Beruflich Dokumente
Kultur Dokumente
BASIC PNEUMATICS
DEGEM® SYSTEMS
Copyright © 2003 by I.T.E. Innovative Technologies in Education. All
rights reserved. This book, or parts thereof, may not be reproduced in any
form without prior written permission from I.T.E. This publication is based
on the exclusive methodology of Degem Systems Ltd.
EQUIPMENT
1 Pneumatic workstation (PN-2001)
1 Single-acting cylinder with spring return CY1 (PN-2140 panel)
1 3/2-way, manual valve spring return with push button V1
(PN-2110 panel)
1 Set of pneumatic accessories (PN-2160)
DISCUSSION
1. 3/2-WAY MANUAL VALVE
The 3/2-way valves, are used in controls that employ single-acting
cylinders, or for the control of final control elements.
In the normal position, the connection from P to A is closed and the
connection from A to R is open.
Valve operation initially closes the connection from P to R. The
connection from P to A then opens, allowing compressed air to flow
to the cylinder. Releasing the knob, will reset the valve by the reset
spring and close the connection from P to A, opening connection A to
R, allowing the compressed air to flow from the cylinder.
PN-2100 1-2
2. SINGLE-ACTING CYLINDERS
With single-acting cylinders, compressed air is applied on one side
only. These cylinders produce work in one direction only.
Therefore, air is required for one direction of movement only. Either a
built-in spring or an external force is required to move the piston in the
opposite direction.
REVIEW QUESTIONS
1. If the air supply pipe is mistakenly connected to port V
instead of port P, then:
The cylinder will not function.
The air will flow through port P.
The cylinder will be constantly activated through the connection
from V to A.
It does not matter.
EXPERIMENTAL PROCEDURE
1. SCREEN SIMULATION PROCEDURE
The simulation screen displays a press circuit simulation.
Activating the valve will simulate the piston movement in the cylinder.
"Releasing" the valve will cause the piston to return to its start position.
PN-2100 1-3
2. SAFETY RULES
2.1 Make sure you close the valve in the air supply and there is no
pressure in the pipe, before connecting or disconnecting components.
2.2 Adjust the pressure regulator on the master board to 2 bars.
3. EXERCISE PROCEDURE
Figure 1.1 shows a press, operated by a single-acting cylinder
equipped with a return spring.
PN-2100 1-4
Note: The customary safety layout requires the use of both hands and
operates on a time basis. Push buttons should be pressed at short
and fixed time intervals. An exercise, based on this principle
is given further on.
In order to operate the cylinder, valve V1 and valve V6 should be pressed
simultaneously.
REVIEW QUESTIONS
1. If only valve (V1) is activated, then:
The press will operate nonstop.
The press will not function.
The valve (V6) will release the air.
The press will function normally.
2. If valve (V6) is connected via port V instead of port P,
then:
The control circuit will no longer be safe.
It does not matter.
The press will not function.
Activating valve (V6) will activate the press.
EXPERIMENTAL PROCEDURE
1. SCREEN SIMULATION PROCEDURE
The simulation screen displays a simulation of the pneumatic
circuit that should be built on the operation panel.
Activating the simulation according to the instructions , will
demonstrate the circuit operation. Observe it carefully!
PN-2100 2-3
2. SAFETY RULES
2.1 Make sure you close the valve in the air supply and there is no
pressure in the pipe, before connecting or disconnecting components.
2.2 Adjust the pressure regulator on the master board to 2 bars.
Also see the pneumatic circuit on figure 2.1 :
PN-2100 2-4
3. EXERCISE PROCEDURE
3.1 Check and find the pressure inlet port, pressure outlet port and vent port in
valves V1 and V6, separately.
3.2 The circuit is built as follows:
3.2.1 Connect one of the air supply outlets to the pressure inlet port of valve V1.
3.2.2 Connect the pressure outlet port of valve V1 to the pressure inlet port
of valve V6.
3.2.3 Connect the pressure outlet port of valve V6 to the inlet port of the cylinder.
3.3 Operating the control circuit.
3.3.1 Press push button of valve V1 only and observe the piston movement.
3.3.2 Press push button of valve V6 only and observe the piston movement.
3.3.3 Press push buttons of valve V1 and valve V6 simultaneously
and
observe the piston movement.
3.3.4 Cease pressing valve V6 only and observe the piston movement.
3.4 Disassemble the circuit as follows:
3.4.1 Close the valve in the air supply and ascertain that there is no
pressure in the pipes.
3.4.2 Disconnect the pipes from the components.
REVIEW QUESTIONS
3. Why are three rather than two junctions required for
valve V1 and valve V6?
A 3/2-way valve must have two vents and one inlet.
Each valve must have two inlets and one outlet.
A 3/2-way valve must have an inlet, outlet and vent.
Both valves should be shut.
4. Pressing valve V1 and valve V6 separately does not
operate the cylinder since:
They are disconnected.
Valve V1 inlet is connected to the valve V6 outlet.
Valve V6 outlet is connected to the valve V1 inlet.
Both valves must be in the open position.
