- 12 13 14 15 16 17 18 19 20 21
11 11 1 11 1 21
1B1 K8 2B3 K9 3S2 K10 3S1 K11 2B1 BN
14 14 4 14 4 24

BK
BU
23 21 21 21
K7 K8 K9 K10
24 24 24 24
A1 A1 A1 A1 A1
K8 K9 K10 K11 K12
A2 A2 A2 A2 A2
24 13 15 33 17 7 19 27 26
15 16 18
32 27 25
33
(2)
Fig. 14/5:
Solution 14
C-77
C-78
Solution 14
(3)
Fig. 14/6:
24 V- 22 23 24 25 26 27 28 29 30 31 32 33
11 21 11 31 11 21 23 33 41 41
BN K13 K14 K12 K9 K15 K15 K3 K5 K8 K9

14 24 14 34 14 24 24 34 44 44
2B2
BK 31 31 41
BU K8 K10 K7
32 34 42
41 21 41
K4 K12 K10
42 22 42
A1 A1 A1
K13 K14 K15 H1 1Y 2Y 3Y
A2 A2 A2
1A+ 2A+ 3A+

24 4 28
25 29
Vacuum generator

C-79
Solution 14
The two-hand safety control is realised in current paths 1 to 4. Relay K2 Solution description
serves here as a delaying element. The maximum time duration allow-
able between the actuation of S1 and S2 is dependent on the switching
time of this relay.
If the two push buttons S1 and S2 are activated simultaneously, cylin-
der 1A extends. These buttons must remain depressed until the cylinder
has reached its forward end position.
The start condition is decided by the connections in current paths 24 -
26. It has been established that the signal from signal generator B5 only
becomes effective when the extractor unit leaves the working area, i.e.
on the return stroke of cylinder 2A.
Relay K15 starts the operation of the vaccum generator which must be
specially stored as the sequence is set before the retraced end position
of cylinder 2A is reached.
5 Relay, 3-off
1 Time relay, 2-off
1 Manifold

C-80
Solution 14

C-81
Solution 15
Pick-and-place unit
Fig. 15/3:
2B1 2B2 *
1A 1S1 1S2 3A 3B1 3B2
2A
4 2 4 2 4 2
1Y 2Y 3Y
5 3 5 3 5 3
1 1 1
0Z2
0Z1
1 2
* For the purposes of carrying out this exercise on the profile plate, cylinder 3A is
replaced by a single-acting cylinder.

C-82
Solution 15
(1)
Fig. 15/4:
24 V- 1 2 3 4 5 6 7 8 9 10 11
13 13 1 13 2B1 BN 13 3B2 21
S1 K1 1S2 K2 K3 K4
14 14 4 14 14 24
BK
13
BU
S2
14
S3 = Magazine
S2 = Gear housing
S1 = START-button
13 23 41 11 11
S3 K3 K4 K5
14 24 42 12 12
23
K1
24
11 21 23 23
K15 K15 K2 K3
12 22 24 24
A1 A1 A1 A1
K1 H1 K2 K3 K4
A2 A2 A2 A2
2 5 4 8 7 11
4 7 10 41 13
22 40 36
Magazine

24 V- 12 13 14 15 16 17 18 19 20 21 22 23 24
3B1 21 1 21 21 21 21
K5 1S1 K6 K7 K8 K9
24 4 24 24 24 24

11
11 11 11 11
K6 K7 K8 K9 K10
12
12 12 12 12
33
K1
34
31 31 31 31 31
K4 K5 K6 K7 K8
34 34 34 34 34
A1 A1 A1 A1 A1 A1 A1
K5 K6 K7 K7' K8 K9 K9'
A2 A2 A2 A2 A2 A2 A2
10 14 13 16 15 18 42 17 21 20 23 43
15 17 36 20 38 22 25
38 42 37
(2)
Fig. 15/5:
Solution 15
C-83
C-84
Solution 15
(3)
Fig. 15/6:
24 V- 25 26 27 28 29 30 31 32 33 34 35
21 13 13 11 11 31 23
K10 K11 K12 K13 K14 S2
24 14 14 14 14 32 24
41 41 2B2 BN
K11 K12
42 42
BK
BU
31 31 23 23 21 21
K9 K10 K11 K12 K13 K14
34 34 24 24 24 24
A1 A1 A1 A1 A1 A1 A1
K10 K11 K11' K12 K13 K14 K15 H2
A2 A2 A2 A2 A2 A2 A2
22 26 25 28 40 27 31 44 32 39 33 1
Gear
43 27 31 32 33 34 4
housing
39 44

