Beruflich Dokumente
Kultur Dokumente
Electropneumatics
Collection of
Transparencies
1 3
3 3
2 2
1 1
095011 GB
Order No.: 095011
Description: EL-PN.FOLIEN-GS
Designation: D:OT-TP201-GB
Edition: 02/2000
Author: Frank Ebel
Graphics: Doris Schwarzenberger
Layout: 10.05.2000, Beatrice Huber
The Collection of Transparencies is conceived for the basic material of the TP200
Electropneumatic Technology Package. The transparency collection and technology
package form part of the The Learning System for Automation from Festo Didactic
GmbH & Co.
The transparencies are designed from a didactical and methodological point of view.
For each transparency, there is a short accompanying text that provides the speaker
with a quick overview of the contents. More information you will find in the textbook
Electropneumatics.
The text pages contain a complete picture of the transparency with some additional
explanations and items which the speaker can mark on the transparency during
instruction.
New! The enclosed CD-ROM contains all the overhead transparencies and accompanying
Electronic presentation text of this edition in an electronically presentable form in the files
„Electropneumatics _ transparencies.pdf“ and „Electropneumatics _text.pdf“. In
addition to the screen presentation, which can be made in any order, the contents
can be printed out and text and graphics can be used for your own training
preparations, insofar as the functionality of the required Adobe® Acrobat® Reader
permits this. This freely distributable software is available on the CD-ROM in the
currently valid English version for Windows 95/98/NT for installation in the directory
„Acrobat_Reader“. Please start the file „rs405eng.exe“ and follow the subsequent
dialogue.
System Elements
Elements of a Control Chain __________________________________ Transparency 1
Pneumatic Components
Single-Acting Cylinder _______________________________________ Transparency 2
Double-Acting Cylinder ______________________________________ Transparency 3
Non-return, Flow Control and Pressure Control Valves_____________ Transparency 4
Pressure Regulating Valve____________________________________ Transparency 5
One-Way Flow Control Valve __________________________________ Transparency 6
Quick Exhaust Valve_________________________________________ Transparency 7
Electropneumatic Components
Conversion of Electrical Signals into Pneumatic Signals ___________ Transparency 8
Conversion of Pneumatic Signals into Electrical Signals ___________ Transparency 9
Switching Symbols for Valves ________________________________ Transparency 10
Directional Control Valves: Ports and Switching Positions_________ Transparency 11
Function Principle of a Solenoid Coil __________________________ Transparency 12
2/2-Way Solenoid Valve without Pilot Control __________________ Transparency 13
Solenoid Valves with Pilot Control ____________________________ Transparency 14
3/2-Way Single Solenoid Valve with Pilot Control _______________ Transparency 15
5/2-Way Single Solenoid Valve with Pilot Control _______________ Transparency 16
5/2-Way Double Solenoid Valve with Pilot Control_______________ Transparency 17
5/3-Way Solenoid Valve ____________________________________ Transparency 18
Electrical Components
Power Supply Units ________________________________________ Transparency 19
Switching Contacts and Types of Actuation _____________________ Transparency 20
Types of Actuation of Switching Elements ______________________ Transparency 21
Switching Symbols for Solenoid Coils and Relays________________ Transparency 22
The Relay ________________________________________________ Transparency 23
Magnetic Proximity Switches (Reed Switches) __________________ Transparency 24
Electrical Output Devices____________________________________ Transparency 25
Logic Functions
The AND Logic Function _____________________________________ Transparency 26
The OR Logic Function ______________________________________ Transparency 27
Electropneumatic Controller
Control Chain _____________________________________________ Transparency 28
Direct Actuation of a Single-Acting Cylinder ____________________ Transparency 29
Indirect Actuation of a Double-Acting Cylinder __________________ Transparency 30
Electrical Memory Circuit – Dominant Set ______________________ Transparency 31
Electrical Memory Circuit – Dominant Reset ____________________ Transparency 32
Electropneumatic Memory Circuit with Double Solenoid Valve _____ Transparency 33
Stroke-Dependent Control___________________________________ Transparency 34
Pressure-Dependent Control _________________________________ Transparency 35
The principle of the control chain is used for the preparation of the circuit diagram.
Every element of a control chain has a certain task to perform in the processing and
further transmission of signals.
This structuring of a system into functional blocks has proven itself in the following
tasks:
· Arrangement of the elements in the circuit diagram
· Definition of the nominal sizes, nominal current and nominal voltage of
components
· Set-up and commissioning of the controller
· Identification of the components for maintenance work
Pneumatics/ Electrics/
Hydraulics Electronics
– Power contactors
– Directional
Control elements – Power transistors
control valves
– Power thyristors
– Directional
Processing – Contactors
control valves
elements – Relays
– Isolating valves (Control elements) – Electronic modules
– Pressure valves
– Switches – Switches
– Push button – Push button actuators
actuators – Limit switches
– Limit switches Input elements – Program module
– Program – Sensors
module – Indicators/generators
– Sensors
Single-Acting Cylinder
Single-acting cylinders can perform work in only in the advance direction of travel.