PN-2100 3-1
EQUIPMENT
1 Pneumatic workstation (PN-2001)
1 Double-acting cylinder CY2 (PN-2120 panel)
1 Double-acting cylinder CY3 (PN-2120 panel)
1 5/3-way, directional valve, 3 position, closed center V7 (PN-2120
panel)
1 3/2-way, manual valve spring return with push button V1 (PN- 2110
panel)
1 3/2 mushroom button valve V6 (PN-2130 panel)
1 Set of pneumatic accessories (PN-2160)
DISCUSSION
The piston can move in both directions in a double-acting
cylinder. The movement is caused by compressed air
applied on either side
of the piston, according to the required direction. Double-acting
cylinders are used when it is necessary to obtain advance and
return
movements.
PN-2100 3-2
REVIEW QUESTIONS
1. Connecting the air supply pipe to port V of valve V1
instead of port P, will cause:
Blocking of the piston while extended.
The piston to move IN and OUT constantly.
The air to issue through port A.
Nothing to happen.
EXPERIMENTAL PROCEDURE
1. SCREEN SIMULATION PROCEDURE
The simulation screen displays a simulation of the pneumatic circuit that
should be built on the operation panel.
Activating the simulation according to the instructions, will demonstrate
the circuit operation. Observe it carefully!
2. SAFETY RULES
2.1 Make sure you close the valve in the air supply and there is no
pressure in the pipe, before connecting or disconnecting components.
2.2 Adjust the pressure regulator on the master board to 2 bars.
3. EXERCISE PROCEDURE - CIRCUIT NO. 1
3.1 Familiarization with 5/3-way lever-operated directional valve,
3 position, closed center (V7):
Closed center is obtained when the valve is not activated
(1
position). When the lever is pushed forward, a given air
passage will
open (2 position), while the lever is pulled backward, the
second air
passage will open (3 position).
PN-2100 3-5
3.1.1 Operate the lever in one direction to detect the blocked vent (V) port.
3.1.2 Operate the level in the other direction to detect the second blocked
vent (V) port. Both ports are release vents.
3.1.3 Detect the port which, when connected to the air pressure
with the
valve being operated in both positions, does not permit air to issue
from the vent. This is the pressure inlet port (P).
3.1.4 Allow compressed air into the pressure inlet port and detect, for each
valve operation position, which port does not let air out. The two ports
(A, B) which allow air to emerge are the connections to the cylinder.
3.1.5 From the test, determine which valve should be operated to achieve
position B+ and which valve should be operated to achieve position B-.
3.2 Build circuit 1 according to figure 3.2.
PN-2100 3-6
3.2.1 Connect the pressure inlet port to one of the air supply
outlets and
open the air supply valve.
3.2.2 Connect the cylinder connections to the valve outlet ports.
3.2.3 From the valve test, determine the cylinder position for each valve
operation condition.
3.2.4 Operate the valve to a given position and compare the
results with
your findings in the previous paragraph.
3.3 Disassemble the circuit:
Make sure you close the valve in the air supply and there is
no
pressure in the pipes before disconnecting components.
4.1.1 Connect the air outles of valves V1 and V6 to both cylinder ports.
V1 will operate B+, and V6 will operate B-.
4.1.2 Connect the pressure inlet of valve V6 to one of the air supply
outlets, and the pressure inlet of valve V1 to another air supply outlet.
PN-2100 3-7
REVIEW QUESTIONS
3. Can the piston be shifted by exerting a force on the
piston rod when the piston is caught somewhere in the
middle of its stroke (the cylinder operated by 5/3-way
valve)?
Yes, easily.
No, this is impossible.
Yes, but only marginally.
This position is unobtainable.
LAB OBJECTIVES
This exercise will enable you to :
Explain how a direct operating system, containing a double-acting cylinder, can be
improved by the addition of a memory element.
Explain the effect and the use of an air spring.
Build the system according to a given diagram.
EQUIPMENT
1 Pneumatic workstation (PN-2001)
1 3/2-way, manual valve spring return with push button V1 (PN-2110
panel)
1 3/2-way, mushroom button valve V6 (PN-2130)
1 Double-acting cylinder CY2 (PN-2120)
1 5/2-way double pilot valve V2 (PN-2130)
1 T distributor (connector)
1 Set of pneumatic accessories (PN-2160)
DISCUSSION
5/2-WAY DOUBLE PILOT VALVE
This valve is operated by compressed air from alternate sides.
When activated from one side, the valve holds its position until
receiving an impulse from the other side.
REVIEW QUESTIONS
1. If you connect the outlet port of valve V6 to the - side of
valve V2, and the outlet port of V1 to the + side of V2,
then:
Blocking of the piston while extended.
The control circuit will function in reverse.
The piston will not move.
The piston will lock in the B+ position.
The piston will lock in the B- position.
PN-2100 4-2
EXPERIMENTAL PROCEDURE
1. SCREEN SIMULATION PROCEDURE
The simulation screen displays a simulation of the pneumatic circuit that
should be built on the operation panel.
Activating the simulation according to the instructions, will demonstrate
the circuit operation. Observe it carefully!
2. SAFETY RULES
2.1 Make sure you close the valve in the air supply and there is no
pressure in the pipe, before connecting or disconnecting components.
2.2 Adjust the pressure regulator on the master board to 2 bars.
The control layout of the press as given in exercise 2, was
modified to improve its performance. A 5/2-way, double
pilot valve was added to the two familiar, 3/2-way valves.
The control layout is shown in figure 4.1.