24 V- 36 37 38 39 40 41 42 43 44
33 41 41 33 33 41 11 33
K3 K9 K5 K11 K2 K6 K9' K12

34 44 44 34 34 44 14 34
41 31 41 31 41 41 11 41 31
K7 K13 K8 K14 K11' K4 K7' K10 K13
42 32 42 32 42 42 12 42 32
H3 1Y 2Y 3Y
1A- 2A- 3A+
Vacuum
generator
(4)
Fig. 15/7:
Solution 15
C-85
C-86
Solution 15
Solution description If one of the magazines is empty, then the installation remains stationary
at position 1 or 2 by resetting the START signal, and waits there until the
magazine has been filled and a new START signal is issued (see current
paths 1, 4, 22).
In order to fulfil the gear sensing, it is necessary to establish whether a
gear housing is available (starting precondition). When the assembly has
been completed, the gear housing must be removed. Without this, it will
no longer be possible to start the installation (see current path 1, 4, 34).
6 Relay, 3-off
1 Manifold

C-87
Solution 16
Galvanising process
Fig. 16/3:
1B1 1B3 1B2
1A
4 2
1Y
5 3
1
0B
P1
0Z2
0Z1
1 2

C-88
Solution 16
(1)
Fig. 16/4:
24 V- 1.0 1.1 1.2 2 3 4 5 6 7 8 9 10
BN 0B 13 21 13 23 11 13 23
K1 K15 K2 K2 K18 K4 K4
1B1 14 24 14 24 14 14 24
BK
23 13
BU 11
K1 K3
K13 24 14
14
S = START-button
11
K15
14
11
K21
14
13
S
14
41 41 11
K2 K5 K7
42 42 12
A1 A1 A1 A1 A1 A1
K21 K1 K2 H1 K3 K4 K5
A2 A2 A2 A2 A2 A2
Bad 1
2 22 3 2 5 8 9 4 11
4 6 10 27
26 42
1A+ 1A-

24 V- 11 12 13 14 15 16 17 18 19 20
31 13 23 35 11 21 41 11
K15 K6 K6 K19 K8 K8 K15 K10
34 14 24 36 14 24 44 14
13 21 21
K5 K7 K9
14 24 24

11 11 21
K9 K11 K13
12 12 22
A1 A1 A1 A1 A1
K6 H2 K7 K8 K9 K10 H3
A2 A2 A2 A2 A2
12 8 15 16 11 18 19
Bath 2
Bath 3
14 36 17 28 21
44 43
1A+ 1A- 1A+
(2)
Fig. 16/5:
Solution 16
C-89
C-90
Solution 16
(3)
Fig. 16/6:
24 V- 21 22 23 24 25 26 27 28 29 30 31 32
21 21 11 13 21 33 23 31 31 17 1B3 BN
K10 K18 K12 S1 K12 K1 K5 K9 K12 K14
24 24 14 14 24 34 24 34 34 18 BK
21
BU
K11
24
S1 = SET-button
41
K1
42
A1 A1 A1 A1 A1 A1
K11 K12 K13 K14 K15 K16
A2 A2 A2 A2 A2 A2
15 22 23 18 2 34 30 2 33
25 37 45 4 37
29 11
45 18
1A-

t1
24 V- 33 34 35 36 37 38 39 40 41 42 43 44 45
11 11 31 21 11 1B2 1 33 31 33 41
K16 K17 K7 K16 K20 K2 K10 K6 K12
4
14 14 32 24 14 34 34 34 44
27
3
K14