The piston rod is driven inwards by the force of a built-in spring or by external forces.
Piston
End cap Reset spring Bearing cap
Piston rod
Double-Acting Cylinder
The force transmitted to the piston rod is greater during the advance stroke than
during the return stroke.
Cylinder barrel
Scraper ring
Bearing cap
Non-return valves block the flow in one direction and release it in the opposite
direction. A distinction is made between:
· Non-return valves
· Shuttle valves (OR)
· Dual pressure valves (AND)
· One-way flow control valves
· Quick exhaust valves
Pressure control valves influence the pressure or are controlled through the size of
the pressure. A distinction is made between:
· Pressure regulating valves
· Pressure relief valves
· Pressure sequence valves
– Pressure-relief valve
2
2
– Pressure sequence
valve-combination
1 3
12
Pressure regulators have the function of keeping the output pressure mainly
constant, independent of variations in the input pressure and the air consumption.
If the pressure rises at the outlet, the diaphragm moves against the spring force and
the flow cross-section at the valve seat is reduced or closed.
If the pressure drops at the outlet, the spring presses against the diaphragm and the
passage cross-section at the valve seat is enlarged or opened.
P1 P2 P1 P2
3
1
The check element blocks the flow of air in one direction, so that it flows across an
adjustable throttle in this direction.
The air flow from the opposite direction lifts the seal of the check element from the
seat. The compressed air can flow almost unrestricted in this direction.
1A
1V2 1V3
1V1
4 2
1Y1 1Y2
5 3
1
Quick exhaust valves are used to achieve the maximum advance and retract speed
of pneumatic cylinders.
3 3
2 2 è
1 1A 1 1A
1V2 1V2
2 2
1 1
3 3
1V1 1V1
2 4 2
1Y1 1Y2
1 3 5 3
1
If control systems are using compressed air and electricity as working mediums,
converter systems must be used.
1 3
3 3
2 2
1 1
unactuated actuated
The PE converter is actuated with compressed air. When the pressure reaches a
preset value, an electric signal is generated.
If the pressure working against the diaphragm overcomes the spring force, a stem
actuates an electrical switch contact.
14
14 14
actuated unactuated
Lines indicate the flow paths, arrows indicate the direction of flow.
Closed ports are shown by two lines drawn at right angles to one another.
The connecting lines for supply and exhaust air are drawn outside the square.
Information about the type of valve can be established from the following features:
· Number of ports
· Number of switching positions
· Port numbering
Number of ports
Number of switching positions
2
4 2
4/2-way valve
flow from 1 à 2 and from 4 à 3
1 3
4 2
5/2-way valve
flow from 1 à 2 and from 4 à 5
5 3
1
4 2
A soft iron core (armature) is drawn into a coil through which a current is flowing.
Coil winding
1 1
2 2
In comparison with solenoid valves without a pilot control, solenoid valves with a
pilot control are distinguished by:
· Lower force required to actuate the armature.
· Smaller dimensions of the coil head.
· Lower power consumption.
· Less heat generated.
An electrical signal is
applied to the solenoid
coil
1 3
3 3
2 2
1 1
4 2
14
84 5 3
1
14
84 5 4 1 2 3 4 2
14
84 5 3
1
14
84 5 4 1 2 3
Manual override
4 2
14 12
84 5 3 82
1
14 12
84 5 4 1 2 3 82 4 2
14 12
84 5 3 82
1
14 12
84 5 4 1 2 3 82
1. In the normal position, the solenoid coils are deenergized and the piston is
centered in its mid-position by the two springs. Ports 2 and 3 as well as 4 and 5
are connected. Port 1 is blocked.
2. If current is applied to the lefthand solenoid coil, the piston moves to the right.
Ports 1 and 4 as well as 2 and 3 are connected with each other.
3. If current flows through the righthand solenoid coil, the piston moves to the left.
In this position, Ports 1 and 2 as well as 4 and 5 are connected.
Each of the two actuated switching positions is held as long as current flows through
the corresponding solenoid coil. If the flow of current is interrupted, the piston
switches back to the mid-position.