PN-2100 4-3
3. EXERCISE PROCEDURE
3.1 Description
3.2. Familiarization with the 5/2-way double pilot valve:
3.2.1 Observe the 5/2-way double pilot valve V2 and try to locate the air
control ports, pressure inlet, two air release ports and two cylinder connections.
3.2.2 Connect the pressure inlet to one of the air supply juncions.
3.2.3 Connect one of the control inlets to the air pressure and locate the air-releasing
(vent) port.
3.2.4 Disconnect the air pressure from the control inlet and connect
it to the
other inlet.
3.2.5 Each control inlet allows air to flow from the pressure inlet to
only
one of the outlets.
3.3. Assembling the control circuit:
3.3.1 Connect the operating valve V2 outlets to the cylinder inlets and the
pressure inlet to the air supply.
3.3.2 Connect the control valve V6 pressure inlet to the air supply
and the
outlet to the valve V2 control in order to obtain B-.
3.3.3 Connect the control valve V1 pressure inlet to the air supply and the
outlet to the valve V2 control, in order to obtain B+.
3.4 Activating the control circuit:
3.4.1 Activate valve V1 and verify that the piston moves to the B+ position.
3.4.2 Activate valve V6 and verify that the piston moves to the B- position.
3.5 Disassemble the circuit:
3.5.1 Make sure you close the valve in the air supply and there is no
pressure in the pipes before disconnecting components.
PN-2100 4-4
REVIEW QUESTIONS
3. Depressing one of the control valves (V1 or V6) briefly, will
cause:
The piston to move slightly and stop.
The piston to complete its stroke.
The piston to remain stationary.
The piston to move exactly to the middle of its stroke.
PN-2100 5-1
2. SAFETY RULES
2.1 Make sure you close the valve in the air supply and there is no
pressure in the pipe, before connecting or disconnecting components.
2.2 Adjust the pressure regulator on the master board to 1 bar.
3. EXERCISE PROCEDURE
3.1 A double-acting cylinder and an air spring control layout were installed
in the press shown in Fig. 5.1.
3.2 Build the control circuit according to Figure 5.1.
Note: Control valve V1 is operated directly from the pressure
line.
The check valve is fed from the air supply outlet.
REVIEW QUESTIONS
1. The air spring effect will be stronger when:
The pressure difference is reduced.
The pressure difference is increased.
The pressure on the piston head is higher then the
pressure beneath the head.
The pressure on the piston head is lower then the
pressure beneath the head.
EQUIPMENT
1 Pneumatic workstation (PN-2001)
1 Flowmeter Fm (PN-2110 panel)
1 Flow control with check valve F1 (PN-2110 panel)
2 Pressure gauges
1 Set of pneumatic accessories (PN-2160)
DISCUSSION
1. THE FLOWMETER
A device that enables us to measure the amount of flow (gas or liquid).
2. THE FLOW CONTROL VALVE
A device that enables us to control a required amount of flow.
3. PRESSURE GAUGE
A gauge for measuring pressure in the appropriate units: lb/sq
in, kg/sq cm, bar, etc.
PN-2100 6-2
EXPERIMENTAL PROCEDURE
1. SCREEN SIMULATION PROCEDURE
The simulation screen displays a simulation of the pneumatic circuit that
should be built on the operation panel.
Activating the simulation according to the instructions, will demonstrate
the circuit operation. Observe it carefully!
2. SAFETY RULES
2.1 Make sure you close the valve in the air supply and there is no
pressure in the pipe, before connecting or disconnecting components.
2.2 Adjust the pressure regulator on the master board to 2 bar.
3. EXERCISE PROCEDURE
3.1 Check the flowmeter (FM)
3.1.1 Examine the flowmeter, detect the pressure inlet, outlet ports and
the needle valve.
3.1.2 Connect the pressure inlet to one of the air supply connections.
3.1.3 Close the needle valve and change the air supply pressure to 6 bars.
Record the flowmeter reading.
3.1.4 Open and close the needle valve and observe the flow changes
measured by the flowmeter.
3.2 Check the flow control by the check valve (F1)
3.2.1 Change the air supply pressure to 2 bars.
3.2.2 Observe the needle valve and try to detect the free flow direction
and that controlled by the needle.
3.2.3 Connect the needle valve to one of the air supply outlets, in order
to control the flow of air.
3.2.4 Close the needle valve and then, open it again. Observe the flow change.
Note: Inverted connection of the needle valve will not impede flow
control.
PN-2100 6-3
3.3. Assemble the control circuit that consists of a flow control valve, a
flowmeter and two pressure gauges as shown in figure 6.1.
3.4. Activating the control circuit:
3.4.1 Open the needle valve in flowmeter (FM) completely.
3.4.2 Close needle valve (F1) completely.
3.4.3 Adjust the pressure on the air supply to 6 bars.
3.4.4 Set needle valve (F1) in four different opening positions (fully closed,
1 turn open, 2 turns open, 3 turns open and 4 turns open).
3.4.5 Measure pressure difference between gauges (P1) and (P2) for
each
position. The recorded difference is marked as ∆ P. Measure the
quantity of the air flow.
3.4.6 Repeat the above procedure, reducing the pressure to 5 bars, 4 bars, 3
bars, 2 bars and 1 bar.
3.4.7 Fill in the following measuring table, according to the valve opening
positions.