31 21
28
K13 K20
32 22
S2 =
Up/Down
35 11 31 13
K14 K22 K18 S2
36 12 32 14
A1 R1 A1 A1 A1 A1
K17 K18 K19 K20 K22 1Y H4
A2 R2 A2 A2 A2 A2
35 40 8 15 42 38 37
22
oscillate
Work surface
t1 > tReturn stroke
Z t2 1A+
(4)
Fig. 16/7:
Solution 16
C-91
C-92
Solution 16
Solution description Initial position: Cylinder 1A is retracted and is located above the work
surface and lamp H4 is illuminated. Cylinder 1A can be extended via the
up/down switch (current path 41). Once the initial start position has been
regained, the cycle is started with the start button. Then lamp H4 is
switched off and the time t1 expires. This switches lamp H1 (bath 1
reached) and allows cylinder 1A to extend via relay K2. Counting pulses
are passed on to the counter via 1B3 (current paths 31-34). Additionally,
1B3 reverses the valve so that cylinder 1A retracts as far as 1B2. As a
result, cylinder 1A is switched back to Extend (current paths 37-40).
This oscillating movement of cylinder 1A is repeated until the counter
switches and interrupts the signal of sensor 1B2.
When the cylinder has retracted, time delay t1 is activated once again by
relay K5, which switches relay K6 when it has completed its cycle. Lamp
H2 is illuminated and cylinder 1A extends. Next, the delay period t2 of
the basket in bath 2 is switched via K7. Then, relay K8 switches, cylinder
1A retracts once again and the time t1 is repeated. When the time relay
has switched, the cylinder enters bath 3 and the motion sequence car-
ried out for bath 1 is repeated. Time period t1 is then activated a final
time and signals the initial start position via lamp H4.
The time t1 must be longer than the time which the cylinder requires for
its return stroke.

C-93
Solution 16
6 Relay, 3-off
1 Time relay, 2-off
1 Manifold

C-94
Solution 16

C-95
Solution 17
Loading station
Fig. 17/4:
*
1B 1 1A1 1B2 1A2 2B1 2B2
2A
1V1 1V2 2V
4 2 4 2 4 2
1Y1 1Y2 2Y1
2Y2
5 3 5 3 5 3
1 1 1
3A 3S1 3S2
4S
*
4M
3V 4V
4 2 4 2 4B
3Y1 3Y2 4Y
5 3 5 3
1 1
0Z2
* For the purposes of this 0Z1

exercise, the rotary actuator 1 2
(4M) is replaced by a single-
acting cylinder, and the rod-
less cylinder (1A) by a 3
double-acting cylinder.

C-96
Solution 17
(1)
Fig. 17/5:
24 V- 1 2 3 4 5 6 7 8 9 10 11
11 11 13 11 11 11 13 11
1B1 K1 1B2 K2 K9 K3 K19 K4 K11 K5
14 14 14 14 14 12 14 14 14
11
K18
13
14
S
14
S = START-button
41 21 21 21 21
K7 K1 K2 K3 K4
42 24 24 24 24
A1 A1 A1 A1 A1
K1 K2 K3 K4 K5
A2 A2 A2 A2 A2
3 35 5 7 20 9 44 11
5 6 8 10 12
35 39 20 44 34
36
1A+ 3A+ 4M+ 4M-

24 V- 12 13 14 15 16 17 18 19 20 21 22 23
13 13 13 1 1 1 11 23 11
K10 K6 K8 3S1 3S2 4S 4B K12 K11 K13
14 14 14 4 4 4 14 24 14

23
K9
24
31
K4
32
21
K18
22
21 23 31 21
K5 K6 K3 K12
24 24 34 24
A1 A1 A1 A1 A1 A1 A1 A1
K6 K7 K8 K9 K10 K11 K12 K13
A2 A2 A2 A2 A2 A2 A2 A2
39 13 2 14 6 12 10 21 33 23
14 28 20 24 22 22 43 24
42 33
43
3A- 1A- 4M+ 4M-
(2)
Fig. 17/6:
Solution 17
C-97
C-98
Solution 17
(3)
Fig. 17/7:
24 V- 24 25 26 27 28 29 30 31 32 33 34
23 11 11 23 11 11 21 31 31
K10 K14 2B1 K15 K8 K16 2B2 K17 K17 K12 K5
24 14 14 24 14 14 24 34 34
21 21 21 21 31
K13 K14 K15 K16 K13
24 24 24 24 32
A1 A1 A1 A1 A1 A1 R1
K14 K15 K16 K17 K18 K19
A2 A2 A2 A2 A2 A2 R2
25 39 27 37 29 41 31 20 8 8 8
27 28 31 32
37 41 38 40
2A- 3A- 2A+ 3A+

24 V- 35 36 37 38 39 40 41 42 43 44
31 41 31 41 41 31 41 33 41 41
K1 K1 K14 K16 K2 K17 K15 K6 K12 K4
34 44 34 44 44 34 44 34 44 44
31 41 41 41