4 2
14 12
5 13
84 82
14 12
4 2
84 5 4 1 2 3 82
14 12
5 1 3
84 82
14 12
4 2
84 5 4 1 2 3 82
14 12
5 1 3
84 82
14 12
84 5 4 1 2 3 82
The following switch contact designs are used as input and processing elements:
· Normally-open contact
· Normally-closed contact
· Changeover contact
Push-button with Rotary switch with Limit switch with normally open
normally open contacts normally open contacts or normally closed contacts,
manually actuated manually actuated mechanically actuated
by pushing by turning
2 4
Type of actuation
(push-button)
1
Connection
Switching element
(normally-closed contact)
Connection
(normally-open contact)
3 3
4
4 4
In electropneumatics, the solenoid coil is the element that switches the valves.
A relay switches 1, 2 or more contacts. The relay can also be a time or temperature-
controlled element.
Y1
K1
The Relay
In practice, the construction of a relay can be very different, but the function is
nevertheless the same in principle:
· When a voltage is applied to the relay coil through contacts A1 and A2, an
electric current flows through the windings. A magnetic field is built up and pulls
the armature against the core of the coil.
· Switch contact 1 is connected with switch contact 4.
· After removing the voltage, the armature is brought back into its initial position
by a spring.
· Switching contact 1 is connected with switching contact 2.
A relay can have multiple switching contacts which can be actuated simultaneously.
12 14 22 24
A1
Return spring
A2
Relay coil 11 21
Armature
Coil core
Insulation
Contact
A1 A2 4 2 1
Reed switches are actuated through a magnetic field. In industrial applications, most
reed switches are used with LED displays.
When the magnetic ring moves past the reed switch, the switching contacts are
closed as a result of the magnetic field and thus provide an output signal.
+24V
BN
BK
BU
0V
Do work:
· For example, electric motors
· Identifying letters in electrical circuit diagrams: M (M1, M2, ...)
Signalling device
Audible indicator: Horn Siren Bell
Illuminating
indicators: Lamp Light emitting diode (LED)
Motors
DC motor
M
The AND logic function consists of at least two switching elements connected in
series:
· The AND logic function can have two or more inputs. A combination of switches
and sensors may be involved.
· The function is represented through a logic symbol with two inputs and one
output.
· Both input signals must be present to switch the output.
1
+24V
S1
Input 1
(S1)
S2
Input 2
& Output
(lamp H1)
(S2)
H1
0V
1 2
+24V
S1 S2
Input 1
(S1)
Input 2
³1 Output
(lamp H1)
(S2)
H1
0V
Control Chain
The principle of the control chain should be understood as being only a guideline.
The signal flow of the control system defines the structure of the control chain:
· In the pneumatic circuit diagram, the signal flow is represented from bottom to
top.
· In the electrical circuit diagram, the signal flow is represented from top to
bottom.
1A 1 2
+24V
S1 Signal
input
Signal flow
1V1 S2
Signal flow
4 2
1Y1 Signal
5 3
K1 K1 processing
1
Signal
1Y1 output
0V
After actuating S1, current flows through the coil 1Y1, which switches the valve 1.1.
Compressed air flows from port 1 to port 2, and the piston rod advances.
If S1 is no longer actuated, there is no current through coil 1Y1. Valve 1.1 switches
back into the initial position.
The cylinder is vented through port 3 of valve 1.1, and the piston rod retracts.
1A 1
+24V
S1
1V1
2
1Y1
1 3
1Y1
0V
1A 1 2
+24V
13 13
S1 K1
14 14
1V1
4 2
1Y1
5 3 A1
1
K1 1Y1
A2
0V
A relay can be held in the switched condition if a holding current path is switched in
parallel to the ON pushbutton through an internal normally-open contact in the
relay.
An OFF pushbutton must be built into the memory circuit. The installed position of
the OFF pushbutton determines the function of the memory circuit.
In this dominating set memory circuit, the pushbutton S1 dominates the pushbutton
S2.
If S1 and S2 are pressed simultaneously, current flows through the relay coil K1.
1 2 3
+24V
13 23
S1 K1 K1
14 24
S2
K1 H1
0V
2
3
A relay can be held in the switched condition if a holding current path is switched in
parallel to the ON pushbutton to the relay coil through an internal normally-open
contact in the relay.
An OFF pushbutton must be built into the memory circuit. The installed position of
the OFF pushbutton determines the function of the memory circuit.
If S1 and S2 are pressed simultaneously, no current flows through the relay coil K1.
1 2 3
+24V
13 23
S1 K1 K1
14 24
S2
K1 H1
0V
2
3
Double solenoid valves are also called bistable valves or memory valves:
· The valve illustrated is actuated by two solenoid coils.
· The valve retains the switched position brought about through energising one of
the coils, even when the signal to switch the valve is cancelled.
· The switched position is reversed only when a signal is applied to the opposite
coil or a manual override is operated.
· To reverse the switched position, a signal only needs to be applied to one coil.
1A 1S2 +24V 1 2 3 4
S1 1S2 K1 K2
1V1
4 2
1Y1 1Y2
5 3
1
K1 K2 1Y1 1Y2
0V
3 4
Stroke-Dependent Control
Limit switches with roller lever actuation are frequently used to check the position of
pneumatic actuators in simple circuits.