Air Position Position Position Position Position
supply A B C D E
pressure Flow ∆P Flow ∆P Flow ∆P Flow ∆P Flow ∆P
6 bars 0 6
5 bars 0 5
4 bars 0 4
3 bars 0 3
2 bars 0 2
1 bar 0 1
PN-2100 6-4
3.4.8 Observe the ∆P - flow graph for each air supply pressure.
REVIEW QUESTIONS
1. Closing the needle valve F1 will:
Increase the air flow.
Reduce the air flow.
Not change the air flow.
Not effect the air flow at all.
2. Will a high ∆P effect the air flow?
Yes it will increase it.
Yes it will reduce it.
No it will not effect the air flow.
Yes it will change the flow direction.
3. In order to increase ∆P, the needle valve should be:
Closed.
Open.
Reversed.
Unchanged.
PN-2100 7-1
EQUIPMENT
1 Pneumatic workstation (PN-2001)
1 Single-acting cylinder with spring return CY1 (PN-2140 panel)
1 3/2-way, manual valve spring return with push button
V1 (PN-
2110 panel)
2 Flow controls with check valves F1 and F2 (PN-2110 panel)
1 Flowmeter FM (PN-2110 panel)
2 Pressure gauges
1 Set of pneumatic accessories (PN-2160)
DISCUSSION
Sometimes, it is necessary to regulate the movement of a
single-acting, spring return cylinder. One way, is by using flow
control with check valves.
By inserting one control in the inlet line and the other in the
outlet line, piston movement can be regulated in both
directions.
REVIEW QUESTIONS
1. The flow control valve F2 regulates:
The A- speed of the piston.
The A+ speed of the piston.
The amount of piston movement.
The air pressure.
EXPERIMENTAL PROCEDURE
1. SCREEN SIMULATION PROCEDURE
The simulation screen displays a simulation of the pneumatic circuit that
should be built on the operation panel.
Activating the simulation according to the instructions, will demonstrate
the circuit operation. Observe it carefully!
PN-2100 7-3
2. SAFETY RULES
2.1 Make sure you close the valve in the air supply and there is no
pressure in the pipe, before connecting or disconnecting components.
2.2 Adjust the pressure regulator on the master board to 2 bars.
3. EXERCISE PROCEDURE
3.1 Check that needle valves F1 and F2 are vis-a-vis free and control
flow directions.
3.2 Build the flow control circuit according to figure 7.1.
3.3 Operating the circuit:
3.3.1 Open both needle valves F1 and F2 completely.
3.3.2 Close valve F1 slightly and press V1. Check the piston speed
and
release V1. Recheck the piston speed.
3.3.3 Repeat the previous step, partially (turning by a quarter turn)
opening valve F1 each time until final opened. Check the piston
speed in every step.
3.3.4 Leave the flow control valve F1 fully opened and close valve F2
slightly and press V1. Check the piston movement and observe the
pressure gauges.
3.3.5 Repeat the previous step, partially (turning by a quarter turn)
opening valve F2 each time until final opened. Check the piston
speed in every step.
3.4 Disassemble the circuit:
Make sure you close the valve in the air supply, there
are no pressure in the pipes before disconnecting
components.
REVIEW QUESTIONS
3. The air flow indicated by the flowmeter is effected by:
The needle valve F1.
The needle valve F2.
The 3/2 valve V1.
Both of the needle valves.
PN-2100 7-4
DISCUSSION
Sometimes, it is necessary to control and regulate the piston
speed of a double-acting cylinder.
To do so in this exercise, you'll be using two needle valves.
Regulating the needle valves will enable you to control the
piston speed, either toward B+ or backward B-.
The control circuit of the double-acting cylinder with valve and
two speed regulators is shown in figure 8.1.
PN-2100 8-2
REVIEW QUESTIONS
1. If valve F1 is turned over, then:
The piston will move toward B- only.
The piston will move toward B+ only.
The piston will lock in the middle of its stroke.
The piston will be blocked in the B+ position.
EXPERIMENTAL PROCEDURE
1. SCREEN SIMULATION PROCEDURE
The simulation screen displays a simulation of the pneumatic circuit that
should be built on the operation panel.
Activating the simulation according to the instructions, will demonstrate
the circuit operation. Observe it carefully!
PN-2100 8-3
2. SAFETY RULES
2.1 Make sure you close the valve in the air supply and there is no
pressure in the pipe, before connecting or disconnecting components.
2.2 Adjust the pressure regulator on the master board to 2 bars.
3. EXERCISE PROCEDURE
3.1 Check the flow control of the one way needle valves F1
and F2
and verify the free and controlled flow directions.
3.2 Build the control circuit according to Figure 8.1. Make
sure that
the valves are oriented in the correct direction.
3.3 Activating the control circuit:
3.3.1 Close both needle valves F1 and F2 completely.
3.3.2 Open valve F2 slightly and press the button of valve V1 to operate
the piston B+ and V6 to operate piston B-.
3.3.3 Observe the piston movement. The piston moves forward, but
doesn't move backward.
3.3.4 Open valve F1 and press the mushroom button to move the piston back.
3.3.5 Observe the piston movement.
3.3.6 Operate the circuit using different opened positions of
flow control
valves F1 and F2 and observe the piston movements.
3.4 Disassemble the circuit:
Make sure you close the valve in the air supply and
there is no pressure in the pipe, before disconnecting
components.