K15 K17 K13 K5
32 42 42 42
31 31 41
K2 K16 K6
32 32 42
1Y1 1Y2 2Y1 2Y2 3Y1 3Y2 4Y H1

cups
1A+ 1A+ 2A- 2A+ 3A+ 3A- 4M+

Suction
(4)
Fig. 17/8:
Solution 17
C-99
C-100
Solution 17
Solution description The loading station is located in step 21 of the subroutine.
Main program When the START button has been pressed, K1 causes cylinder 1A to
extend. Then cylinder 3A is extended via K2 and cylinder 3A is switched
to the unpressurised condition.
Next, the jump from K3 to K12 into the subroutine takes place. When the
subroutine has run through, the return jump through K18 and K19 to K4
in the main program takes place. Cylinder 4M advances and is retracted
by K5. The, cylinder 3A is retracted by K6 and cylinder 1A by K7.
Subroutine Movements 4M+, 4M-, 2A- (with every 2A- movement, cylinder 1A which
has been switched unpressurised, is pushed back by a partial stroke),
3A-, 2A+, 3A+ are executed in the subroutine and repeated three times
via a counter. When the counter has reached the preselected figure, the
return jump to the main program is carried out.
Comment In the case of this motion sequence, costs make it necessary to realise
this by means of a repetition of a program section (subroutine).
Increased expenditure on planning is justified here by a considerable
saving on relays and very much simpler circuitry, so that in this case, the
solution shown is more economical than a solution with the full sequence
which requires less planning.

C-101
Solution 17
6 Relay, 3-off
1 Manifold

C-102
Solution 17

C-103
Solution 18
Rotary indexing station
Fig. 18/3:
(6B)
6S2

(6S)
6S1
3
1
1
4
5
6A
12Y
6Y
11S1 11S2
5S2
5Y2
5S1
3
1
1
4
5
5A
11A
5Y1
11Y
10S1 10S2
4S2
4Y2
4S1
3
1
1
4
5
4A
10A
4Y1
10Y
9S2
3S2
3Y2
9S1
3S1
3
1
1
4
5
3A
9A
3Y1
9Y
8S2
2S2
2Y2
8S1
2S1
3
(2B1) (2B2)
1
4
5
2A
8A
2Y1
8Y
(1B1) (1B2)
1S2
7S2
1Y2
1S1
7S1
2
3
1
1
4
5
1A
7A
1Y1
7Y
For the purposes of this exercise, cylinders 3A and 4A are not con-
structed. Feed units 6A to 11A are represented in the construction by a
single-acting cylinder. The on/off valve with filter regulator and manifold
are not represented.

Solution 18
C-104
(1)
Fig. 18/4:
24 V-
1 2
13 31
S2
14 32
3 4 5 6 7 8 9 10 11 12 13 14
13 23 17 2B1 13 23 1B2 13 11 13 23
S1 K1 K2 K2 K4 K17 K5 K5
14 24 18 14 24 14 14 14 24
1
6S 13
4
13 K3
S3 14
S1 = ON
14
S4 = OFF
11
K16
14
41
S3 = Sensing of parts
K6
S2 = AUTO/MANUELL
31
35 42 11
S4 27
K1 32 K1 K9
36 28 12
A1 A1 A1 A1 A1 A1
H1 K1 H2 K2 K3 K4 K5 K6
A2 A2 A2 A2 A2 A2
1 3 36 7 28 11 11 13 6 17
Pump
6 8 44 24 14 46
START
34 57 34

24 V-
15
16 17 18 19 20 21 22 23 24 25 26 27 28
1B1 13 11 21 2B2 11 21 23 11 21 6B
BN
K7 K8 K8 K10 K10 K4 K12 K12

14 14 24 14 24 24 14 24
BK
13 BU 1 1 23
K6 5S2 5S1 K7
14 4 4 24
21 21 21
K9 K11 K13
24 24 24
11 11 21 41
K11 K13 K16 K3
12 12 22 42
A1 A1 A1 A1 A1 A1 A1 A1
K7 K8 K9 K10 K11 K12 K13 K14
A2 A2 A2 A2 A2 A2 A2 A2
17 18 11 21 22 17 24 34 25 21 28 29
28 19 36 23 45 26 47 31
51 52 49 53 55 33
(2)
Fig. 18/5:
Solution 18
C-105
Solution 18
C-106
(3)
Fig. 18/6:
34 35 36 40 41 42
21 13 11
24 V-
S5 K21
22 14 14
38 39
13 23 31
S6
29 30 31 32 33 37
14 24 32
11 11 21 21 31 33 21 31 11
K14 K15 K14 K15 K14 K2 K17 K9 K18
14 12 24 24 34 34 24 34 14
33
K4
34
S6 = RESET
31 41
S5 = EMERGENCY-Stop
K12 K2
32 42
A1 A1 A1 A1 A1 A1 A1
K15 K16 K17 K18 K19 K20 K21
A2 A2 A2 A2 A2 A2 A2
30 32 24 6 44 12 37 48 56 50 42
50 35 56 51
43 54