The use of limit sensors in a control depends upon the required accuracy of the
sensor.
S1 1S2 K1 K2
1V1
4 2
1S1
1Y1 1Y2
5 3
1
K1 K2 1Y1 1Y2
0V
3 4
Pressure-Dependent Control
A pneumatic-electric signal converter measures the air pressure in the supply line of
cylinder 1A and compares it with a preset value.
As soon as this value is reached, the signal converter generates an electrical signal.
1B2
1A +24V 1 2 3 4 5 6 7
1B2 1B1
p
1B1 S1 K1 K2
p
K3
1V1
4 2
K1 K2 K3 1Y1 1Y2
1Y1 1Y2
5 3
1
0V
5 6 6
In the electrical circuit diagram, the current paths are numbered consecutively from
left to right.
The common circuit diagram elements form the interfaces between the pneumatic
and the electrical circuits. In this case, they are the coils 1Y1 and 2Y1, as well as the
limit sensors 1B1, 1B2, 2S1 and 2S2.
1B1 1B2
1A 2A 2S1 2S2
1V1 2V1
4 2 4 2
1Y1 2Y1
5 3 5 3
1 1
+24V 1 2 3 4 5 6 7 8 9 10 11 12 13
K1
K6 K3 K4 K5 K5
K1 K2 K3 K4 K5 K6 1Y1 2Y1
0V
5 7 6 8 13 10 5
7 9 11
12 13
Pneumatic · The arrangement of the components follows the signal flow accordingly from
bottom to top.
· Cylinders and valves are drawn horizontally.
· The outward travel motion of cylinders should be from left to right.
Electrical · The arrangement of the components follows the signal flow accordingly from top
to bottom.
· The electrical circuit diagram can be subdivided into a control part and a power
part.
1A 1S2 +24V 1 2 3 4
S1 1S2 K1 K2
1V2
K2
1V1
4 2
K1 K2 1Y1 1Y2
1Y1 1Y2
5 3
1
0Z
0V
3 4
Displacement-Step Diagram
Step
1 2 3 4 5=1
1
1A
0
1
2A
The terminal connection diagram shows the physical implementation of the current
circuit.
The identifications used in the circuit diagram are used in the terminal connection
diagram.
The terminal points and the cables are numbered. This facilitates the setting-up of
the controller as well as troubleshooting and maintenance.
1B1
1A 1S2
Machine Control cabinet
Target
Target
Terminal no. X1
1V1
Component
Component
Connection
Connection
4 2
Jumper
1Y1
code
code
code
code
5 3
1
+24V 1 2 3 4 5 +24V 1 X1 9
2 X1 12
X1-1 X1-2 X1-3 X1-4
3 X1 14
X1-9 X1-12 X1-14
4 K2 21
3 1 21 0V 5 X1 11
1B1 S1 1S2 K2 6 K1 A2
4 2 24
X1-13 X1-15 7 K2 A2
11 11 8 X1 17
K1 K2 1B1 + 9 X1 1
X1-11 X1-10 14 14 1B1 10 K1 A1
1B1 11 X1 5
X1-16 S1 3 12 X1 2
A1 A1
K1 K2 1Y1 S1 4 13 K1 11
A2 A2 1S2 1 14 X1 3
X1-17 1S2 2 15 K2 11
X1-5 X1-6 X1-7 X1-8 1Y1 16 K2 24
1Y1 17 X1 8
0V
18
3 4 19
5 20
è Each current path must be connected è Enter all external components with the
to the positive +24 V rail via a terminal. designation of the connection in the
terminal connection diagram.
è Each current path must be connected è Systematically check all current paths
to the negative 0 V rail via a terminal. and complete the wiring diagram.
A high induction voltage can be generated which can have the following effects:
· Damage to the coil insulation
· Burning of contacts
I1 I1 = 0
IM = I1 IM
ID = 0 ID = IM
+24V +24V
0V 0V
Alterable Controls
Relay-controlled systems are hard wired. The relay control can be replaced in whole
or in part by a programmable controller.
The structure of a system that is controlled via a programmable logic controller (PLC)
is similar to that of a relay-controlled system. Both systems can be subdivided as
follows:
· Signal input
· Signal processing
· Signal output
The signal processing part is the part that can be hard wired or freely programmable.
S2 K2
S3 K3 K3 K4 H2
S4 K4
+ +
Program:
S1 WHEN E0.1 H1
E1 AND E0.2 A1
S3 WHEN E0.3 H2
E3 AND E0.4 A2
THEN SET A0.2
S4 OTHERWISE RESET A0.2
E4 Processor
+ +
Inputs Outputs