REVIEW QUESTIONS
3. Reversing valve F2 will cause:
The piston to lock in position B-.
The piston to lock in position B+.
Unregulated speed toward the B- position.
Unregulated speed toward the B+ position.
PN-2100 9-1
DISCUSSION
1. 3/2-WAY ROLLER VALVE, SPRING RETURN
The construction and the function of the 3/2-way spring
returned, roller valve is similar to the familiar 3/2-way
valve, with the exception that the roller type is equipped
with a lever and a roller.
This type of valve is usually operated by the movement of the piston.
2. DESCRIPTION
A semi-automatic pneumatic control enables a pneumatic circuit to be
driven through one cycle only, for each operation.
Each time valve V1 is operated, the piston will travel and then immediately
retract to the B- position.
REVIEW QUESTIONS
1. Exchanging the air pipes that are connected to the cylinder will
cause:
The piston to function in a reverse cycle.
The piston to lock in the middle of its stroke.
The piston to lock in the B+ position.
Nothing to happen.
EXPERIMENTAL PROCEDURE
1. SCREEN SIMULATION PROCEDURE
The simulation screen displays a simulation of the pneumatic circuit that
should be built on the operation panel.
Activating the simulation according to the instructions, will demonstrate
the circuit operation. Observe it carefully!
PN-2100 9-3
2. SAFETY RULES
2.1 Make sure you close the valve in the air supply and there is no
pressure in the pipe, before connecting or disconnecting components.
2.2 Adjust the pressure regulator on the master board to 2 bars.
3. EXERCISE PROCEDURE
3.1 Checking valve LV5:
Before using valve LV5, check it and locate the pressure
inlet, air
outlet and vent port.
3.1.1 Valve LV5 is blocked by valve 1 according to the procedure
described in lesson 1.
3.1.2 Make sure that the piston rod is not pressing against valve LV5.
3.1.3 Air pressurize each of the two valve ports. The blocked port
corresponds to the pressure inlet.
Note: the vent port is located under the lever arm.
3.1.4 Connect the pressure inlet to one of the air supply outlets.
3.1.5 Manually press the pulley in order to operate the valve. Air pressure
will materialize through a particular port - the outlet port.
3.2 Build the semi-automatic control circuit according to figure 9.1.
3.3 Operate the circuit:
3.3.1 Press valve V1 momentarily. Observe the piston
movement, it has
to move to B+, B-.
3.3.2 Press valve V1 continuously. Observe the piston movement, it has
to stop in position B-, until the push button V1 is released.
3.4 Disassemble the circuit:
Make sure you close the valve in the air supply, there
are no pressure in the pipes before disconnecting
components.
PN-2100 9-4
REVIEW QUESTIONS
EQUIPMENT
1 Pneumatic workstation (PN-2100)
1 3/2-way manual valve, spring return with push button V1 (PN-2110 panel)
1 Double-acting cylinder CY2 (PN-2120 panel)
1 5/2-way, double pilot valve V2 (PN-2130 panel)
2 3/2-way, roller valves,spring return LV4 and LV5 (PN-2140 panel)
1 Set of pneumatic accessories (PN-2160)
DISCUSSION
An automatic control circuit is necessary to operate a machine
that can dispense items consecutively and stop automatically
when no more items are available.
Two 3/2-way roller valves and a manual push button must be
combined, operated by the item-dispensing piston. The sensors
are simulated as item 1 is valve V1 and item 2 is roller valve
LV5.
System for a machine supplying items one by one is shown in figure 10.1.
PN-2100 10-2
REVIEW QUESTIONS
1. With valve V1 located between the air supply and the pressure inlet
of valve LV4:
The order of operation will be reversed.
The piston will stop at the B+ position.
The order of operation will not change.
The piston will stop at the B- position.
PN-2100 10-3
EXPERIMENTAL PROCEDURE
1. SCREEN SIMULATION PROCEDURE
The simulation screen displays a simulation of the pneumatic circuit that
should be built on the operation panel.
Activating the simulation according to the instructions, will demonstrate
the circuit operation. Observe it carefully!
2. SAFETY RULES
2.1 Make sure you close the valve in the air supply and there is no
pressure in the pipe, before connecting or disconnecting components.
2.2 Adjust the pressure regulator on the master board to 2 bars.
3. EXERCISE PROCEDURE
3.1 Check valves V1, LV4 and LV5, detecting:
* Pressure inlet port
* Outlet port
* Vent port
REVIEW QUESTIONS
3. Switching the air supply pipes to the cylinder will cause:
The circuit not to operate.
The piston to lodge in the B+ position.
The circuit to function normally.
The piston to move one cycle only.
PN-2100 11-1
LAB OBJECTIVES
This exercise will enable you to :
Explain the construction and the operation of a
grinding machine - pneumatic control circuit.
Build the control circuit needed for the grinding
machine.
EQUIPMENT
1 Pneumatic workstation (PN-2001)
1 3/2-way, manual valve, spring return with push button V1 (PN-2110
panel)
1 Double-acting cylinder CY3 (PN-2120 panel)
1 5/2-way, double pilot valve V2 (PN-2130 panel)
2 3/2-way, roller valves, spring return LV1 and LV2 (PN-2140 panel)
1 T distributor
1 Set of pneumatic accessories (PN-2160)
DISCUSSION
In order to regulate the position of the piston (C), accurately and
independently of force changes, an integrated position control unit is used.