43
24 V-
48 51 54 56
11 21 31
K19 K19 K19
44 45 46 47 49 50 52 53 55 57
14 24 34

31 23 31 23 31 41 31 33 31 41 41 21 33
K17 K3 K11 K6 K13 K9 K16 K7 K8 K11 K13 K18 K3
34 24 34 24 34 44 34 34 34 44 44 24 34
41 21 17
K17 K21 K20
42 22 18
Air blast
Vacuum generator
H3 1Y1 1Y2 2Y1 2Y2 5Y1 5Y2 6Y 12Y
1A+ 1A- 2A+ 2A- 5A+ 5A- 6A+

(4)
Fig. 18/7:
Solution 18
C-107
C-108
Solution 18
Solution description Current paths 1 to 3 fulfill the following functions: START and STOP via
push buttons, display of the start signal and simulation of the central
lubrication system.
Power to the installation is switched off with the EMERGENCY-STOP in
order to add a memory and secure the movement 2A-. Otherwise,
cylinder 2A would retract as a result of the automatic setting condition if
cylinder 1A is already located in its initial start position.
The status of the vacuum generator is stored by current paths 33 and
34. After EMERGENCY-STOP, the unit is reset and a restart can be
made. If the fact that the vacuum generator is active has now been
stored, steps 1 and 2 (1A+, 1A-) are now skipped because a workpiece
has already been collected.
In manual mode, the initial start position of the machining station can be
achieved via the RESET button, cylinder 2A only being able to retract
when cylinder 1A is in its initial position. In addition, processing is started
via the RESET key if memory K18 reports that no processing has yet
been carried out. Memory K21 (EMERGENCY-STOP actuated) is reset.
In order to limit the cost incurred through additional equipment, relay

K21 can be replaced by the counter (preselected figure 1).

C-109
Solution 18
40 41 Fig. 18/8:
21 13
(3)
S5 Addition with counter
22 14
38 39
13 23 31
S6
14 24 32
A1 A1 A1 R1
K19 K20 K21
A2 A2 A2 R2
S5 = EMERGENCY-STOP
S6 = RESET

C-110
Solution 18
6 Relay, 3-off
1 Time relay, 2-off
1 Manifold

C-111
Solution 19
Checking station
Fig. 19/3:
*
2A 2B1 2B2 4A 4S1 4S2
1B1 1B2
3A 3S 3B
1A
4 2 4 2
2Y 4Y
4 2 5 3 4 2 5 3
1 1
3Y
1Y1 5 3 1Y2 5 3
1 1
0Z2
0Z1
1 2
* For the purposes of this exercise, cylinder 4A is to be replaced by a single-acting

cylinder.

Solution 19
C-112
(1)
Fig. 19/4:
24 V- 1 2 3 4 5 6 7 8 9 10 11 12
13 13 1 1 23 11 1B2 BN 11 11 1B1 BN
S1 K1 3S 4S1 K1 K4 K5 K6
14 14 4 4 24 14 BK 14 14 BK
13 23
BU BU
K2 K2
14 24
13 23
S1 = START-button
K3 K3
14 24
31 17 21
S2 K19 K4
32 18 24
A1 A1 A1 A1 A1 A1 A1
K1 K2 K3 K4 K5 K6 K7
S2 = STOP-button
A2 A2 A2 A2 A2 A2 A2
2 1 1 6 9 37 10 15
5 5 5 9 16
37 38
39

24 V- 13 14 15 16 17 18 19 20 21 22
2B1 13 17 11 2B2 13 11
K7 K9 K10 S3 K12
14 18 14 14 14
13

K8
14
S3 = Tolerance check
21 21
K6 K10
24 24
= 3s
A1 A1 A1 A1 A1 A1
K8 K9 K10 K10' K11 K12
A2 A2 A2 A2 A2 A2
15 16 17 39 23 41 22
21 40
23
33
(2)
Fig. 19/5:
Solution 19
C-113
Solution 19
C-114
(3)
Fig. 19/6:
24 V- 23 24 25 26 27 28 29 30 31 32
11 11 3B 13 11 21 11 11
K11 K13 4S2 K14 K14 K15 K17
14 14 14 14 24 14 14
31 21
K10 K13
34 24
A1 A1 A1 A1 A1 A1
K13 K14 K15 K16 K17 K17'
A2 A2 A2 A2 A2 A2
24 28 31 40 32 41
29 29 33
40 36
41

24 V- 33 34 35 36 37 38 39 40 41
21 11 21 31 31 41 41 31 41
K17 K18 K18 K17 K4 K6 K4 K13 K13
24 14 22 34 34 44 44 34 44
13 21 31

S4 K12 K12
14 24 32
= Interrogate container
41 31 11 41 11
K10 K6 K10' K17 K17'
44 32 12 42 12
A1 A1
K18 K19 H1 1Y1 1Y2 2Y 3Y 4Y
A2 A2
1A+ 1A- 2A- 3A+ 4A+

35 34 5
Conveyor belt
(4)
Fig. 19/7:
Solution 19
C-115
C-116
Solution 19
Solution description In this solution, end position sensing is indirectly interconnected. The
START and STOP conditions for continuous cycle using one push
button each, are both realised by means of relay K1.
Selection between tolerance conditions Good/Reject is made with the
switch S4 (K12), with the result that either cylinder 3A or 4A extends.
Parts are counted by 3B (position C+) indirectly via K14.
The conveyor belt is started by the final step (K17) and does not stop
until the timer which resets the sequence has run through. The time
delay is not started until the control is in the final step and a container
(S4) has been signalled as being present.
The time element with switch-on delay is activated immediately after
power supply has been switched on, meaning that interruption of this
causes delayed start-up behaviour. That is, the time element switches to
its normal position when the time has expired. However, for this purpose
it is necessary to store the interruption signal (see K18).
6 Relay, 3-off
1 Time relay, 2-off
1 Manifold

C-117
Solution 20
Handling device
2B1 2B2 Fig. 20/3:

1A 1S1 1S2 Circuit diagram, pneumatic
2A
4 2 4 2
1Y 2Y
5 3 5 3
1 1
4S
* 4M
3A 3B1 3B2
4B
4 2 4 2 4 2
3Y 5 3 4Y1 5 3 4Y2 4Y3 5 3 4Y4

1 1 1
0Z2
0Z1
1 2

Rotary actuator 4M is replaced by a double-acting cylinder.

Solution 20
C-118
(1)
Fig. 20/4:
24 V- 1 2 10
21 11
S6 K1
22 14 3
13 31
S2
14 32 7 8
4 5 6 9 11 12 13 14 15 16 17
S2 = MAN/AUT
13 23 13 13 17 13 3B1 13 21 13 1 13
S1 K4 S5 K10 K5 K6 K15 K7 1S2 K8
S1 = START-button
S3 = Sensing of parts
14 24 14 14 18 14 14 24 14 4 14
11 13 11 41 23
K18 K2 K15 K2 K2
14 14 14 42 24
13
S3
S4 = STOP
14
S5 = RESET
31
S4
32 11 11 23 23
11
K16 K13 K6 K7
K3 12 12 24 24
S6 = EMERGENCY-STOP
12
A1 A1 A1 R1 A1 A1 A1 A1 A1
K1 K2 H1 K3 K4 K5 K6 K7 K8
A2 A2 A2 R2 A2 A2 A2 A2 A2
46 2 6 3 2 7 22 10 13 15 42 17
48 45 12 50 30 14 16 19
START
42 41

2A+ 1A+ 2A-
24 V-
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
1B1 11 41 21 27 21 1 11 21 31 11 1B2
BN BN
K9 K5 K16 K10 K11 1S1 K12 K18 K9 K14