A similar control circuit will be studied in the following exercise.
The system for a grinder driven by pneumatic cylinder is shown in figure
11.1.
PN-2100 11-2
REVIEW QUESTIONS
1. Connecting valve LV1 to C- of valve V2 and valve LV2 to C+
of valve V2, will cause:
The control circuit not to function.
The piston to move to the C+ position and then stop.
The control circuit to continue functioning as before.
The piston to stop in the middle of its stroke.
PN-2100 11-3
PN-2100 12-1
LAB OBJECTIVES
This exercise will enable you to :
Understand sensor integrated control circuit operation.
Build a pneumatic, sensor integrated control circuit, with a
double-acting cylinder.
Perform simple condition analysis.
EQUIPMENT
1 Pneumatic workstation (PN-2001)
1 3/2-way, manual valve, spring return with push button V1 (PN-2110 panel)
1 3/2-way, mushroom button valve V6 (PN-2130 panel)
1 Double-acting cylinder CY3 (PN-2120 panel)
1 5/2-way, double pilot valve V2 (PN-2130 panel)
2 3/2-way, roller valves, spring return LV1 and LV2 (PN-2140 panel)
1 3/2-way manual valve V3 (PN-2130 panel)
1 Set of pneumatic accessories (PN-2160)
DISCUSSION
Figure 12.1 shows a control circuit for a machine that dispenses
items consecutively.
This control circuit is similar to the circuit described in lesson
10, with the addition of two sensors V3 and V6.
PN-2100 12-2
2. SAFETY RULES
2.1 Make sure you close the valve in the air supply and there is no
pressure in the pipe, before connecting or disconnecting components.
2.2 Adjust the pressure regulator on the master board to 2 bars.
3. EXERCISE PROCEDURE
3.1 Check all 3/2 valves and detect:
* Pressure inlet port
* Outlet port
* Vent port
3.2 Check 5/2 valve and detect:
* Cylinder outlet ports
* Pressure inlet port
* Control C+ and control C- ports
* Vent ports
3.3 Review the control circuit given in figure 12.1 to understand its
operation and action cycle.
3.4 Build the control circuit according to figure 12.1.
3.5 Run the control circuit and check the action sequence.
3.5.1 Press valves V1 and V3 and observe the piston operating cycle.
3.5.2 Keeping pressed valves V1 and V3, press V6. Observe the piston
operating cycle.
3.5.3 Press valve V6 and alternately valves V1 and V3. Observe the
piston operating cycle.
3.6 Disassemble the control circuit:
Make sure you close the valve in the air supply and there is
no pressure in the pipe, before disconnecting components.
PN-2100 12-4
REVIEW QUESTIONS
1. Valves V1 and V3 were connected in series. Why?
To prevent either one of them failing.
Each valve answers for one direction of movement.
To ensure that cylinder can be operated only when
both valves are activated.
This type of connection does not effect the control circuit action.
LAB OBJECTIVES
This exercise will enable you to:
Explain the function of an automatic circuit with a double-
acting cylinder.
Build the control circuit without reference to a layout or
diagram.
EQUIPMENT
1 Pneumatic workstation (PN-2001)
1 3/2-way mushroom button valve V6 (PN-2130 panel)
1 Double-acting cylinder CY3 (PN-2120 panel)
2 3/2-way, roller valves, spring return LV1 and LV2 (PN-2140 panel)
1 5/2-way, double pilot valve V2 (PN-2130 panel)
1 3/2-way, manual valve V3 (PN-2130 panel)
1 Set of pneumatic accessories (PN-2160)
DISCUSSION
A pneumatic control circuit is shown in figure 13.1.
Valves V3 and V6 enable two modes of circuit operation :
* Single cycle
* Automatic operation
PN-2100 13-2
REVIEW QUESTIONS
1. The single cycle mode is enabled by:
The 3/2-way valve V3.
The 3/2-way valve V6.
The 3/2-way roller valve LV1.
The 3/2-way roller valve LV2.
EXPERIMENTAL PROCEDURE
1. SCREEN SIMULATION PROCEDURE
The simulation screen displays a simulation of the pneumatic circuit that
should be built on the operation panel.
Activating the simulation according to the instructions, will demonstrate
the circuit operation. Observe it carefully!
PN-2100 13-3
2. SAFETY RULES
2.1 Make sure you close the valve in the air supply and there is no
pressure in the pipe, before connecting or disconnecting components.
2.2 Adjust the pressure regulator on the master board to 2 bars.
3. EXERCISE PROCEDURE
3.1 Study the control circuit shown in figure 13.1.
3.2 Build the control circuit according to figure 13.1.
3.3 Operate the control circuit:
3.3.1 Press valve V6 and observe the piston movement.
3.3.2 Press valve V3 and observe the piston movement.
3.3.3 Find out why the C1 position is the basic position of the piston?
3.4 Disassemble the control circuit:
Make sure you close the valve in the air supply and there is no
pressure in the pipes before disconnecting components.
REVIEW QUESTIONS
3. Can the piston be halted in the C- position?
Yes. Releasing valve V3 will stop the piston in any
position.
No. The piston will always stop in the C+ position.
Yes. Pressing valve V6 will halt the piston in the C-
position.
Yes. If both valves are activated.
PN-2100 14-1
EQUIPMENT
1 Pneumatic workstation (PN-2001)
1 3/2-way, manual valve, spring return with push button V1 (PN-2110
panel)
1 Double-acting cylinder CY3 (PN-2120 panel)
1 5/2-way, double pilot valve V2 (PN-2130 panel)
1 5/2-way, pilot spring return valve V4 (PN-2110 panel)
1 3/2-way, roller valve, spring return LV2 (PN-2140 panel)
1 Reservoir R (PN-2120 panel)
1 Pressure gauge
1 T distributor
1 Flow control with check valve F1 (PN-2110 panel)
1 Set of pneumatic accessories (PN-2160)
1 Stopwatch
DISCUSSION
Sometimes, it is necessary to delay a particular action of a control circuit.
One way, is to use a pneumatic reservoir.
PN-2100 14-2
The circuit shown in figure 14.1 uses a reservoir for delaying the back action
of the piston, forcing it to linger in position B+.
1. DESCRIPTION - CIRCUIT No. 1
EXPERIMENTAL PROCEDURE
1. SCREEN SIMULATION PROCEDURE
The simulation screen displays a simulation of the pneumatic circuit that
should be built on the operation panel.
Activating the simulation according to the instructions, will demonstrate
the circuit operation. Observe it carefully!
2. SAFETY RULES
2.1 Make sure you close the valve in the air supply and there is no
pressure in the pipe, before connecting or disconnecting components.
2.2 Adjust the pressure regulator on the master board to 5 bars.
3.3.4 Open the flow control valve position by 2/8 of a turn, press valve V1
and observe the piston movement.
3.3.5 Open the flow control valve position by 3/8 of a turn, press valve V1
and observe the piston movement.
3.3.6 Open the flow control valve position by 4/8 of a turn, press valve V1
and observe the piston movement.
Please note the relation between the flow rate and the delay.
3.4 Disassemble the control circuit:
Make sure you close the valve in the air supply and there is
no
pressure in the pipes before disconnecting components.
4. EXERCISE PROCEDURE - CIRCUIT No. 2
4.1 Study the control circuit in figure 14.2 to understand its operation.
Note:Valve V4 is a 5/2-way, air-spring operated valve,
converted
into a 3/2-way, air-spring valve.
4.1.1 Compare this control circuit to the previous one.
4.2 Build the control circuit according to the diagram shown in figure 14.2.
4.3 Operate the control circuit and observe the pressure gauge P1.
4.3.1 Fully open (by rotating the adjusting screw) the flow control valve
and press valve V1. Observe the speed of the piston.
4.3.2 Close the flow control valve and press valve V1. Observe the speed
of the piston.
4.3.3 Set the flow control valve by rotating the adjusting screw based on
the table and the measured the time delay for each setting.
REVIEW QUESTIONS
1. Does reservoir size affect time delay?
Yes. But marginally.
No. No effect at all.
Yes. Significantly.
It depends on its location in the circuit.
Figure 15.1 shows a pneumatic control layout, for the operation of one cylinder
in a semi-automatic way.
The system includes pneumatic delay based on pressure discharge principle.
EXPERIMENTAL PROCEDURE
1. SCREEN SIMULATION PROCEDURE
The simulation screen displays a simulation of the pneumatic circuit that
should be built on the operation panel.
Activating the simulation according to the instructions, will demonstrate
the circuit operation. Observe it carefully!
2. SAFETY RULES
2.1 Make sure you close the valve in the air supply and there is no pressure
in the pipe, before connecting or disconnecting components.
2.2 Adjust the pressure regulator on the master board to 5 bars.
3. EXERCISE PROCEDURE
3.1 Study the control circuit in figure 15.1 and try to understand its mode
of operation.
PN-2100 15-3
REVIEW QUESTIONS
1. When valve V1 is not activated, the piston position will be:
In position B+.
In the middle of its stroke.
In position B-.
Either in position B+ or in B-.
The control circuit shown in figure 16.2 is used for operating a press.
EXPERIMENTAL PROCEDURE
1. SCREEN SIMULATION PROCEDURE
The simulation screen displays a simulation of the pneumatic circuit that
should be built on the operation panel.
Activating the simulation according to the instructions, will demonstrate
the circuit operation. Observe it carefully!
2. SAFETY RULES
2.1 Make sure you close the valve in the air supply and there is no pressure
in the pipe, before connecting or disconnecting components.
2.2 Adjust the pressure regulator on the master board to 3 bars.
3. EXERCISE PROCEDURE
3.1 Study the control circuit in figure 16.2 and try to understand
how the
system operates.
3.2 Check the following components:
* 5/2-way operating valve V2
* Limit valves LV2 and LV5
* 3/2-way manual valves V1 and V6
REVIEW QUESTIONS
1. Why are valves V1 and V6 connected in series?
Valve V1 is on standby in case V6 fails.
To ensure two-handed press operation.
Valve V6 serves as an air passage.
Valve V1 serves as a safety valve.
When a package reaches the end of conveyor #1, it activates sensor V6,
operating cylinder CY3, which shifts the package to conveyor #2. Cylinder
CY2 then responds by pushing the package on to conveyor #2.
Valve V3 enables the operator to stop the automatic operation of the cycle.