14 42 24 28 24 4 14 24 34 14
BK 23 BK
BU K5 BU
24
21
11
K17
K17
22
14
23 11 21 31 21 31
K8 K11 K9 K11 K12 K12
24 12 24 34 24 32
A1 A1 A1 A1 A1 A1 A1 A1 A1
K9 K9' K10 K11 K12 K12' K13 K14 K15
A2 A2 A2 A2 A2 A2 A2 A2 A2
20 45 9 22 25 30 27 45 47 12 31 5
24 24 41 26 44 29 49 43 14
30
44
3A+ 4M+ 1A- 3A- 4M-
(2)
Fig. 20/5:
Solution 20
C-119
Solution 20
C-120
(3)
Fig. 20/6:
24 V- 46 48
40 50
31 41 23
K1 K1 K4
34 35 36 37 38 39 41 42 43 44 45 47 49
32 42 24
3B2 4B 1 33 33 21 41 21 21 31
4S K7 K6 K14 K9 K1 K12' K12'
4 34 34 24 44 24 24 34
11
K9'
14
11
K12'
12
41 41 41
K11 K8 K12
A1 A1 A1 42 42 42
K16 K17 K18 H2 H3 1Y 2Y 3Y 4Y1 4Y2 4Y3 4Y4
A2 A2 A2
9 23 30 22 2
MAN
AUTO
29
1A+ 2A+ 3A+ 4M+ 4M+ 4M- 4M-

C-121
Solution 20
The continuous cycle is introduced via the START button. The handling Solution description
device then runs until a STOP is actuated at the end of the cycle or until
the counter has reached the preselected figure or no parts are reported
as being present.
At this point, lamp H1 indicates whether the start signal is still stored.
Memories K5 and K14 cause cylinder 3A to move every second cycle.
Lamp H2 indicates that the installation is operating in AUTOMATIC
mode. H3 lights up when MANUAL mode is operating (RESET).
6 Relay, 3-off
1 Time relay, 2-off
1 Manifold

C-122
Solution 20

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Learning System for Automation and Technology

Order no.: 094467

Copyright by Festo Didactic GmbH & Co., D-73770 Denkendorf 2002

The technology packages deal with the technologies of pneumatics,

TP202 Festo Didactic

The modular design of the Learning System permits applications beyond

All training packages are based on an identical structure:

The hardware consists of industrial components and systems which

TP202 Festo Didactic

Latest information about the technology package pneumaticTP 202

TP202 Festo Didactic

TP202 Festo Didactic

Exercise 1: Bench drill A-3

Exercise 8: Embossing device A-21

TP202 Festo Didactic

TP202 Festo Didactic

Working pressure should be a maximum of p = 6 bar (= 600 kPa)

Optimum operational safety is achieved by operating the control system

TP202 Festo Didactic

TP202 Festo Didactic

Notes on safety and operation

TP202 Festo Didactic

The profile plate for the assembly of components is equipped for

Please observe the data sheets in Part D for information regarding

TP202 Festo Didactic

Training contents of basic level and advanced level

Physical fundamentals of electricity and pneumatics

Advanced level (TP202)

Function and use of electro-pneumatic components

TP202 Festo Didactic

List of training aims Exercise Training aim

1 To teach the student the principle of the latching sequence.

TP202 Festo Didactic

Equipment set for the basic level (TP201)

Designation Order No. Quantity Equipment set for the

TP202 Festo Didactic

Symbols of the Signal input plate, electrical

Indicator/distributor, electrical Relay, 3-off

Single-acting cylinder Double-acting cylinder

On/off valve with filter regulator Manifold

TP202 Festo Didactic

Proximity sensor with cylinder mounting Pneumatic-electric converter Symbols of the

Limit switch, electrical, 3/2-way solenoid valve,

5/2-way solenoid valve 5/2-way double solenoid valve

TP202 Festo Didactic

Equipment set for the advanced level (TP202)

Equipment set for Designation Order No. Quantity

TP202 Festo Didactic

Signal input plate, electrical Symbols of the

Time relay, 2-off

Preselect counter, electrical, incrementing EMERGENCY-STOP button

Proximity sensor, inductive Proximity sensor, capacitive

Proximity sensor, optical 5/2-way double solenoid valve

TP202 Festo Didactic

Component and exercise allocation (table)

Time relay, 2-off 1 1 1 1 1 1 1

Distributor plate, electrical 1 2 1 1 2 1 1 1 1 1 2 2 2 2 2 1 2 2 2 2

Limit switch, electrical,

Limit switch, electrical,

5/2-way solenoid valve 2 2 2 2 2 2 2 2 2 2 2 1 2 2 2 2

TP202 Festo Didactic

Methodical structure of the exercises

TP202 Festo Didactic