PN-2100 17-3
EXPERIMENTAL PROCEDURE
1. SCREEN SIMULATION PROCEDURE
The simulation screen displays a simulation of the pneumatic circuit that
should be built on the operation panel.
Activating the simulation according to the instructions, will demonstrate
the circuit operation. Observe it carefully!
2. SAFETY RULES
2.1 Make sure you close the valve in the air supply and there is no pressure
in the pipe, before connecting or disconnecting components.
2.2 Adjust the pressure regulator on the master board to 3 bars.
3. EXERCISE PROCEDURE
3.1 Check all the valves and detect all the ports.
3.2 Study the circuit in figure 17.2 and try to understand its operation.
3.3 Build the control circuit according to figure 17.2.
3.4 Operate the control circuit:
3.4.1 Press valves V3 and V6 alternatively. Observe the operation of the
circuit.
3.4.2 Press valves V3 and V6 simultaneously. Observe the operation of
the circuit. You will find the sequence of the circuit is C+, B+, C- and B-.
3.4.3 During the operating cycle deactivate valve V3. Observe the
operation of the circuit. Deactivation of valve V3 will stop the
system operation, so in that case valve V3 operates as an emergency stop.
Note : If the operation of the circuit doesn't follow the above
mentioned sequence, study the diagram again and try to
detect the error(s) that were made setting up the system.
3.5 Disassemble the control circuit:
Make sure you close the valve in the air supply, there are no
pressure in the pipes before disconnecting components.
PN-2100 17-4
REVIEW QUESTIONS
1. With valve V6 inactive, the circuit will:
Activate cylinder C only.
Activate cylinder B only.
Not be activated at all.
Operate in reverse.
EQUIPMENT
DISCUSSION
The control circuit, the subject of this exercise is similar to the
circuit in lesson 17, with the one exception :
In lesson 17 the pistons return to the start position, one after the other.
In this lesson, both pistons return simultaneously.
The system comprises of two conveyors and an automatic
pneumatic elevator. The control circuit is shown in figure 18.1.
PN-2100 18-2
EXPERIMENTAL PROCEDURE
1. SCREEN SIMULATION PROCEDURE
The simulation screen displays a simulation of the pneumatic circuit that
should be built on the operation panel.
Activating the simulation according to the instructions, will demonstrate
the circuit operation. Observe it carefully!
2. SAFETY RULES
2.1 Make sure you close the valve in the air supply and there is no pressure
in the pipe, before connecting or disconnecting components.
2.2 Adjust the pressure regulator on the master board to 3 bars.
3. EXERCISE PROCEDURE
3.1 Check all the valves and detect all the ports.
3.2 Study the control circuit in figure 18.1 and try to understand its operation.
3.3 Build the control circuit according to figure 18.1.
3.4 Operate the control circuit by pressing valves V1 and V6.
Note : If the control circuit does not function, study the diagram
again or run the simulation.
3.5 Disassemble the control circuit:
Make sure you close the valve in the air supply, there are no
pressure
in the pipes before disconnecting components.
PN-2100 18-3
REVIEW QUESTIONS
1. When both pistons return simultaneously to the "-" position, you know that:
They are operating in the same direction.
"-" controls on V5 and V2 are connected to the same
pipeline.
V1 and V6 are connected in series.
There are four 3/2 roller valves.
2. DESCRIPTION
The control circuit in figure 19.1, describes a semi-automatic control circuit
used for operating a handling system with two conveyors and a pneumatic
elevator.
Double controls are inserted, to disable the control circuit.
You'll have to locate the double controls and find a solution to cancel their
effect.
EXPERIMENTAL PROCEDURE
1. SCREEN SIMULATION PROCEDURE
The simulation screen will display a control circuit with two double-acting
cylinders. The control circuit includes a number of faults. Your assignment
is to detect these faults and provide a solution.
You'll be required to implement your solution in the circuit that you build on
the pneumatic workstation.
Activating the simulation according to the instructions, will demonstrate
the circuit operation. Observe it carefully!
2. SAFETY RULES
2.1 Make sure you close the valve in the air supply and there is no pressure
in the pipe, before connecting or disconnecting components.
2.2 Adjust the pressure regulator on the master board to 3 bars.
PN-2100 19-3
3. EXERCISE PROCEDURE
3.1 Check all the valves and detect all the ports.
3.2 Study the control circuit is shown in figure 19.1 and try to understand
its operation.
3.3 Build the control circuit according to figure 19.1.
Note: Valve V1 is a standard push button.
3.4 Operate the control circuit:
3.4.1 Press valve V1. You will discover that the circuit doesn't work.
3.4.2 Detect the two double controls in the circuit.
3.4.3 The first double control is located between C- and C+.
3.4.4 Pressing valve V6 overcomes the double control.
Note:In practice, a "command cut" valve is installed as a
substitute for valve V6. "Command cut" is a reverse time
delay, transferring air briefly before interrupting the flow.
3.4.6 In order to overcome the control, replace the limit valve LV2 with a
one-way operated valve LV3 so that cylinder C presses the valve on
its way out, releasing an air pulse.
REVIEW QUESTIONS
4. Installing the "command cut" valve in the circuit will convert the circuit to:
A time delayed control circuit.
No change will occur.
A reverse control circuit.
An automatic control circuit.